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PRIOR APPLICATION
The present application is a continuation of U.S. patent application Ser. No. 623,099 filed Dec. 6, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a martensitic stainless steel suitable for use as a material of members which operate at high speed in water, such as foils and struts of a high speed vessel, e.g., a hydrofoil, runner of a water turbine, and so forth. More particularly, the present invention is concerned with a martensitic steel which is superior in strength, corrosion resistance, erosion resistance, fatigue properties and weldability, as well as an advantageous method for producing such a steel.
2. Description of the Related Art
In recent years, speed of vessel is becoming higher, as well as operation speed of high-speed rotation members such as a water turbine runner. This has given a rise to the demand for higher corrosion and erosion resistances of the steel.
In particular, foils and struts of high-speed vessel such as a hydrofoil are required to have high strength partly because they are required to bear the weights of cargo, passengers and the hull and partly because they must be constructed to have a reduced weight to reduce the total weight. In addition, the whole or part of the load is applied repeatedly to the struts and foils as a result of rolling and pitching of the vessel. The frequency of application of such a repetitious load is not so high as that in the case of a propeller or a water turbine. In addition, the foils and struts are used in sea water. Therefore, the steel used as a material for such a hydrofoil is required to have high strength against low cyclic frequency fatigue load in sea water, as well as high resistances to corrosion and erosion which are caused by sea water which attacks the foils and struts at high relative velocity.
In order to cope with these demands, Ni-containing steels containing 13 wt % of Cr and 3 to 5 wt % of Ni have been used. As disclosed in Japanese Patent Publication No. 42-16870, this type of steel has been produced by cooling the steel after full-austenization, followed by a tempering at 550° to 650° C. so as to allow formation of 15 to 40 wt % of retained austenite. This type of steel exhibits a proof strength of 60 to 70 kgf/mm 2 , as well as good toughness.
Martensitic stainless steels generally exhibit inferior weldability and workability as compared with austenitic stainless steel. A steel ASTM CA6NM (13Cr-4Ni), has been developed as cast steel material of having section structure. However, cast steel products in general exhibit quite inferior resistance to erosion because of casting defect. Furthermore, existence of internal casting defect impairs the soundness of the whole product. In order to obviate this problem, Japanese Patent Laid-Open Publication No. 1-127620 discloses a method of producing a martensitic stainless steel employing a hot rolling step. More specifically, in this method, a cast martensitic stainless steel is subjected to hot rolling so as to extinguish any casting defect, thereby greatly reducing any degradation in the resistance to erosion and in fatigue strength. This steel, however, exhibits a proof strength of 60 to 70 kgf/mm 2 at the greatest, which is still unsatisfactory.
The current demand for higher speed of high-speed boats requires the weight of the foils and struts to be reduced. There also exists a demand for higher operational speed of rotary machines such as a runner of a water turbine. Under these circumstances, there is an increasing demand for high-strength martensitic stainless steel having a proof strength of 80 kgf/mm 2 or greater. In general, steels having greater strength exhibit inferior weldability, as well as lower fatigue strength and resistance to erosion. Therefore, it has been difficult to obtain a high strength without being accompanied by impairment in the characteristics such as weldability, resistances to erosion and corrosion and fatigue strength.
A steel called 17-4PH steel has been known as an example of a high-strength stainless steel having a proof strength of 80 kgf/mm 2 or greater. In the production of this steel, precipitation hardening heat treatment is necessary to precipitate carbides and Cu so as to attain a high proof strength. When this precipitation hardening type high-strength steel is subjected to a welding, however, the precipitates are dissolved again in the weld region due to heat applied during welding, resulting in a reduction in the strength. In order to obtain a desired strength, therefore, the welded structure has to be subjected again to a precipitation hardening treatment. Thus, the known steels of the type described require cumbersome heat treatment repeatedly after welding. Further, when the welded structure is large in size, for applying such a heat treatment after welding, a large-size heat-treating furnace is required.
Japanese Patent Laid-Open Publication No. 62-124218 discloses a method of producing a high-strength stainless steel in which contents of alloy elements such as Ni and Mn are adjusted to keep the Ms point near the level of the room temperature, and annealing is conducted at a specific temperature range for a specific time, thereby attaining a high workability and high weld-softening resistance. Japanese Patent Laid-Open Publication No. 62-124218, however, does not mention at all any measure for improving fatigue properties of the steel in corrosive or erosive condition. In addition, use of large amounts of alloy elements is uneconomical, and there is an increasing demand for a high-strength stainless steel which do not require addition of large quantity of alloy elements.
Japanese Patent Publication No. 61-23259 discloses stainless steel which exhibits superior ductility at the weld region and corrosion resistance due to formation of a massive martensitic structure at the weld region by virtue of adjustment of the contents of elements such as C, N, Cr and Ni. Japanese Patent Publication No. 61-23259, however, does not mention at all fatigue characteristic of the steel in corrosive and erosive condition, as well as the strength level of the material, although a description is made as to corrosion resistance, bending characteristic and toughness of the weld region formed by the use of a 410 Nb welding rod. The adjustment of alloy-element contents, particularly the amount of Al, in Japanese Patent Publication No. 61-23259 differs from the present invention in which the adjustment of these contents is intended to improve the fatigue strength of the material in sea water.
Japanese Patent Publication Nos. 2-243739 and 2-243740 disclose methods of producing steel suitable for use in oil and gas wells, through specific adjustment of elements such as C, N, Cr, Ni, Nb and V. Steels produced by the methods disclosed in these publications exhibit improved corrosion resistance under corrosive conditions containing carbon dioxide gas, hydrogen sulfide and chloride ions. These publications, however, do not mention at all improvement in fatigue properties of the steels when used in corrosive conditions to which the present invention is directed. In particular, these publications do not at all mention the effect of addition of Cu which is proposed by the present invention and which produces a significant effect in improving fatigue properties in sea water. Furthermore, these publications fail to mention proof strength which is a significant factor in structural designs. Thus, none of the prior art references mentioned above provide any idea for attaining an improvement in low cyclic frequency fatigue properties in sea water to which the present invention pertains.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a high-strength martensitic stainless steel which has a proof strength of 80 to 110 kgf/mm 2 or greater and which is superior in resistances to corrosion and erosion, fatigue properties in sea water and weldability, as well as a method for producing such a steel.
The present inventors have conducted an intense study for the purpose of attaining a higher strength of martensitic stainless steels and have found that, in order to attain a higher strength without reducing corrosion resistance, it is most important to prevent precipitation of coarse carbides in the grain boundaries.
The inventors also have found that prevention of such carbides can effectively be suppressed and, hence, corrosion resistance and weldability are improved, by optimizing the contents of elements such as C, N, Cr and Ni and also by the addition of elements such as Mo and V. The present inventors also have found that fatigue failure at low cyclic frequency loading cycle in sea water is triggered by a pit formed by corrosion at the surface of the steel, and that low cyclic frequency fatigue strength in sea water is improved by a reduction in the impurities such as Al 2 O 3 . Furthermore. the present inventors have discovered that addition of Nb is effective in improving strength, while addition of Cu and Mo is effective in improving fatigue properties in sea water. The inventors further found that a finer structure and, hence, an improved strength is obtainable by conducting tempering subsequent to a hot rolling conducted under specific conditions. More specifically, the inventors have found that a greater strength is obtained when the temperature at which the hot rolling is finished is chosen in the moderate range and the rate of a subsequent cooling is preferably controlled.
The present invention has been accomplished with these knowledge.
According to one aspect of the present invention, there is provided a high-strength martensitic stainless steel having superior fatigue properties when used in a corrosive or erosive environment, the stainless steel possessing a proof strength of 80 to 110 kgf/mm 2 and having a chemical composition containing: 0.005 to 0.04 wt % of C, not more than 1.0 wt % of Si, not more than 2.0 wt % of Mn, 12.0 to 17.0 wt % of Cr, 3.0 to 6.0 wt % of Ni, 0.1 to 1.5 wt % of Mo, 0.02 to 0.5 wt % of V and 0.005 to 0.02 wt % of N, and the balance substantially Fe and incidental inclusions, the contents of C, Si, Mn, Cr, Ni, Mo, V and N being determined such that an Ni equivalent Nieq given by the following formula (1) ranges between 10.5 and 12.9 wt %:
Nieq=[Ni]+[Mn]+0.5[Cr]+0.3[Si]+[Mo] (1)
where, [Ni], [Mn], [Cr], [Si] and [Mo] respectively represent the contents of Ni, Mn, Cr, Si and Mo in weight %.
According to another aspect of the present invention, there is provided a method of producing a high-strength martensitic stainless steel possessing a proof strength of 80 to 110 kgf/mm 2 and having superior fatigue properties when used in a corrosive or erosive environment, comprising the steps of: preparing a steel having a composition containing: 0.005 to 0.04 wt % of C, not more than 1.0 wt % of Si, not more than 2.0 wt % of Mn, 12.0 to 17.0 wt % of Cr, 3.0 to 6.0 wt % of Ni, 0.1 to 1.5 wt % of Mo, 0.02 to 0.5 wt % of V, 0.005 to 0.02 wt % of N, one or both of 0.01 to 0.5 wt % of Nb and 0.2 to 2.0 wt % of Cu, and the balance substantially Fe and incidental inclusions, the contents of C, Si, Mn, Cr, Ni, Mo, V, N, Nb and Cu being determined such that an Ni equivalent Nieq given by the following formula (1') ranges between 10.5 and 12.9 wt %:
Nieq=[Ni]+[Mn]+0.5[Cr]+0.3[Si]+[Mo]+[Cu] (1')
where, [Ni], [Mn], [Cr], [Si], [Mo] and [Cu] respectively represent the contents of Ni, Mn, Cr, Si, Mo and Cu in weight % respectively comprising subjecting the steel to a heating to a temperature of 1250° C. at the maximum; subjecting the heated steel to a hot rolling at a final rolling temperature of not less than 800° C.; cooling the hot-rolled steel to a temperature not higher than 100° C. at a cooling rate which is not smaller than the cooling rate Vc (°C./min) which is computed in accordance with the following formula (2); and subjecting the cooled steel to a tempering or a quenching-tempering treatment:
Vc=2×{[Ni]+100([C]+[N])} (2)
where, [Ni], [C] and [N] respectively represent the contents of Ni, V and N in the steel.
The above and other objects, features and advantages of the present invention will become clear from the following description of the preferred embodiment when the same is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the relationship between the ratio of area occupied by nonmetallic inclusions and the number of loading cycles till rupture as observed in a tensile fatigue test;
FIG. 2 is a graph showing the influence of the heating temperature on hot-workability of martensitic stainless steel;
FIG. 3 is a graph showing the heating pattern in a high-temperature, high-speed tensile test; and
FIG. 4 is a front elevational view of a model of a hydrofoil as an example of a hydrofoil.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, the contents of components are limited for the following reasons.
C: 0.005 to 0.04 wt %
C is an element which easily forms Cr carbides with Cr, so as to reduce the corrosion resistance. In addition, the presence of a large amount of C undesirably reduces the toughness of the steel. For these reasons, the C content is determined not to exceed 0.04 wt %. A too small C content, on the other hand, makes it difficult to maintain the required strength. For these reasons, therefore, the C content is determined not to exceed 0.005 wt %.
Si: 1.0 wt % or less
Si is an element which is essential for deoxidation and to attain an appreciable deoxidation effect, Si content is preferably determined to be 0.1 wt % or less. On the other hand, addition of Si in excess of 1.0 wt % causes a reduction in the toughness. For these reasons, the Si content is determined to be 1.0 wt % or less.
Mn: 2.0 wt % or less
Mn is an element which fixes S in the steel and which broadens the austenitic region at high temperature thereby improving hardenability. In order to obtain an appreciable effect, Mn content preferably exceeds 0.2 wt %. Addition of a too large amount of Mn, however, reduced toughness of the steel. For these reasons, therefore, the Mn content is determined to be 2.0 wt % or less.
Cr: 12.0 to 17.0 wt %
Cr is an element which is important for obtaining a high corrosion resistance while maintaining martensitic structure. These effects, however, are not appreciable when the Cr content is below 12.0 wt %. On the other hand, a Cr content exceeding 17.0 wt % allows formation of 8 ferrite when the steel is heated to a high temperature, so as to impair hot workability of the steel. For these reasons, the Cr content is determined to range from 12.0 wt % to 17.0 wt %.
Ni: 3.0 to 6.0 wt %
Ni is an element which is effective in improving corrosion resistance and toughness. These effects becomes appreciable when the Ni content is increased beyond 3.0 wt % so that this content value is determined to be the lower limit of the Ni content. On the other hand, excessively large Ni content increases the amount of austenite phase after the rolling or hardening, resulting in a reduction in the strength. For this reason, the upper limit of the Ni content is set at 6.0 wt %.
Mo: 0.1 to 1.5 wt %
Mo improves corrosion resistance and is effective in improving strength because it forms fine carbides in tempering. In order to obtain these effects, the Mo content should be at least 0.1 wt %. A too large Mo content, however, undesirably reduces the hot workability. For these reasons, the upper limit of the Mo content is set at 1.5 wt %.
V: 0.02 to 0.5 wt %
V is an element which forms carbides with C and causes precipitation of such carbides in grains, thus offering a remarkable effect in improving the strength. This element also remarkably improves the resistance to softening of tempered martensite. These effects become appreciable when the V content is increased beyond 0.02 wt %. Consequently, the lower limit of V content is set at 0.02 wt %. Conversely, a too large V content undesirably reduces the toughness so that the upper limit of V content is set at 0.5 wt %.
N: 0.005 to 0.02 wt %
N is an element which is effective in attaining high strength. Unlike C, N exhibits only a small tendency for formation of Cr nitrides in the grain boundaries. It is therefore preferred to positively add N to attain a higher strength. This element, however, is liable to generate blow holes when welded by electron-beam welding. The upper N content, therefore, is determined to be 0.02 wt % or less.
C+N:
The total content of C and N should be determined to be 0.05 wt % or less, since the risk of weld cracking is enhanced when the total content of C and N exceeds this value.
Nb: 0.02 to 0.5 wt %
Nb causes precipitation of carbides in grains with C. This suppresses precipitation of coarse carbides in the grain boundaries so as to improve strength, while remarkably retarding tempering-softening of martensite as a tempering temperature rises. The effect of addition of Nb becomes appreciable when the Nb content is increased beyond 0.02 wt %. On the other hand, a too large Nb content, particularly exceeding 0.5 wt %, causes a reduction in the hot workability so that the upper limit of Nb content is set at 0.5 wt %.
Cu is an element which is effective in improving fatigue properties in sea water. This effect, however, is not appreciable when the Cu content is 0.2 wt % or less. Conversely, addition of Cu in excess of 2.0 wt % causes a reduction in the hot workability, so that the amount of addition is set to range from 0.2 to 2.0 wt %.
According to the present invention, a nickel equivalent value Nieq, which is determined by said formula (1) in case of the first invention which employs addition of Cu and by said formula (1') in case of the second invention which employs addition of Cu, falls within the range between 10.5 and 12.9 wt %.
In order to attain a high strength, it is necessary to set the Ni equivalent Nieq to a low level so as to raise the level of the Ms point thereby reducing the retained austenite. Therefore, the upper limit of the Nieq is determined to be 12.9 wt %. On the other hand, the lower limit of the Nieq value is set to 10.5 wt % since no appreciable solid solution effect is obtained when the Nieq value is below this level.
Al: 0.010 wt % or less
Al is an element which is necessary for deoxidation. This element, however, remains in the steel in the form of Al 2 O 3 so as to reduce the fatigue properties. The Al content of the steel, therefore, should be 0.010 wt % or less in the state after deoxidation.
Non-metallic inclusions
Satisfactory fatigue properties cannot be obtained when the ratio of area occupied by non-metallic inclusions in the section taken along the rolling direction exceeds 0.01 wt %. Therefore, non-metallic inclusions should be dispersed uniformly in such an amount that the above-mentioned ratio of the area is 0.01% or less.
A description will now be given of a correlation between the ratio of the area occupied by non-metallic inclusions and the fatigue properties.
FIG. 1 shows the result of the tensile fatigue test conducted on different steels which have chemical compositions meeting the requirement of this invention and having different values of the ratio of the area occupied by non-metallic inclusions. The tensile fatigue test was conducted by applying a stress of 400 MPa at a frequency of 1 Hz in 3.5 wt % NaCl solution. The ratio of the area occupied by non-metallic inclusions was determined by polishing a sectional surface of the steel parallel to the rolling direction, measuring the sizes and numbers of the non-metallic inclusions appearing in the polished surface through an optical-microscopic observation of 120 fields of vision at a magnification 800, and conducting an image analysis on these data. As will be seen from FIG. 1, the rate of increase in the number of the loading cycles till rupture increases as the ratio of the area occupied by the non-metallic inclusions is reduced. The number (Nf) of loading cycles till rupture is as large as 1×10 5 when the ratio of the area occupied by non-metallic inclusions is 0.01% or less.
A preferred method of producing the steel of the present invention comprises the steps of subjecting the steel to a heating to a high temperature which is 1250° C. at the maximum, subjecting the heated steel to hot rolling which is conducted at the final temperature of 800° C., cooling the hot-rolled steel to a cooling so as to cool the steel to a temperature not higher than 100° C. at a cooling rate Vc (°C./min) calculated by a formula (2), and subjecting the cooled steel to a tempering or quenching-tempering treatment.
Conventionally, martensitic steel has been processed by quenching-tempering. In order to obtain high corrosion resistance and toughness, however, it is preferred that a thermo-mechanical heat treatment including a hot work and a subsequent cooling is preferably executed for the reasons shown below.
Namely, the thermo-metrical heat treatment consisting in hot working and subsequent cooling effectively enhances the strength due to higher fineness of the structure than the structure obtained after ordinary quenching or annealing. In case of a steel containing Nb, in order to obtain an effective precipitation of Nb of, for example, 0.05% in the solid solution through an annealing, it is necessary that a reheating at a temperature above 1100° C. is necessary when computed in accordance with Irvine's equation of log[Nb][C+(12/14)N]=-(6770/T)+2.26, where [Nb] represents the solved Nb (%) and C and N represent amounts of C and N added, assuming that C and N are respectively 0.03 wt % and 0.009 wt %. According to the invention, however, reheating to such a high temperature is not necessary because precipitation of Nb with C and N is suppressed by the rolling and subsequent cooling and a required amount of effective solved Nb which precipitates through the tempering is obtained. Although tempering is preferably conducted subsequent to the thermo-metrical heat treatment, it is possible to conduct an ordinary quenching-annealing treatment.
According to the present invention, the maximum heating temperature of the steel material in advance of hot rolling is limited to 1250° C. for the following reasons. Sample steels each having a composition containing 0.03 wt % C, 0.3 wt % Si, 0.6 wt % Mn, 13.5 wt % Cr, 5.0 wt % Ni, 0.3 wt % Mo, 0.05 wt % V and 0.01 wt % Ni, were heated to different temperatures and then subjected to a high-temperature high-speed tensile test, for the purpose of examination of hot workability of these steels. The results of this test are shown in FIG. 2. The high-temperature high-speed tensile test was conducted by subjecting the steels to a temperature hysteresis as shown in FIG. 3. From FIG. 2, it will be seen that good hot workability is obtained when the steels are heated to a temperature not higher than 1250° C. Therefore, according to the present invention, the upper limit of the temperature of heating conducted prior to the hot rolling is set at 1250° C. The preferable lower limit of the heating temperature is 1100° C., from the view point of load on the rolling mill and the rolling efficiency.
The present invention does not pose any specific limitation in the rolling reduction. However, when the rolling reduction is below 10% per pass, recrystallization during hot rolling is retarded to allow local presence of coarse grain, resulting in a reduction in toughness. The rolling is therefore conducted preferably at a rolling reduction of 10% or greater per pass.
When the final temperature in the hot rolling is too low, carbides are precipitated in the hot-rolled steel so as to impair corrosion resistance of the steel. In order to obviate this problem, therefore, the finish rolling temperature in the hot rolling is limited to be not lower than 800° C.
In order to suppress precipitation of carbides in the cooling subsequent to hot rolling, the cooling is preferably conducted at a rate which is not smaller than the rate Vc given by the following formula.
Vc=2×{[Ni]+100[C]+[N])} (°C./min).
The temperature at which the cooling is terminated should be not higher than 100° C. because the toughness of the steel is seriously impaired when the tempering subsequent to the cooling is conducted with a large amount of austenite retained in the steel after the cooling.
According to the invention, the range of the tempering temperature which enables the tempered steel to exhibit a proof strength of 80 to 110 kgf/mm 2 depends on the composition of the steel. When Cu and Nb are not added, the tempering temperature preferably ranges between 400° and 500° C. Namely, when the temperature is below 400° C., it is impossible to obtain a proof strength of 80 kgf/mm 2 or greater because such a low tempering temperature cannot cause precipitation of fine carbides. On the other hand, tempering at high temperatures exceeding 500° C. causes precipitation of coarse carbides, with the result that corrosion resistance is impaired due to precipitation of coarse carbides. When Cu and Nb are added, the tempering temperature may be raised to 650° C.
The high-strength martensitic stainless steel of the present invention can suitably be used as the materials for parts of a high speed vessel shown in FIG. 4, more particularly the hull 1, struts 2 supporting the hull 1 and foils 3 for generating a lift. The hull 1, struts 2 and the foils 3 constructed from the high-strength martensitic stainless steel of the present invention exhibit superior strength and high resistances both to corrosion and erosion in sea water, thus enabling a reduction in the weight of these parts and, accordingly, realizing a greater cruising speed of the boat.
A description will now be given of the reasons for the limitation of the proof strength of the steel to the range between 80 and 110 kgf/mm 2 .
When the proof strength is below 80 kgf/mm 2 , the effect of weight reduction is not so appreciable. On the other hand, a higher proof strength, though it contributes to a reduction in the weight, requires a greater amount of alloying elements. The use of large amounts of alloying elements is not preferred partly because it reduces weldability and partly because it raises the cost. For these reasons, the proof strength is determined to range from 80 to 110 kgf/mm 2 .
Foils and struts are usually constructed by assembling sheets of the steel material by TIG, MIG or EBW welding. In the case of conventional 17-4PH stainless steel, it is necessary that the whole structure assembled by welding is subjected to a solid solution treatment and an aging treatment. When this known material is used, therefore, a specific consideration has to be given to the sequence of assembly and the condition of heat treatment.
In contrast, in the invention of this application, it is possible to obtain a high proof strength of 80 to 110 kgf/mm 2 , even by a tempering treatment at high temperature. According to the present invention, therefore, it is possible to conduct the post-welding stress relieving heat treatment at a temperature of, for example, about 600° C. which is higher than that in the conventional process. Stress-relieving heat treatment conducted at such a high temperature relieves residual stress substantially completely. In addition, undesirable deformation of the whole structure in the heat treatment, which inevitably takes place in solid solution heat treatment, can be avoided, thus eliminating necessity for specific consideration which heretofore has been necessary to eliminate any influence of deformation during heat treatment.
EXAMPLE 1
Steels having the chemical compositions shown in Table 1 were prepared. Steel sheets 25 mm thick were produced through the various processes shown in Table 2 from slabs of 110 mm thick obtained from the above-mentioned steels. Mechanical properties, corrosion resistance and weldability of each of the thus produced steel sheets are shown in Table 3.
The corrosion resistance was evaluated through a corrosion test conducted with a 65% nitric acid solution. Samples marked by x are those which exhibited heavy intergranular attack. The erosion resistance was examined by using an opposing type magnetostrictive vibration cavitation erosion tester. Marks ◯ and × are respectively given to samples exhibiting a corrosion weight loss of 15 g/(m 2 h) or less and to samples exhibiting corrosion weight loss greater than 15 g/(m 2 h). The strength of the weld portion was evaluated in terms of the hardness of the steel sheet surface when the welding was conducted by TIG welding method. Weldability was evaluated by so-called y-slit method. Namely, test welding was conducted after pre-heating to 120° C. and the welded samples were checked for any weld cracking. Marks ◯ and × are respectively given to samples exhibiting no crack and samples exhibiting a crack or cracks. Fatigue strength was examined by conducting a uni-axial tensile fatigue test by repeatedly applying a stress of 400 MPa at a frequency of 1 Hz to the samples held in a 3.5 % NaCl solution. Marks ◯ and × are respectively given to samples which did not fail at the load cycles of 1×10 5 or more and to samples which failed within this number of load cycles.
As will be seen from Table 3, the sample steels of the present invention are superior to steels of known compositions and steels produced by known processes in terms of strength, toughness and corrosion resistance. In addition, each of the steels prepared in accordance with the present invention exhibited a strength of Hv 330 or higher at the weld region, so that the steel could be subjected to use without requiring any post-welding treatment, without any risk of insufficiently of strength.
TABLE 1__________________________________________________________________________Type Chemical compositionof steel C Si Mn Cr Ni Mo V N Nb Cu Al P S Nieq Vc(*1) Remarks__________________________________________________________________________ 1 0.040 0.35 0.60 13.3 5.3 0.15 0.068 0.010 -- -- 0.009 0.025 0.003 12.81 21 Example 2 0.038 0.35 0.58 13.0 5.3 0.40 0.012 0.010 -- -- 0.008 0.020 0.002 12.78 20 Example 3 0.039 0.35 0.65 13.1 4.2 1.00 0.035 0.008 -- -- 0.008 0.018 0.001 12.51 18 Example 4 0.040 0.35 0.40 13.3 5.0 0.15 0.015 0.012 -- -- 0.007 0.020 0.002 12.31 20 Example 5 0.035 0.35 0.62 13.4 3.2 0.25 0.045 0.009 0.008 -- 0.009 0.020 0.002 10.08 15 Example 6 0.065 0.30 0.70 13.6 5.8 0.20 0.040 0.02 0.009 -- 0.020 0.023 0.002 13.59 29 Comp. Ex. 7 0.040 0.34 0.55 13.1 1.0 0.01 0.040 0.20 -- -- 0.009 0.022 0.003 8.21 50 Comp. Ex. 8 0.030 0.32 0.51 13.7 6.5 0.02 0.007 0.01 0.015 -- 0.010 0.027 0.001 13.96 21 Comp. Ex. 9 0.035 0.35 0.58 13.1 4.8 0.80 0.050 0.01 0.035 -- 0.008 0.020 0.002 12.84 19 Example10 0.025 0.30 0.40 12.8 4.6 0.50 0.045 0.01 0.040 0.5 0.005 0.024 0.002 12.49 16 Example11 0.035 0.30 0.60 17.0 5.2 0.10 0.045 0.02 -- -- 0.010 0.020 0.001 14.49 21 Comp. Ex.12 0.045 0.25 0.58 10.5 4.2 0.04 0.050 0.01 -- -- 0.020 0.023 0.002 10.15 19 Comp. Ex.13 0.005 0.35 0.50 13.5 3.5 0.85 0.080 0.010 0.08 -- 0.008 0.022 0.002 11.71 10 Example14 0.035 0.34 0.60 12.2 6.0 0.20 0.050 0.012 -- -- 0.008 0.022 0.003 12.60 21 Example15 0.025 0.35 0.60 12.9 4.5 0.80 0.020 0.010 -- -- 0.009 0.022 0.002 12.46 16 Example16 0.008 0.35 0.50 13.0 2.6 0.90 0.080 0.15 -- -- 0.008 0.022 0.002 10.61 37 Comp. Ex.17 0.035 0.40 0.60 13.2 4.3 0.70 0.050 0.014 0.02 -- 0.007 0.022 0.004 12.32 18 Example18 0.037 0.35 0.65 13.4 4.8 0.60 0.040 0.010 0.5 -- 0.005 0.022 0.002 12.86 19 Example19 0.030 0.45 0.65 12.8 4.8 0.60 0.060 0.008 -- 0.2 0.007 0.022 0.002 12.80 17 Example20 0.025 0.32 0.60 12.9 3.2 0.50 0.060 0.012 -- 2.0 0.007 0.022 0.004 12.85 14 Example__________________________________________________________________________ (*1): Vc = 2 × {[Ni] + 100 ([C] + [N])}-
TABLE 2__________________________________________________________________________Heating Rolling Hot-rolling Cooling Quenching TemperingProcesstemp. reduction per finish temp Cooling termination temp. temp.No. (°C.) pass (%) (°C.) rate temp. (°C.) (°C.) (°C.)__________________________________________________________________________1 1200 15 800 100 20 → 4502 1200 15 800 100 20 930 4503 1200 15 800 10 20 → 4504 1200 15 800 100 120 → 4505 1200 15 750 100 20 → 4506 1200 15 800 100 20 → 6007 1200 15 800 100 100 → 450__________________________________________________________________________
TABLE 3__________________________________________________________________________ Hardness Fatigue of weld propertiesSteel Process 0.2% P.S. T.S. vE.sub.0 Corrosion Erosion region y-slit in seatype No. (kgf/mm.sup.2) (kgf/mm.sup.2) EI (%) (kgf · m) resistance resistance (Hv) cracking water Remarks__________________________________________________________________________1 1 95.3 112.3 19 12.5 ◯ ◯ 389 ◯ ◯ Example of Invention1 2 94.7 110.8 22 14.8 ◯ ◯ 386 ◯ ◯ Example of Invention1 3 85.4 95.7 18 9.0 X ◯ 337 ◯ X Known steels1 4 82.6 96.5 20 4.7 ◯ ◯ 336 ◯ ◯ Known steels1 5 97.6 115.7 21 8.5 X ◯ 402 ◯ X Known steels1 6 78.5 89.8 23 14.3 X X 310 ◯ X Known steels2 1 97.8 115.5 21 11.6 ◯ ◯ 392 ◯ ◯ Example of Invention3 1 98.4 117.5 21 12.4 ◯ ◯ 387 ◯ ◯ Example of Invention4 1 96.1 115.7 20 13.5 ◯ ◯ 385 ◯ ◯ Example of Invention4 6 92.7 113.5 22 14.1 ◯ ◯ 386 ◯ ◯ Example of Invention5 1 96.7 116.4 21 12.8 ◯ ◯ 378 ◯ ◯ Example of Invention6 3 82.5 109.8 22 12.9 X ◯ 402 X X Known steels7 1 77.5 94.3 18 6.7 ◯ X 380 X X Known steels8 1 72.4 89.4 23 12.4 ◯ X 375 ◯ ◯ Known steels9 1 98.2 118.4 22 13.4 ◯ ◯ 394 ◯ ◯ Example of invention9 6 92.1 104.3 21 13.6 ◯ ◯ 360 ◯ ◯ Example of invention10 1 87.4 98.1 21 13.2 ◯ ◯ 389 ◯ ◯ Example of invention10 6 72.4 85.6 24 14.3 ◯ X 289 ◯ ◯ Known steels11 1 78.4 92.7 23 9.4 X X 368 X X Known steels12 1 81.3 94.3 21 10.3 X ◯ 352 X X Known steels13 1 89.5 108.6 20 12.8 ◯ ◯ 372 ◯ ◯ Example of invention14 1 83.6 102.8 22 12.8 ◯ ◯ 360 ◯ ◯ Example of invention15 1 92.4 110.6 20 11.9 ◯ ◯ 387 ◯ ◯ Example of invention16 1 108.7 121.3 18 11.8 ◯ ◯ 422 ◯ ◯ Known steels17 1 92.1 111.6 20 13.1 ◯ ◯ 392 ◯ ◯ Example of invention18 1 105.3 115.7 17 11.9 ◯ ◯ 403 ◯ ◯ Example of invention19 1 89.8 107.6 20 13.2 ◯ ◯ 370 ◯ ◯ Example of invention20 1 105.9 119.8 18 12.0 ◯ ◯ 412 ◯ ◯ Example of invention__________________________________________________________________________
EXAMPLE 2
A steel was melt-formed in a converter to have a composition containing 0.03 wt % C, 0.01 wt % N, 13.5 wt % Cr, 0.30 wt % Si, 0.60 wt % Mn, 0.020 wt % P and 0.004 wt % S. Using this steel as the starting material, a secondary refining was conducted in a small-sized ESR furnace under various controls of non-metallic impurities and trace elements, thus obtaining 15 types of sample steels in the form of ingots. Each of these sample steels was bloom-rolled into slabs 100 mm thick, after a 4-hour heating at 1200° C. The thus obtained slab was then subjected to a 2-hour heating at 1200° C., followed by a hot rolling into a steel sheet 30 mm thick at a rolling finish temperature of 900° C. The steel sheet thus obtained was then subjected to a tempering heat treatment conducted at 600° C. so as to become the final product. Some of the hot rolled steels, however, were subjected to a normalizing conducted at 930° C., in advance of the tempering. Each of the sample steel sheets was subjected to a tensile fatigue test for evaluation of fatigue strength in sea water, a salt spray test for the evaluation of resistance to corrosion and erosion test for evaluating erosion resistance in salt water. The results of the evaluation are shown in Table 4 together with chemical compositions of the sample steel sheets.
A description will be given of the conditions of the tests mentioned above, as well as of marks appearing in Table 4.
Fatigue properties in sea water
A tensile fatigue test was conducted by repeatedly applying a stress of 400 MPa at a frequency of 1 Hz to each sample steel sheet held in 3.5 wt % NaCl solution, and the number (Nf) of load cycles till failure was measured. A mark ⊚ is given to the samples which did not fail at the load cycles of 1×10 5 or more (Nf≧1×10 5 ), while a mark × is given to sample steel sheets which failed at the load cycles of less than 1×10 5 (Nf<1×10 5 ).
Corrosion resistance
A 16-hour salt spray test was conducted by using 3.5 wt % NaCl solution, and the numbers of rust points per unit area (cm 2 ) were measured. Marks ⊚, ◯, Δ and × are given to samples which showed 0.1 or less rust points per cm 2 , 0.1 to 1 rust points per cm 2 , 1 to 10 rust points per cm 2 and more than 10 rust points per cm 2 , respectively, thus evaluating the corrosion resistance.
Erosion resistance
An erosion test was conducted in a 3.5 wt % NaCl solution by using an opposing type magnetostrictive vibration cavitation erosion tester under the following conditions.
Frequency: 20 KHz
Amplitude: max 25 μm
Distance between surface of specimen and end of horn: 0.5 mm
Testing time: 24 Hr
The evaluation of erosion resistance was conducted by measuring the erosion weight loss. Marks ◯ and × are given to samples which showed erosion weight loss of 15 g/m 2 or less and samples which showed erosion weight loss exceeding 15 g/m 2 .
As will be understood from Table 4, the steels which meet the conditions specified by the invention exhibit superior fatigue properties in sea water, resistance to corrosion and erosion, as well as high proof strength of 80 kgf/mm 2 or greater, as compared with comparison steels which fail to meet the conditions specified by the present invention in at least one of the factors such as the area ratio of non-metallic inclusions, C content, Ni content, Mo content, V content, Nb content, Al content and N content.
TABLE 4__________________________________________________________________________Sample Steel Chemical composition (wt %) NieqNo. type C N Si Mn Ni Cr Mo Nb V Cu Al O (%)__________________________________________________________________________1 Example 0.03 0.008 0.3 0.6 5.0 13.5 0.6 ≦0.01 0.08 -- 0.008 0.0060 12.842 Comp. Ex. 0.03 0.008 0.3 0.6 5.0 13.5 0.6 ≦0.01 0.08 -- 0.020 0.0100 12.793 Comp. Ex. 0.03 0.008 0.3 0.6 5.0 13.5 0.6 ≦0.01 0.08 -- 0.025 0.0100 12.794 Example 0.02 0.005 0.3 0.4 4.9 12.8 1.0 0.02 0.05 -- 0.006 0.0060 12.795 Comp. Ex. 0.02 0.005 0.3 0.4 4.9 12.8 1.0 0.02 0.05 -- 0.010 0.0075 12.796 Comp. Ex. 0.02 0.005 0.2 0.4 4.9 12.8 1.0 0.02 0.05 -- 0.020 0.0060 12.797 Example 0.04 0.009 0.2 0.4 4.7 12.8 1.0 0.08 0.20 0.20 0.008 0.0070 12.768 Comp. Ex. 0.04 0.012 0.3 0.4 4.7 12.8 1.0 0.08 0.20 0.20 0.005 0.0100 12.769 Example 0.02 0.005 0.3 0.5 4.3 12.8 1.5 0.08 0.20 -- 0.009 0.0070 12.7910 Example 0.03 0.008 0.2 0.4 3.4 14.3 0.8 0.10 0.20 1.0 0.008 0.0060 12.8111 Example 0.03 0.008 0.3 0.4 4.0 13.5 0.5 0.06 0.08 1.0 0.007 0.0070 12.7412 Comp. Ex. 0.03 0.012 0.3 0.6 5.2 13.5 0.5 0.06 0.08 1.0 0.010 0.0090 14.1413 Example 0.03 0.008 0.3 0.5 5.1 13.4 0.4 0.04 0.05 -- 0.009 0.0070 12.7914 Example 0.03 0.008 0.3 0.6 5.2 13.2 0.3 0.06 0.02 -- 0.006 0.0080 12.7915 Comp. Ex. 0.03 0.008 0.3 0.6 5.2 12.8 2.5 0.04 0.04 -- 0.018 0.0060 14.79__________________________________________________________________________ Ratio of area Fatigue occupied by propertiesSample Steel non-metal in sea Corrosion Erosion 0.2% P.S. T.S.No. class inclusions water resistance resistance (kgf/mm.sup.2) (kgf/mm.sup.2) EI (%)__________________________________________________________________________1 Example 0.008 ⊚ ⊚ ◯ 82.0 97.2 202 Comp. Ex. 0.015 ⊚ Δ ◯ 82.9 98.0 213 Comp. Ex. 0.025 X Δ ◯ 82.0 95.8 214 Example 0.006 ⊚ ⊚ ◯ 83.5 98.7 215 Comp. Ex. 0.015 ⊚ Δ ◯ 84.2 99.2 196 Comp. Ex. 0.024 X Δ ◯ 81.8 98.7 207 Example 0.008 ⊚ ⊚ ◯ 97.9 118.9 208 Comp. Ex. 0.025 X ◯ ◯ 98.8 118.7 199 Example 0.005 ⊚ ◯ ◯ 103.6 120.1 1910 Example 0.009 ⊚ ⊚ ◯ 97.0 121.5 2011 Example 0.010 ⊚ ⊚ ◯ 101.9 120.6 2212 Comp. Ex. 0.025 X ◯ ◯ 101.7 118.7 1913 Example 0.005 ⊚ ◯ ◯ 83.0 95.1 2114 Example 0.005 ⊚ ◯ ◯ 81.8 94.3 2015 Comp. Ex. 0.005 ⊚ ⊚ ◯ 104.2 121.8 12__________________________________________________________________________
As will be fully understood from the foregoing description, according to the present invention, there is provided a high-strength martensitic stainless steel which is superior in corrosion resistance, erosion resistance and fatigue properties in sea water and which enables removal of residual stress by a post-welding heat treatment alone, by virtue of the optimum selection of contents of C, N, Cr and Ni and by addition of Mo and V. Furthermore, the high-strength martensitic stainless steel of the present invention can effectively be used as a material of a welding structural member which exhibits proof strength of 80 to 110 kgf/mm 2 . In addition, the high-strength martensitic stainless steel of the present invention can exhibit a further improvement in the strength and fatigue properties in sea water by the addition of Nb and/or Cu. Furthermore, the method of the present invention can advantageously produce high-strength martensitic stainless steel by adopting a thermo-metrical heat treatment which includes a hot work and a subsequent cooling. | A high strength martensitic stainless steel having superior anti-fatigue characteristics when used in a corrosive or erosive environment. The steel has a proof strength of 80 to 110 kg/mm 2 and a composition containing specified amounts of carbon, silicon, manganese, chromium, nickel, molybdenum, vanadium, and nitrogen, the balance being substantially iron and incidental inclusions. The contents of the additives are such that a nickel equivalent Nieq given by the following Formula (1) ranges between 10.5 and 12.9 wt. %:
Nieq=[Ni]+[Mn]+0.5[Cr]+0.3 [Si]+[Mo] (1)
where, [Ni], [Mn], [Cr], [Si], and [Mo], respectively represent the contents of Ni, Mn, Cr, Si, and Mo, respectively. The steel may also contain niobium or copper. The steel is produced by a process which includes a hot work and a subsequent cooling at a specific cooling rate to a specific temperature range. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to web handling, and more particularly relates to web transport apparatus for feeding webs through web treatment apparatus.
In numerous industrial applications, flat materials such as paper, film, foil and the like are handled in semicontinuous web form. Such materials are often processed by drawing each web through the active zone of a treatment device and operating the treatment device while the web is moving through it.
Web transport apparatus is used to draw the webs through the treatment device. The transport apparatus normally includes a payout stand, a takeup stand and support structure defining a transport path which extends from the payout stand to the takeup stand. The transport apparatus is juxtaposed with the treatment device so that the transport path extends through the active zone of the treatment device. A coil containing each web is loaded into the payout stand and the leading end of the web is threaded along the transport path to the takeup stand. The web is then drawn through the active zone of the treatment device by winding it onto a coil at the takeup stand while unwinding it from the coil at the payout stand.
After each web has been completely fed through the apparatus in this manner, it is removed from the apparatus and a new web is loaded and threaded. With the web transport apparatus of the prior art, the treatment device has been idle during each such unloading and reloading cycle. Certain types of web treatment devices can process webs at extremely high speeds. The web transport apparatus associated with such devices must be reloaded frequently so that the productive capacity of such treatment devices is diminished.
For example, a laser beam treatment device can perforate cigarette tipping paper drawn through it at a linear speed of up to 7,000 feet per minute. Even if the paper is supplied in webs of the maximum practicable length, the transport apparatus used with such a treatment device must be reloaded after only about 2 to 3 minutes of operation. If each such reloading cycle takes only one minute, from 25 to 33 percent of the productive capacity of the treatment device will be lost.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide web transport apparatus which can be unloaded, threaded and reloaded while it is drawing a web through a treatment device, so that the associated treatment device can be operated without any but insubstantial interruption.
It is another object of the present invention to provide a method of feeding a series of webs through a treatment device which minimizes interruption in operation of the treatment device.
As used herein, the term "downstream" refers to the direction of movement of the linearly-extensive portions of a web in a travel course in the web transport apparatus. The term "upstream" refers to the direction opposite to the downstream direction. The terms "lateral" and "laterally" refer to directions transverse to the web travel course.
The web transport apparatus of the present invention includes a pair of payout stands and a pair of takeup stands. Each of the takeup stands is associated with one of the payout stands. The apparatus also includes an active support structure for supporting a web extending from either of the payout stands to the associated takeup stand on an active path so that such web can be fed from such payout stand to such takeup stand. A storage support structure is provided for simultaneously supporting a web extending from the other one of the payout stands to its associated takeup stand on a storage path which is parallel to the active path but laterally remote from the active path. Web shift means are provided for laterally moving a web from the storage support structure to the active support structure so as to shift it from the storage path to the active path.
In use, the transport apparatus is juxtaposed with the desired treatment apparatus so that the active path of the transport apparatus extends through the active zone of the treatment apparatus, and any web moving along the active path can be processed by the treatment apparatus during movement along the active path.
A sequence of semi-continuous webs can be treated by threading each web from one of the payout stands to the associated takeup stand along the storage path while the immediately preceding web in the sequence is fed from the other payout stand to the associated takeup stand along the active path. When the web being so fed along the active path has been exhausted and the active path is empty, the web which is disposed in the storage path is laterally shifted onto the active path. While this replenishment web in turn is being fed through the treatment apparatus on the active path, the preceding web is removed from the takeup stand onto which it was fed and a new web is installed on the associated payout stand and threaded along the storage path to such takeup stand.
Thus, the unloading of processed webs and loading of new webs to be processed is accomplished while the treatment apparatus is running. The treatment apparatus is only inactive during the brief periods required to laterally shift each web from the storage path into the active path and accelerate it along the active path.
These and other objects, features and advantages of the present invention will be more readily apparent from the following detailed description of the preferred embodiments when read in conjunction with the accompanying drawings, in which like reference numerals are used to denote like features in the various views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of web transport apparatus according to the preferred embodiment of the present invention in conjunction with typical web treatment apparatus.
FIG. 2 is a schematic plan view of the apparatus depicted in FIG. 1.
FIG. 3 is a fragmentary sectional view taken along line 3--3 in FIG. 2.
FIG. 4 is a fragmentary sectional view taken along line 4--4 in FIG. 2.
FIGS. 5, 6 and 7 are each fragmentary sectional views similar to FIG. 3, each of these views depicting a different alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, web transport apparatus according to a preferred embodiment of the present invention includes a frame 10 and a pair of payout stands 12a and 12b disposed at the upstream end of the frame. Each payout stand includes a supply coil shaft 14a, 14b which is rotatably mounted to the frame 10 and a brake 16a, 16b at the inboard end of the shaft. Each payout stand also includes a web directing roller 18a, 18b rotatably mounted to the frame 10 downstream from the associated supply coil shaft. Appropriate conventional devices (not shown) are provided for releasably retaining a coil containing a web to be processed on each of the supply coil shafts.
The apparatus also includes a pair of takeup stands 20a and 20b. Each takeup stand includes a takeup coil shaft 22a, 22b which is rotatably mounted on an arm 24 which in turn is pivotally mounted to the frame 10. Each of the takeup stands also includes a drive roller 26a, 26b and a drive motor 28a, 28b connected with such drive roller by a belt 30. The drive roller of each takeup stand is rotatably mounted to the frame beneath the takeup coil shaft of such takeup stand. Each takeup stand also includes a fluid operated cylinder 32 which is connected to the arm 24a, 24b of such takeup stand and to the frame. The cylinders 32 are connected to an appropriate source of pressurized fluid (not shown) through appropriate valving so that the arm and takeup coil shaft of each takeup stand may be biased selectively downwardly towards the drive roller 26 of such takeup stand. Each takeup stand also includes a web directly roller 34a, 34b which is rotatably mounted to the frame upstream of the takeup coil shaft and drive roller of such takeup stand.
The brakes 16a, 16b of the payout stands 12a, 12b and the drive motors 28a, 28b of the takeup stands 20a, 20b are each connected with an appropriate control apparatus 35.
Web support means 36 is provided between the payout stands 12a, 12b and the takeup stands 20a, 20b. As best seen in FIGS. 2 and 3, the web support means 36 includes an active support structure 38 adjacent to the back plate 39 of the frame and a storage support structure 40 remote from the back plate 39. The active support structure 38 includes a plurality of struts 42 which are disposed in parallel side by side relation so that the struts extend in a row and define a linearly-extensive active path. As shown in FIG. 3, each strut 42 includes an internal member 44 which is fixedly mounted to the back plate 39 of the frame and an external cylindrical roller 46 which is rotatably mounted to the internal member 44 by suitable anti-friction bearings (not shown). Each roller 46 is provided with a shoulder 48 at its end adjacent to the back plate 39 of the frame. As shown in FIG. 4, the struts 42a at the center of the row are disposed higher than the struts 42b at the ends of the row. When a web is being fed along the active path, these differences in elevation will help to maintain tension in those portions of the web which are at the middle of the active path.
The storage support structure 40 (FIGS. 2 and 3) includes a plurality of sloping storage support rods 50 which are supported in side by side relation with one another by brackets 52. The lower end 54 of each support rod 50 is adjacent to the active support structure 38; the upper end 56 of each of the storage support rods is remote from the active support structure. The lower end 54 of each of the storage support rods is disposed above the associated bracket 52 by the same amount. As seen in FIG. 4, the brackets 52a at the middle of the row are disposed at higher elevations than the brackets 52b at the end of the row. The storage support rods 50 in the middle of the row are disposed at higher elevations than the storage support rods at the ends of the row. This arrangement helps to maintain tension in any web disposed on the support rods.
The lower end 54 of each storage support rod is adjacent to the outboard end of one of the struts 42 but is at a higher elevation than such strut. A connecting column 58 extends from the lower end of each storage support rod to the associated bracket 52. The inner face 60 of each such column lies immediately adjacent to the outboard end of the associated strut 42.
As seen in FIGS. 2 and 4, the directing rollers 18a and 18b of the payout stands lie upstream of the support means 36 and are disposed at elevations lower than the elevation of the end struts 42b of the active support structure. The directing rollers 34a and 34b of the takeup stands are disposed downstream of the support means 36 and at lower elevations than the end struts 42b of the active support structure.
Each of the payout stands 12a and 12b is associated with one of the takeup stands 20a and 20b. Thus, as best seen in FIG. 1, the web 62a which extends from a supply coil 64a on the supply coil shaft 14a of the upper payout stand 12a extends to a takeup coil 66a on the takeup coil shaft 22 of the upper takeup stand 20a. The web 62b which extends from the supply coil 64b on the supply coil shaft 14b of the lower payout stand 12b extends to the takeup coil 66b on the takeup coil shaft 22 of the lower takeup stand 20b.
As seen in FIGS. 1 and 2, the web 62a which extends from the upper payout stand 12a to the associated upper takeup stand 20a extends over the struts 42 of the active support structure 38. That is, the web 62a is supported by the active support structure on the active path defined by the struts 42. The web 62b extending from the lower payout stand 12b to the associated lower takeup stand 20b is received on the storage support rods 50 of the storage support structure 40. That is, the web 62b is supported on a storage path defined by the top surfaces of the storage support rods 50.
As best appreciated with reference to FIGS. 2 and 3, the storage path defined by the support rods 50 of the storage support structure 40 is parallel to but laterally displaced from the active path defined by the struts 42 of the active support structure 38. However, both of the payout stands 12a and 12b are arranged to dispense their respective webs in lateral alignment with the active path and both of the takeup stands 20a and 20b are arranged to receive their respective webs in lateral alignment with the active path. The payout stands are both arranged to hold their respective supply coils 64a and 64b in lateral alignment with the active path, and the directing rollers 18a and 18b of the payout stands are both laterally aligned with the active path. The takeup stands 20a and 20b are both arranged to hold their respective takeup coils 66a and 66b in lateral alignment with the active path and the directing rollers 34a and 34b of both takeup stands are laterally aligned with the active path. Thus, as will be readily appreciated with reference to FIGS. 1 and 2, the web 62a which extends along the active path from the upper payout stand 12a to the upper takeup stand 20a can be fed along the active path without going through any lateral travel course deviation, and such web can therefore be fed reliably at high speed.
The support structures can also accommodate webs in an arrangement inverse to that depicted in the drawings. In such inverse arrangement, the web which extends from the lower payout stand 12b to the lower takeup stand 20b will extend along the active path defined by the active support structure 38 and the web which extends from the upper payout stand 12a to the upper takeup stand 20a will extend along the storage path defined by the storage support structure 40. In this inverse arrangement, as in the arrangement depicted in the drawings, the two webs will not contact one another.
Thus, the active support structure 38 can support a web extending from either one of the payout stands 12a or 12b to the associated one of the takeup stands 20a or 20b so that such web can be fed along the active path, and the storage support structure 40 can simultaneously support a web extending from the other one of such payout stands to the associated takeup stand.
The web transport apparatus described above is utilized in conjunction with web treatment apparatus. The web treatment apparatus is depicted by way of illustration in the drawings as being a laser beam emitting unit 68 which is arranged to emit pulses of intense coherent light at preselected intervals. These pulses are directed downwardly along preselected axes within the active zone 70 of the treatment apparatus. Thus, the light beams emitted by the treatment apparatus will impinge on any web which is fed through this zone. Treatment apparatus of this type is used, for example, in perforating cigarette tipping paper; the light beams impinging on the paper burn holes in it and perforate it. It should be understood that the web transport apparatus described above can be utilized with other types of web treatment apparatus including, for example, spark perforation devices.
The treatment apparatus 68 is juxtaposed with the web transport apparatus, as by mounting the treatment apparatus to the frame of the web transport apparatus, so that the active path defined by the active support structure 38 of the web transport apparatus extends through the active zone 70 of the treatment apparatus, but the storage path defined by the storage support structure 40 of the web transport apparatus does not extend through the active zone of the treatment apparatus.
When the web transport apparatus described above is juxtaposed with web treatment apparatus in this manner, the resulting combination can be utilized to treat a series of webs, each supplied in the form of a coil, in the following manner: At start up, two supply coils are loaded into the apparatus, each being received on the supply coil shaft of one of the payout stands. The leading end of the web contained in one such coil is threaded from the payout stand on which the coil is mounted along the active path to the associated takeup stand. The leading end of the web contained in the second coil is threaded from the payout stand on which such coil is mounted to the associated takeup stand along the storage path. As seen in the drawings, the web 62a corresponds to the web of the first coil and the web 62b corresponds to the web of the second coil. The brake 16b associated with the payout stand holding the web which extends along the storage path is engaged by the control means 35 to maintain tension in such web. Such tension holds the web 62 b firmly against the upper surfaces of the storage support rods 50.
The motor 28a of the takeup stand associated with the web extending along the active path is operated to draw the first web 62a along the active path defined by the active support structure 38 and thus feed this web through the treatment zone 70 of the treatment apparatus. Of course, this action causes the web 62a to unwind from the supply coil 64a and wind onto the takeup coil 66a. The control means 35 engages the brake 16a of the payout stand 12a so as to maintain tension in the web 62a while it is being fed. The treatment apparatus is operated to treat the web while it is being fed.
When the first web 62a has been completely transferred from the supply coil 64a to the takeup coil 66a the active path will be empty and it will be ready to accept the second web 62b. To shift the second web 62b from the storage path to the active path, the control means releases the brake 16b associated with the payout stand 12b and starts the motor 28b of the takeup stand 20b. The motor 28b rotates the drive roller 26b of the lower takeup stand to draw the second web 62b into the lower takeup stand and wind it onto the takeup coil 66b. As the second web 62b starts to wind onto the takeup coil 66b, that portion of the second web 62b which is supported on the storage support rods 50 of the storage support structure 40 slides downwardly along the top surfaces of the support rods 50 until it drops onto the active support struts 42 of the active support structure 38. Thus, the second web is rapidly positioned on the active path defined by the active support structure.
It is believed that this sliding action is facilitated by two mutually contributing factors. First, release of the brake 16b by the control means reduces the tension in the web 62b and thereby reduces the force with which the web 62b bears on the storage support rods. Second, because the web 62b is moving downstream under the influence of the takeup stand 20b, the coefficient of friction between the web 62b and the top surfaces of the storage support rods is the dynamic coefficient of friction rather than the static coefficient of friction. Because the dynamic coefficient of friction is generally lower than the static coefficient of friction, such movement of the web helps to release the frictional engagement between the web and the support rods.
Once the second web has been shifted onto the active path as described above, the brake 16b is reengaged by the control means to tension the web 62b and the motor 28b of the lower takeup stand is brought up to normal operating speed by the control means, thus accelerating the second web along the active path. The second web 62b will be fed under tension along the active path through the treatment zone 70 of the treatment apparatus, and the treatment apparatus can be operated to treat the second web as it is being fed.
While the second web is being fed along the active path and processed by the treatment apparatus, a supply coil holding a third web (not shown) is installed on the supply coil shaft 14a of the upper payout stand 12a. This third web is then threaded from the upper payout stand to the upper takeup stand along the storage path, and the control means activates the brake of the upper payout stand to tension the third web and help retain it on the storage path. When the second web has been completely fed from the lower payout stand to the lower takeup stand, the control means releases the brake of the upper payout stand and starts the motor of the upper takeup stand to shift this third web into the active path. As will be readily appreciated, this process can be continued indefinitely; as each web in a sequence of webs is being fed along the active path from one of the payout stands to the associated takeup stand, the next web in the sequence is threaded between the other payout stand and the associated takeup stand along the storage path so that such next web is ready for transfer to the active path.
Thus, the treatment apparatus is only inactive while a web is being shifted from the storage path to the active path and accelerated along the active path. Each such shifting and acceleration period will ordinarily last for only a few seconds. The treatment apparatus will continue to run while a coil holding a fully treated web is unloaded from one of the takeup stands, a new supply coil is loaded onto the associated payout stand and the web contained in such coil is threaded along the storage path.
Web transport apparatus according to an alternate embodiment of the present invention is partially depicted in FIG. 5. This apparatus is similar to the apparatus described above. However, a catch finger 72 is slidably mounted to each of the storage support rods 50 of this apparatus. Each such catch finger is linked to a fluid operated cylinder 74 which in turn is connected to the control means of the apparatus. Thus, each such catch finger can be selectively moved between the blocking position depicted in FIG. 5, in which it extends upwardly above the top surface of the associated storage support rod 50 and a retracted position wherein it is recessed beneath such top surface. When the catch fingers are in their blocking positions, as depicted in FIG. 5, they will prevent the web 62b which is supported on the storage support rods 50 from sliding downwardly onto the active path. However, when the catch fingers are retracted, they will permit a web to slide from the storage path to the active path.
A pusher 76 is slidably mounted to the storage support rods 50 of the apparatus depicted in FIG. 5. The pusher is connected to a fluid operated cylinder 78 which in turn is connected to the control means of the apparatus. The cylinder 78 can be activated by the control means to move the pusher from the web engaging position depicted in FIG. 5, in which the pusher is adjacent to the upper end of the storage support rods 50, downwardly along the storage support rods to an advanced position in which the pusher 76 is adjacent to the lower ends 54 of the storage support rods. Such movement of the pusher will cause any web which was initially positioned on the storage rods to slide downwardly along the storage support rods to the active support structure 38.
The control means of this apparatus is arranged to operate the cylinders associated with the catch fingers 72 and the pushers 76 so that the catch fingers are retained in their blocking positions and the pusher is retained in its retracted or web engaging position except during transfer of a web from the storage path to the active path. During such transfer, the control means activates the cylinders associated with the catch fingers to retract them from their blocking positions and activates the cylinder associated with the pusher to advance it down the support rods. Thus, any web disposed on the support rods 50 will be positively retained thereon by the catch fingers until such time as transfer is desired and will then be positively shifted by the pusher.
Apparatus according to a further alternate embodiment of the present invention is partially depicted in FIG. 6. This apparatus is similar to the apparatus described above with reference to FIGS. 1 through 4. However, each of the storage support rods 150 of the apparatus depicted in FIG. 6 includes a lower element 152 and an upper element 154. The lower element of each support rod is fixed to the frame 10 of the apparatus. The upper element 154 of each support rod is connected to the lower element of such support rod by a pair of leaf springs 156. A vibrator 158 is mounted to the underside of each of the upper elements 154. Each vibrator 158 is connected to the control means so that the vibrator 158 can be selectively activated by the control means.
This apparatus is operated in much the same manner as the apparatus described above with reference to FIGS 1-4. However, when a web is to be shifted from the storage support structure to the active support structure, the vibrators are activated by the control means to shake the upper elements and thus vibrate the top surfaces of the storage support rods. These vibrations aid in releasing the frictional engagement between the web supported by the support rods and the top surfaces of the support rods, and thus permit sliding motion of the web toward the active support structure.
Apparatus according to yet another alternate embodiment of the present invention is partially depicted in FIG. 7. This apparatus is similar to the apparatus described above with reference to FIGS. 1 through 4. However, each of the storage support rods 250 of the apparatus depicted in FIG. 7 has a plurality of holes or passageways 252 extending through it so that each of these holes is open to the top surface of the support rod 250. Each of the holes 252 communicates with a manifold 254 which in turn is connected to a source of gas under pressure via a control valve 256. Each such control valve is connected to the control means of the apparatus so that it may be opened or closed by the control means.
When a web 62b disposed on the storage support rods 250 of this apparatus is to be shifted onto the active support structure 38 of the apparatus, the control means signals each valve 256 to open and gas flows from the gas source through each manifold 254 and through the holes 252 in each of the support rods. This gas will be forced between the web to be shifted and the top surfaces of the rods. Thus, the frictional engagement between the web to be shifted and the support rods will be released so that web can readily slide down the support rods and towards the active support path. Because each of the holes 252 in each support rod is directed towards the active support structure 38 (to the left in FIG. 7) the gas flowing from each such hole will flow towards the active support structure and will thereby impel the web 62b towards the active support structure.
Although each active support strut 42 of the active support structure 38 in the apparatus described above with reference to FIGS. 1-4 includes a rotatable cylindrical roller 46 (FIG. 3) defining its web support surface, this feature is not essential in all applications. However, the webs processed during use of the apparatus will slide across the top surfaces of the active support struts if the rollers are omitted. Therefore, such surfaces should be extremely smooth and abrasion resistant. Merely by way of example, ceramic wear pads can be mounted atop each active support strut if the rollers are omitted.
As numerous variations and combinations of the features described above can be utilized without departing from the spirit of the present invention as defined in the claims, the foregoing description of the preferred embodiments should be taken by way of illustration rather than by way of limitation of the present invention. | A web transport apparatus having an active support structure defining an active web transport path and a storage support structure defining a web storage path parallel to the active path. In use, the apparatus is juxtaposed with a treatment device so that the active path extends through the active zone of the treatment device. A sequence of semi-continuous webs may be treated by feeding each web along the active path while the next web is being threaded along the storage path, and shifting the next web laterally from the storage path to the active path upon exhaustion of the web being fed along the active path. The treatment device can remain operative while the storage path is being threaded. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority of U.S. Provisional Patent Application Ser. No. 61/351,117, filed 3 Jun. 2010, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to continuous batch washers or tunnel washers. More particularly, the present invention relates to an improved method of washing textiles or fabric articles (e.g., clothing, linen) in a continuous batch multiple module tunnel washer wherein the textiles are moved sequentially from one module to the next module. A counter flowing rinse is boosted (e.g., using pumps) to elevate and/or maintain a selected flow rate or flow pressure head. Even more particularly, the present invention relates to a method and apparatus for washing fabric articles in a continuous batch tunnel washer using an improved flow arrangement wherein the pressure head is boosted at selected modules of the multiple modules of the continuous batch tunnel washer using one or more booster pumps that maintain substantially constant pressure of the rinse liquid that is counter flowed. Multiple dual use modules can be employed which provide faster rinsing with high velocity counterflow, more through put with less water usage by recycling water. After a final module, fabric articles can be transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water.
[0006] 2. General Background of the Invention
[0007] Currently, washing in a commercial environment is conducted with a continuous batch tunnel washer. Such continuous batch tunnel washers are known (e.g., U.S. Pat. No. 5,454,237) and are commercially available (www.milnor.com). Continuous batch washers have multiple sectors, zones, stages, or modules including pre-wash, wash, rinse and finishing zone.
[0008] Commercial continuous batch washing machines in some cases utilize a constant counterflow of liquor. Such machines are followed by a centrifugal extractor or mechanical press for removing most of the liquor from the goods before the goods are dried. Some machines carry the liquor with the goods throughout the particular zone or zones.
[0009] When a counterflow is used in the prior art, there is counterflow during the entire time that the fabric articles or textiles are in the main wash module zone. This practice dilutes the washing chemical and reduces its effectiveness.
[0010] A final rinse with a continuous batch washer has been performed using a centrifugal extractor or mechanical press. In prior art systems, if a centrifugal extractor is used, it is typically necessary to rotate the extractor at a first low speed that is designed to remove soil laden water before a final extract.
[0011] Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples of such patented tunnel washers, each listed patent of the table being hereby incorporated herein by reference.
[0000]
TABLE
PATENT
ISSUE DATE
NO.
TITLE
MM-DD-YYYY
4,236,393
Continuous tunnel batch washer
12-02-1980
4,485,509
Continuous batch type washing machine
12-04-1984
and method for operating same
4,522,046
Continuous batch laundry system
06-11-1985
5,211,039
Continuous batch type washing machine
05-18-1993
5,454,237
Continuous batch type washing machine
10-03-1995
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention provides an improved method of washing fabric articles in a continuous batch tunnel washer. The method includes providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid.
[0013] The method of the present invention provides a counterflow (or counter flow) of liquid in the washer interior during rinsing including some interrupted counterflow. The counterflow is along a path that is generally opposite the direction of travel of the fabric articles. Booster pumps can be placed at intervals to increase the pressure and/or velocity of counter flowing rinse water. For example, in a twelve (12) module continuous batch washer there can be booster pumps placed at the fourth and eighth modules.
[0014] At a final module, the fabric articles are transferred via the discharge to a water extraction device or extractor (e.g., press or centrifuge). The extractor is used to remove excess water from the fabric articles after they have been discharged from the continuous batch tunnel washer.
[0015] For the greatest part of each cycle, processing without counterflow creates standing baths so that chemicals are allowed to do their job without being diluted. Then, for a very short portion of each cycle, high-velocity counterflow is applied thus providing the first part of the required dilution effect. A second stage of dilution ensures the goods move into far cleaner water every time. Dedicated rinse modules are not required, meaning more production from fewer modules.
[0016] The counterflow is stopped for about the first 65-75% of each transfer cycle. The entire amount of counterflow water is then pumped at a very fast rate in the final 25-35% of the time remaining. The pumps are preferably high-volume, variable speed inverter-driven so that both flow rate and duration of the counter-flowing water can be fully varied based on goods being processed. The high speed flow gives better rinsing action and uses far less water.
[0017] Washers of the present invention achieve very low fresh water consumption. For light soil linen, the water consumption is about 0.3 G/lb (2.5 l/kg) of linen processed. For most heavy soil linen, the expected water consumption is about 0.5 G/lb (4 l/kg).
[0018] The method and apparatus of the present invention saves water with these features:
[0019] 1) Interrupted Counterflow—Water only flows for rinsing which is about the last 25-35% of each cycle;
[0020] 2) Controlled Flow—Water is delivered by high-volume inverter pumps with vigorous flow that removes suspended soil and used chemistry faster, with less water;
[0021] 3) Dual-Use Modules—Each module is used for both standing bath washing and counterflow rinsing; and
[0022] 4) Full Water Availability—Fresh water and recycled press water are collected in a single tank mounted within the washer frame (e.g., under the load scoop). No external tanks are required.
[0023] The present invention is able to achieve maximum chemical performance with standing bath washing and high-velocity counterflow rinsing. High-speed water recirculation within the first module allows fast sluicing and wet-down, causing the chemistry to instantly penetrate the soiled linen.
[0024] After the transfer of the goods, the counterflow is interrupted creating a standing bath with no water flow so that chemistry is not diluted. Chemicals work at full concentration from the start of each bath. Chemicals work faster because of the large cylinder volume and fast intermixing with the goods.
[0025] Programmable high-volume pumps create a vigorous flow to remove exhausted chemistry and suspended soil effectively. Fixed partitions between each module prevent chemical mixing and leakage. No seals are required between modules.
[0026] Flow is paused at the start of each cycle to create standing baths without dilution so chemicals work faster. Counterflow water is pumped at high volume for the very last portion of the cycle. Vigorous flow removes contaminants much more quickly, thus reducing overall cleaning time. All wash modules are used for two functions, standing bath and high-speed counterflow for faster, better rinsing. Because of the dual-use modules fewer modules are required. Rinsing occurs immediately after chemical action in each wash module. No separate rinse modules are required. Water and chemistry recirculate at high-velocity within the first module. Goods are sluiced faster and more completely into the machine. Wet-down is almost instantaneous. Chemistry penetrates the linen instantly which is important for protein stains. The first module can thus be a working module.
[0027] The present invention requires fewer modules because of faster rinsing with high-velocity counterflow, more throughput with dual-use modules, and less water usage by recycling water.
[0028] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid, moving the fabric articles from the intake to the modules and then to the discharge in sequence, wherein, in the step of moving the fabric articles, multiple of the modules define a dual use zone having modules that function as both wash and rinse modules, adding a washing chemical to the volume of liquid in the dual use zone, after a selected time period, counter flowing a rinsing liquid in the dual use zone along a flow path that is generally opposite the direction of travel of the fabric articles in prior steps, and, during the step of counter flowing, boosting pressure of the counter flowing rinsing liquid with a pump at one or more positions spaced in between the intake and the discharge.
[0029] Preferably, in the step of boosting pressure, multiple booster pumps are provided, each pump boosting counter flowing rinsing liquid flow rate at a different one of said modules.
[0030] Optionally, during the step of counter flowing, the counter flow is at a flow rate of between about 20 and 300 gallons (76-1,136 liters) per minute.
[0031] Optionally, during the step of counter flowing, the counter flow is at a flow rate of between about 25 and 220 gallons (95-833 liters) per minute.
[0032] Optionally, during the step of counter flowing, the counter flow is at a flow rate of between about 35 and 105 gallons (132-397 liters) per minute.
[0033] Preferably, the booster pumps are spaced apart by more than one module.
[0034] Optionally, the booster pump discharges liquid into a module that is a dual use module wherein textile articles are both washed and rinsed.
[0035] Optionally, the booster pumps each discharge liquid into a module that is a dual use module wherein textile articles are both washed and rinsed.
[0036] Optionally, liquid flow in the dual use module is substantially halted for a time period that is less than about five minutes.
[0037] Optionally, liquid flow in the dual use zone is substantially halted for a time period that is less than about three minutes.
[0038] Optionally, liquid flow in the dual use zone is substantially halted for a time period that is less than about two minutes.
[0039] Optionally, liquid flow in the dual use zone is substantially halted for a time period that is between about twenty and one hundred twenty (20-120) seconds.
[0040] Preferably, a volume of liquid in a plurality of the modules is heated to a temperature of between about 100 and 190 degrees Fahrenheit (38-88 degrees Celsius).
[0041] Preferably, the counter flow during the step of counter flowing extends through multiple of the modules.
[0042] Preferably, the dual use zone includes multiple modules.
[0043] Preferably, each booster pump discharges counter flowing fluid into a module that is not a module closest to the discharge.
[0044] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior, wherein multiple of the modules define a dual use zone having modules that each function as both wash and rinse modules, moving the fabric articles from the intake to the discharge, adding a washing chemical to the dual use zone wherein modules in the dual use zone wash the fabric articles with a combination of water and said washing chemical, after a selected time interval and after the step of adding a washing chemical, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in the step of moving the articles, and counter flowing water through the modules of said dual use zone to effect a rinse of the fabric articles.
[0045] Preferably, the present invention further comprises boosting the flow rate in the step of counter flowing so that it is maintained at a desired value.
[0046] Preferably, wherein multiple booster pumps are employed in order to boost the flow rate.
[0047] Preferably, wherein there are a plurality of modules in between the booster pumps.
[0048] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules that segment the interior, and wherein a plurality of said modules define a dual use zone, moving the fabric articles from the intake to the discharge and through the modules in sequence, the fabric articles traversing the dual use zone during the step of moving the fabric articles from the intake to the discharge, adding a washing chemical to the dual use zone, and rinsing the fabric articles in the dual use zone by counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in prior steps.
[0049] Preferably, the present invention further comprises extracting excess fluid from the fabric articles after the step of rinsing the fabric articles.
[0050] Preferably, there is substantially no counterflow during the step of adding a washing chemical to the dual use zone and for a time period after this step.
[0051] Preferably, the time period is less than about five minutes.
[0052] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior, the interior including at least one dual use zone that includes multiple of said modules that each function as both a wash module and a rinse module, moving the fabric articles and a volume of liquid in a first direction of travel from the intake to the discharge and through the dual use zone, washing the fabric articles with a chemical bath in the dual use zone, and rinsing the fabric articles by counter flowing a rinse liquid in the dual use zone along a second flow path that is generally opposite the first direction of travel of the fabric articles in the step of moving the fabric articles.
[0053] Preferably, the present invention further comprises the step of boosting the flow pressure head of the counter flowing liquid in the step of rinsing the fabric articles by counter flowing at one or more modules.
[0054] Preferably, in the step of rinsing the fabric articles by counter flowing, the counter flow has a duration of between about 2 and 6 minutes.
[0055] Optionally, the counter flow is at a flow rate of between about 20 and 300 gallons (76-1,136 liters) per minute.
[0056] Optionally, the counter flow is at a flow rate of between about 25 and 220 gallons (95-833 liters) per minute.
[0057] Optionally, the counter flow is at a flow rate of between about 35 and 105 gallons (132-397 liters) per minute.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0058] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0059] FIG. 1 is a schematic diagram showing a preferred embodiment of the apparatus of the present invention; and
[0060] FIG. 2 is a schematic diagram showing a preferred embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0061] FIG. 1 shows a schematic diagram of the textile washing apparatus of the present invention, designated generally by the numeral 10 . Textile washing apparatus 10 provides a tunnel washer 11 having an inlet end portion 12 and an outlet end portion 13 . In FIG. 1 , tunnel washer 11 provides a number of modules 14 - 25 . The plurality of modules 14 - 25 can include modules which can be dual use modules in that some of the modules function as both main wash and rinse modules.
[0062] The total number of modules 14 - 25 can be more or less than the number of modules shown in FIGS. 1-2 .
[0063] Inlet end portion 12 can provide a hopper 26 that enables the intake of textiles or fabric articles to be washed. Such fabric articles, textiles, and goods to be washed can include clothing, linens, towels, and the like. An extractor 30 can be positioned next to the outlet end portion 13 of tunnel washer 11 . Flow lines are provided for adding water and/or chemicals (e.g., cleaning chemicals, detergent, etc.) to tunnel washer 11 .
[0064] When the fabric articles, goods, and linens are initially transferred into the modules 14 - 25 , an interrupted counterflow for a part of the batch transfer time is used. By using this interrupted counterflow for part (e.g., between about fifty and ninety percent (50-90%), preferably about seventy-five percent (75%)) of the batch transfer time, each module 14-25 performs as a separate batch. Batch transfer time can be defined as the time that the fabric articles/linens remain in a module before transfer to the next successive module.
[0065] By halting counterflow when some of the modules are functioning as main wash modules, this creates essentially a standing bath for the washing process and allows the cleaning chemicals to perform their function fully without any dilution from a counterflow of fluid within the tunnel washer 11 . Counterflow returns for the last part (e.g., last 25%) of the transfer time and is pumped at a higher rate (e.g., between about three hundred and four hundred percent (300%-400%) of the normal rate, see FIG. 1 ). This higher rate is thus higher than the flow rate of prior art machines using full time counterflow. For example, prior art machines with full time counterflow typically employ a flow rate of between about ten and thirty (10-30) gallons (38-114 liters) per minute and creates a full rinsing hydraulic head. The present invention eliminates the need to have additional modules dedicated to the function of rinsing and finishing as required in the prior art, thus saving cost and floor space.
[0066] FIGS. 1-2 show a preferred embodiment of the apparatus of the present invention illustrated generally by the numerals 10 ( FIG. 1) and 10A ( FIG. 2 ). FIGS. 1-2 also illustrate the method of washing fabric articles in a continuous batch tunnel washer. Textile washing apparatus 10 , 10 A each provide tunnel washer 11 or 11 A having inlet end portion 12 and outlet end portion 13 . Tunnel washer 11 interior 31 is divided into sections or modules. These modules can include modules 14 - 25 ( FIG. 1 ) and can include additional modules or fewer modules such as modules 14 - 21 of FIG. 2 .
[0067] In FIG. 1 , water extracting device 30 (e.g., press or centrifuge) is positioned next to discharge 27 . The extraction device 30 is used to remove excess water or extracted water from the fabric articles after they have been discharged from the tunnel washer 11 and placed within the extractor 30 . Extraction devices 30 are commercially available. An extraction device 30 could be used with the embodiment of FIG. 1 or 2 .
[0068] The modules 14 - 25 in FIG. 1 or the modules 14 - 21 of FIG. 2 can include dual use modules. If a module is a dual use module, it is used for both standing bath washing and counterflow rinsing. The modules 14 - 25 can thus include pre-wash modules, main wash modules, and rinse modules, some being dual wash modules. For example, modules 14 - 24 are dual use modules in FIG. 1 . Modules 14 - 20 are dual use modules in FIG. 2 . When functioning as a main wash or standing bath, counterflow via lines 28 , 36 can be slowed or halted for a time. Then, counterflow resumes during rinsing. In FIG. 1 , a fresh water storage tank 29 can provide fresh water via flow line 38 . Module 25 can be injected with a selected sour solution and/or a selected finishing solution that is delivered via inflow line 32 . Flow line 32 transmits the sour solution and/or finishing solution from tank 37 to module 25 . Finishing solutions can be any desired or known finishing solution, for example a starch solution or an antimold agent.
[0069] An extracted water tank 33 can be positioned to receive extracted water from an extraction device 30 . Flow line 34 is a flow line that transfers water from extraction device 30 to tank 33 . Water contained in tank 33 can be recycled via flow lines 35 or 36 . A sour or finishing solution can be injected at module 25 via inflow tank 37 . Freshwater can be added to tank 33 via freshwater inflow line 38 . Flow line 35 is a recirculation line that transfers extracted water from tank 33 to hopper 26 . Another recirculation flow line is flow line 36 . The flow line 36 transfers extracted water from tank 33 to flow line 28 and then interior 31 of tunnel washer 11 , beginning at final module 24 and then by counterflow to modules 23 , 22 , 21 , 20 , 19 , 18 , 17 , 16 , 15 in sequence.
[0070] For the continuous batch washing apparatus 10 of FIG. 1 , twelve modules are shown as an example. The temperature of some of the modules is shown as an example. The modules 14 , 25 can thus have a temperature of around 40 degrees Celsius. The modules 15 , 16 can have a temperature of around 70 degrees Celsius. The module 19 can have a temperature of around 50 degrees Celsius.
[0071] In the example of FIG. 1 , each of the modules 14 - 24 can be dual use modules. In FIG. 1 , each of the modules 14 - 24 could thus be part of both a wash function and then a rinse function. In FIG. 1 , rinse liquid counterflows via flow line 28 to module 24 , then to module 23 , then to module 22 .
[0072] The flow lines 35 and 36 can be provided with pumps in order to boost pressure in those flow lines. The flow line 35 can provide pump 39 for transmitting water to hopper 26 via flow line 35 . Pump 40 is provided in flow line 36 for transmitting water to tank 32 or flow line 28 for counterflow rinsing.
[0073] The flow line 36 splits at tee fitting 47 into flow line 28 and flow line 32 . The flow line 32 is a flow line that carries re-circulated extracted water from tank 33 to tank 37 . Inflow tank 37 can be used to supply sour or finishing chemicals via flow line 32 to the final module 25 , which can be a finish module.
[0074] Flow line 28 is a re-circulation flow line that enters module 24 and then flows water in counterflow to modules 23 , 22 in sequence. A booster pump 41 receives flow from flow line 28 . The booster pump 41 then discharges its flow via flow line 43 to module 21 . Flow then transfers from module 21 to module 20 then to module 19 and then to module 18 where it transfers via flow line 43 to booster pump 42 . Booster pump 42 then discharges its counter flowing rinsing fluid via flow line 44 to module 17 and then to module 16 and then to module 15 .
[0075] At module 15 , the rinsing fluid can be discharged via discharge valve 45 . A discharge valve 46 can also be provided for module 14 .
[0076] The booster pumps 41 , 42 ensure that counter flowing rinsing fluid is maintained at a selected flow rate, flow volume and flow pressure. The booster pumps 41 , 42 ensure that a desired pressure head is maintained.
[0077] In the example of Table 1 below, a batch size can be between about fifty (50) and three hundred (300) pounds (23-136 kg) of textiles. Total water consumption could be about 0.62 gallons per pound (5.1 liters/kg) of cotton textile fabrics. Total water consumption could be about 0.64 gallons per pound (5.3 liters/kg) poly cotton. The modules 14 - 18 could have differing capacities.
[0078] FIG. 2 shows an alternate embodiment of the apparatus of the present invention, designated generally by the numeral 10 A. Textile washing apparatus 10 A in FIG. 2 is an eight module machine, providing modules 14 , 15 , 16 , 17 , 18 , 19 , 20 , and 21 . As with the preferred embodiment of FIG. 1 , the textile washing apparatus 10 A provides a tunnel washer 11 A having an inlet end portion 12 and an outlet end portion 13 . The outlet end portion 13 can provide a water extraction device 30 , not shown in FIG. 2 for purposes of clarity.
[0079] Inlet end portion 12 provides hopper 26 for enabling fabric articles such as linen articles to be added to the interior 31 of tunnel washer 11 A. A discharge 27 receives effluent from the last or final module 21 where it enters an extractor 30 (not shown). Fluid is then discharged via flow line 51 for collection and extracted water tank 33 . Pump 50 receives flow from extracted water tank 33 . Pump 50 then transfers fluids from extracted water tank 33 to pulse flow tank 54 . A valve 53 can be provided in flow line 52 . Pump 55 can be a variable speed pump that transfers fluid from pulse flow tank 54 to flow line 70 and then to module 20 . Flow line 70 can be provided with valve 71 , flow meter 72 . Line 70 discharges at flow discharge 73 into module 20 .
[0080] Pump 56 transmits fluid from pulse flow tank 54 to flow line 67 and then to final module 21 . The flow line 67 can be provided with a tee fitting 87 . Flow line 67 discharges at 69 into module 21 . Flow line 67 can be provided with valve 68 . Flow line 86 communicates with flow line 67 at tee fitting 87 . Flow line 86 can be provided with valve 88 and flow meter 89 . The flow line 86 discharges into hopper 26 as shown.
[0081] Pulse flow tank 54 can receive make up water from flow line 57 . Flow line 57 can be valved with valve 58 to receive influent water from a user's water supply. Flow line 57 can be provided with flow meter 59 . Flow line 57 can also be provided with a back flow preventer or check valve 60 .
[0082] Pump 62 can be a variable speed pump. Pump 62 receives flow from module 18 through suction line 61 . Pump 62 then transmits fluid through flow line 63 to module 17 at flow line discharge 66 . Flow line 63 can be provided with valve 64 and flow meter 65 .
[0083] A number of chemical injectors or chemical inlets 74 - 82 can be provided for transmitting a selected chemical into a selected module of the modules 14 - 21 . Examples are shown in FIG. 2 . Module 14 has a chemical inlet 74 for adding or injecting alkali. Module 14 is also provided with a chemical inlet 75 for adding or injecting detergent. Similarly, chemical inlets 74 and 75 are provided on module 15 . Module 16 is provided with chemical inlet 76 and 77 which enables injection or addition of peracetic acid and peroxide respectively. Modules 17 and 18 can be fitted with chemical inlets 78 for the addition or injection of bleach. Modules 19 and 20 are fitted with chemical inlet 79 that can be used to inject any selected chemical. Module 21 is a final module that can receive finishing chemicals such as a sour, softener, and bacteriostat. The chemical inlet 80 designates sour injection. The chemical inlet 81 designates softener injection. The chemical inlet 82 is for injecting a bacteriostat.
[0084] Multiple steam inlets 83 can be provided as shown in FIG. 2 . In FIG. 2 , a steam inlet 83 is provided for each of the modules 14 - 21 . Flow line 84 receives flow from module 14 . Pump 90 then pumps flow received from flow line 84 into flow line 85 which then discharges into hopper 26 as shown in FIG. 2 . A flush zone is thus created in hopper 26 by water entering the hopper 26 from flow line 85 as well as water entering hopper 26 from flow line 86 as shown in FIG. 2 . The effect of these flow lines 84 , 85 is to transform the hopper 26 and first module 14 into a process area where fabric articles are quickly wetted and initially cleaned. A flow line 91 can be provided for counterflow of one module (e.g. module 20 ) to the previous module (e.g. module 19 ). Flow lines 91 are thus provided for each module 15 , 16 , 17 , 18 , 19 , 20 as seen in FIG. 2 .
[0085] Table 1 show examples of water flow rates (in gallons per minute and liters per minute) for light soil and heavy soil for either embodiment ( FIG. 1 or FIG. 2 ). Water flow time (examples) are shown in seconds. Exemplary weights (linen) are shown in pounds and in kilograms. Fresh water consumption is shown for light soil linen in gallons per pound (e.g., 0.1-0.8 gallons per pound) and liters per kilogram (e.g., 1.7-6.7 liters per kilogram for heavy soil linen).
[0000]
TABLE 1
Water Volumes
Linen Classification
Light Soil
Heavy Soil
GPM
LPM
GPM
LPM
Water
Minimum
25
95
50
190
Flow Rate
Middle
105
398
120
455
Maximum
220
833
220
833
Seconds
Seconds
Water
Minimum
10
10
Flow Time
Middle
30
30
Maximum
360
360
Pounds
KG
Pounds
KG
Linen
Minimum
50
23
50
23
Weight
Middle
110
50
110
50
Maximum
300
137
300
137
Gal/Lb
L/Kg
Gal/Lb
L/Kg
Fresh
Minimum
0.1
0.8
0.2
1.7
Water
Middle
0.3
2.5
0.4
3.3
Consumption
Maximum
0.8
6.7
0.8
6.7
[0086] The following is a list of parts and materials suitable for use in the present invention.
[0000]
PARTS LIST
Part Number
Description
10
textile washing apparatus
10A
textile washing apparatus
11
tunnel washer
11A
tunnel washer
12
inlet end portion
13
outlet end portion
14
module
15
module
16
module
17
module
18
module
19
module
20
module
21
module
22
module
23
module
24
module
25
module
26
hopper
27
discharge
28
flow line
29
fresh water tank
30
water extraction device
31
interior
32
flow line
33
tank
34
flow line
35
flow line
36
flow line
37
inflow tank
38
freshwater flow line
39
pump
40
pump
41
booster pump
42
booster pump
43
flow line
44
flow line
45
valve
46
valve
47
tee fitting
50
pump
51
flow line
52
flow line
53
valve
54
pulse flow tank
55
pump
56
pump
57
flow line
58
valve
59
flow meter
60
back flow preventer/check valve
61
suction line
62
pump
63
flow line
64
valve
65
flow meter
66
flow line discharge
67
flow line
68
valve
69
flow line discharge
70
flow line
71
valve
72
flow meter
73
flow line discharge
74
chemical inlet (alkali)
75
chemical inlet (detergent)
76
chemical inlet (peracetic acid)
77
chemical inlet (peroxide)
78
chemical inlet (bleach)
79
chemical inlet
80
chemical inlet (sour)
81
chemical inlet (softener)
82
chemical inlet (bacteriostat)
83
steam inlet
84
flow line
85
flow line
86
flow line
87
Tee fitting
88
valve
89
flow meter
90
pump
91
flow line
[0087] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
[0088] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A method of washing fabric articles in a tunnel washer that includes moving the fabric articles from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles. A dual use zone includes multiple of the modules or sectors. In a dual use zone, a module or modules can be used to both wash and thereafter rinse the fabric articles. While counterflow rinsing, the flow rate can be maintained at a selected flow rate or flow pressure head. One or more booster pumps can optionally be employed to maintain constant counterflow rinsing flow rate or constant counterflow rinsing pressure head. | 3 |
FIELD OF THE INVENTION
The present invention relates to a text input method, and more specifically, to a text input method which is integrated in a text input program or device supporting word input and assists a user in easily inputting a word or a phrase relating to a certain word.
BACKGROUND
In many languages, it is common that some words are relating to other words. For example, in English, the verb “play” has related words such as “plays”, “playing”, “played”. The noun “element” has related words such as “elements”. The verb “entertain” is relating to its noun “entertainment” formed by adding a suffix “ment”. The verb “wonder” is relating to its adjective “wonderful” formed by adding a suffix “ful”.
Relevance means that there is some correlation between two words or phrases. For example, in English, the relevance of words may be as follows:
1. Various tense forms of a verb, e.g., past tense, continuous tense, perfect tense, third person singular form, etc. For example, for the verb “write”, the past tense is “wrote”, the continuous tense is “writing”, the perfect tense is “written”, and the third person singular form is “writes”, etc.
2. The plural form of a noun. For example, the plural form of “teacher” is “teachers”, and the plural form of “mouse” is “mice”, etc.
3. Different properties of a word. For example, the verb “entertain” is relevant to its noun form “entertainment”. The noun “wonder” is relevant to its adjective form “wonderful”. The adjective “similar” is relevant to its noun form “similarity”.
4. The comparative degree and the superlative degree of an adjective. For example, the comparative degree of the adjective “smart” is “smarter”, and the superlative degree is “smartest”.
5. The near-synonym and the antonym of a word. For example, the antonym of “advantage” is “disadvantage”, and the near-synonym of “same” is “similar”, etc.
6. The possessive form of noun. For example, the possessive form of “we” is “our”, the possessive form of “China” is “Chinese”, the possessive form of “company” is “company's”, etc.
Two or more words with relevance are related words for one another. The foregoing descriptions are merely some examples of the concept of related words. In practice, two words or phrases may be regarded as related words as long as there is relevance between them. In addition to English, such concept of related words also exists in other languages. For example, in Chinese, “I” is relevant to “my”. In German, “vollkommen” is relevant to “Verkollkommnung”. In French, “roman” is relevant to “romantique”.
After an initial word is input, a user may usually desire to input a related word with a fast method. However, the conventional input method fails to meet the requirement. The user has to spell a complete word, which is time-consuming and laborious. For example, after “consume” is inputted, the user cannot input its noun form “consumption” fast.
Some software keyboard and input method may provide a word prediction function. For example, when the user input a word “won”, the software keyboard and input method can predict that the user may desire to input the contents “won”, “wonder”, etc., and indicate the user by providing these predicted words as candidate inputs for user selection. In traditional input methods, the word “wonderful” relating to “wonder” may be the word that the user desires to input, however, the word “wonderful” cannot be displayed as a candidate word due to various condition restrictions. Thus, if the user desires to input “wonderful”, the user has to further input more information to help the text input program or device filter other candidate words, so that “wonderful” may meet the requirement for being displayed as a candidate word. Accordingly, the input efficiency is impaired.
SUMMARY
With respect to the above problems, a method for fast inputting a related word is proposed by the present invention, to thereby accelerate the input rate and efficiency, and reduce the key-press times for a user.
According to a first aspect of the present invention, a method for fast inputting a related word is provided. The method includes: a first step of displaying a user editing text; a second step of selecting a word in the editing text and invoking a related word selection mode of the selected word by a specific operation approach; a third step of displaying one or more related words of the selected word; and a fourth step of inputting a user desired related word.
According to a second aspect of the present invention, a method for fast inputting a related word is provided. The method includes: a first step of displaying a user inputting text, and one or more candidate words of an inputting word in said inputting text; a second step of selecting said candidate word based on a user input, and invoking a related word selection mode of the selected candidate word by a specific operation approach; and a third step of inputting a user desired related word.
According to a third aspect of the present invention, a method for fast inputting a related word is provided. The method includes: a first step of displaying a user inputting text and one or more predicted words of an inputting word in said inputting text; a second step of selecting said predicted word based on a user input and invoking a related word selection mode of the selected predicted word by a specific operation approach; and a third step of inputting a user desired related word.
According to a fourth aspect of the present invention, a computer device is provided. The computer device includes: an input apparatus configured to receive a user input text and a user input command; a storage apparatus configured to store a computer program command; a control apparatus configured to accomplish, in the control of the computer program command, each step in the method of any above-mentioned aspect according to the user input command; and a display apparatus configured to display the text.
According to a fifth aspect of the present invention, a device for fast inputting a related word is provided. The device includes: a first apparatus for displaying a user editing text; a second apparatus for selecting a word in the editing text, and invoking a related word selection mode of the selected word by a specific operation approach; a third apparatus for displaying a related word of the selected word; and a fourth apparatus for inputting a user desired related word.
According to a sixth aspect of the present invention, a method for fast inputting a related word is provided. The method includes: a first apparatus for displaying a user inputting text, and one or more candidate words of an inputting word in said inputting text; a second apparatus for selecting the candidate word based on a user input, and invoking a related word selection mode of the selected candidate word by a specific operation approach; and a third apparatus for inputting a user desired related word.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a basic block diagram illustrating a computer device or portable terminal device 100 which is applicable to the text input method of the present invention;
FIG. 2 a is a schematic illustrating a text before editing according to a first embodiment of the present invention;
FIG. 2 b is a schematic illustrating a related word selection interface according to the first embodiment of the present invention;
FIG. 2 c is a schematic illustrating a text after editing according to the first embodiment of the present invention;
FIG. 3 is a flowchart illustrating a related word input procedure according to the first embodiment of the present invention;
FIG. 4 is a schematic illustrating another related word selection interface according to the first embodiment of the present invention;
FIG. 5 is a schematic illustrating a candidate word list according to a second embodiment of the present invention;
FIG. 6 is a schematic illustrating a first software keyboard according to the second embodiment of the present invention;
FIG. 7 is a schematic illustrating a second software keyboard according to the second embodiment of the present invention;
FIG. 8 is a schematic illustrating a third software keyboard according to the second embodiment of the present invention;
FIG. 9 is a schematic illustrating an interface presented to a user in a related word selection mode according to the second embodiment of the present invention;
FIG. 10 is a schematic illustrating a device with a keyboard in a related word selection mode by entering a shortcut key according to the second embodiment of the present invention;
FIG. 11 is a flowchart illustrating a related word input procedure according to the second embodiment of the present invention;
FIG. 12 a is a schematic illustrating a predicted word display mode according to a third embodiment of the present invention;
FIG. 12 b is a schematic illustrating a predicted word switching mode according to the third embodiment of the present invention;
FIG. 12 c is a schematic illustrating a related word display mode according to the third embodiment of the present invention;
FIG. 13 a is a schematic illustrating another predicted word display mode according to the third embodiment of the present invention;
FIG. 13 b is a schematic illustrating another predicted word switching mode according to the third embodiment of the present invention;
FIG. 13 c is a schematic illustrating another related word display mode according to the third embodiment of the present invention; and
FIG. 14 is a flowchart illustrating a related word input procedure according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a basic block diagram illustrating a computer device or portable terminal device 100 which is applicable to the text input method of the present invention. A user input apparatus 101 is configured to receive a user input command. The user input apparatus 101 includes a touch screen, or an electronic device screen equipped with a pointing system (e.g., a mouse, an induction plate, etc.). A storage apparatus 102 stores basic program commands that support routine work for the computer device or portable terminal device, e.g., operating system, common software, etc. In addition, the storage device 102 further stores computer program commands for implementing a text input method according to the following embodiments of the present invention. Moreover, the storage apparatus 102 further stores related information that connects each word with its related words, word frequency, and user configuration information, etc. A control apparatus 103 may be implemented by any kind of microprocessor, micro control and programmable logic element, dedicated integrated circuit or similar device in the conventional art. The control device 103 is configured to implement the below text input method according to the present invention. A display apparatus 104 is configured to provide the user with a visional interface illustrating a user input text, together with a word, a candidate word, a predicted word, a related word, and a control process thereof, which are to be mentioned below. The display apparatus may be separated from the user input apparatus 101 , or may be integrated with the user input apparatus 101 , e.g., a touch and display plate.
The following embodiments are specifically illustrated for a better understanding of the technical contents of the present invention.
Embodiment One
FIG. 2 a illustrates a part of text in an edit status which is displayed in a screen 200 . The user desires to change a word 201 “favor” to its adjective form “favorite”. In the screen of the touch screen, the user may press the area where the word 201 locates with a finger or a stylus, and may enter a related word selection mode by a specific motion (e.g., sliding downward).
FIG. 2 b illustrates an interface presented to the user in a related word selection mode. A related word list 202 is presented under the word 201 “favor”, and lists all the related words of the word 201 , e.g., favorite, favors, etc. The user may click a desired related word, “favorite” in this example. Then, the system may replace the word 201 “favor” by the word 203 “favorite”, as shown in FIG. 2 c.
If the screen 200 is associated with a device having a keyboard, the user may also enter the related word selection mode as shown in FIG. 2 b by moving the cursor to the word 201 and then pressing a pre-specified key (e.g., an Enter key). Next, the user may select a desired related word by moving the cursor upward or downward via a direction key, and then press another pre-specified key (e.g., an Enter key), and input the related word into the text, as shown in FIG. 2 c.
FIG. 3 is a flowchart illustrating a related word input procedure 300 according to the first embodiment of the present invention. The procedure includes the following steps. Step 301 : Display a user editing text. Step S 302 : Select a word in the user editing text, and invoke a related word selection mode of said word by a specific operation approach. Step 303 : Display the related words of said word. Step 304 : Input a user desired related word.
In terms of step 301 , the specific operation approach for entering the related word selection mode may be implemented in various ways. For example, operations performed on a touch screen, or an electronic device screen equipped with a pointing system (e.g., a mouse, an induction plate, etc.) include: clicking the word, double-clicking the word, sliding a contact point along a certain direction after pressing the word, long pressing the word over a specified period, hovering a mouse over a candidate word over a specified period, right-clicking the word by the mouse, or any kind of predetermined motion or mouse action. For another example, operations performed on an electronic device screen equipped with a keyboard (including hardware keyboard and software keyboard) or equipped with a key-press include: pressing a specified key (e.g., Enter key, direction key, special function key) after moving the cursor to the word; pressing specified combined keys (e.g., simultaneously press CTRL+NUMBER, or first press key A and then press key B within a specified period) after moving the cursor to the word; moving the cursor to the word and then hovering over the word over a specified period.
In terms of step 302 , there are various ways for displaying a related word. For example, displaying a list of all related words horizontally in an area near the word or in a specified area on the screen; displaying a list of all related words vertically in an area near the word or in a specified area on the screen.
After the related word display mode is entered, a selected word is highlighted, and the selected word is switched among different related words via a specified key (e.g., direction key of up, down, left or right). As shown in FIG. 4 , an original word is “favor”. After the user enters the related word mode via step 301 and step 302 , the present related word displayed at the screen is a word 401 “favorite”.
In terms of step 304 , there are various ways for inputting a user desired related word. For example, clicking the related word, or pressing a confirmation key after the cursor is moved to the specified related word, etc.
Although the related word input procedure 300 includes a series of steps performed in sequence, apparently, the procedure may include more or less steps, and the steps may be performed in series or in parallel (e.g., using a multithread processor), or several steps may be combined into one step. Moreover, in addition to the various ways for implementing each step mentioned above, it is readily appreciated by those skilled in the art that other ways (e.g., changing the key-press input into a voice input) may be adopted for implementing a certain step, while not compromising the essential of the related word input procedure according to present invention.
Embodiment Two
Some input methods may have the function of displaying a candidate word list based on a user input.
For example, when the user input “pro” via a hardware keyboard, a candidate word list is automatically predicted and displayed according to the input method, as shown in FIG. 5 . The list may be arranged horizontally or vertically, and may be presented at a fixed position in the screen, or may be presented at an area near the current input word (e.g., below the cursor).
For another example, in a software/hardware keyboard 600 as shown in FIG. 6 , two letters share one key. When the user presses key 601 , key 602 and key 601 in sequence, the candidate word list as shown in FIG. 5 is automatically predicted and displayed according to the input method.
For another example, in a software/hardware keyboard 700 as shown in FIG. 7 , three or more letters share one key. When the user presses key 701 , key 701 and key 702 in sequence, the candidate word list as shown in FIG. 5 is automatically predicted and displayed according to the input method.
Yet for another example, in a software/hardware keyboard 800 as shown in FIG. 8 , each letter occupies one key. When the user presses key 801 “p”, key 802 “r” and key 803 “o” in sequence, the candidate word list as shown in FIG. 5 is automatically predicted and displayed according to the input method.
In general cases, the user may select a candidate word by clicking the candidate word or a specified key. However, in the cases that the user desired word is not a candidate word but a related word of a certain candidate word, the traditional text input methods fail to perform a fast input.
The present embodiment provides a text input method, with which the user may select a related word of the candidate word, and thereby accelerating the input.
For example, in the candidate word list as shown in FIG. 5 , the user desires to input “productivity”, i.e., a related word of the candidate word “product”. In a touch screen, the user may press the candidate word “product” with a finger or a stylus, and may enter a related word selection mode by a specific motion (e.g., sliding downward).
FIG. 9 illustrates an interface presented to the user in a related word selection mode. All the related words of “Product” are presented in a list below “Product”. After the user clicks the related word “Productivity” that he desires to input, the word is then input to the current editing text.
Without the related word input method of the present invention, the user has to press twelve keys for inputting the word “productivity”. According to the present invention, the user may input the word by merely pressing three keys together with two selection actions. Thus, the input efficiency is significantly increased.
In many cases, the user needs a faster method for inputting some common related words, e.g., the plural form of a noun, various tense forms of a verb, etc. At this point, the steps of related word list may be bypassed via fast input, and thereby a user specified related word may be selected directly. For example, in the candidate area as shown in FIG. 5 , the user may slide a contact point rightward from the position of the word “Product”, and directly input the word's plural form “Products”.
If the device has a keyboard, the user may also enter the related word selection mode as shown in FIG. 9 by moving the cursor to the word “Product” and then pressing a pre-specified key (e.g., an Enter key). Next, the user may select a desired related word by moving the cursor upward or downward via a direction key, and then press another pre-specified key (e.g., a space key), and input the related word into the text.
If the device has a keyboard, as shown in FIG. 10 , the user may directly enter the related word selection mode in FIG. 10 via a key corresponding to each candidate word. For example, in FIG. 10 , each candidate word corresponds to a shortcut key, K 1 , K 2 , K 3 and K 4 , respectively. After pressing K 2 , the user enters a related word selection mode of the word “Product”.
FIG. 11 is a flowchart illustrating a related word input procedure 1100 according to the second embodiment of the present invention. The procedure includes the following steps. Step 1101 : Display a user inputting text, and one or more candidate words of an inputting word in said inputting text. Step S 1102 : Select a candidate word based on the user input, and invoke a related word selection mode of the selected candidate word. Step 1103 (optional): Display one or more related words of the selected candidate word. Step 1104 : Input a user desired related word.
In terms of step 1102 , operation approaches for entering the related word selection mode may be implemented in various ways. For example, operations performed on a touch screen, or an electronic device screen equipped with a pointing system (e.g., a mouse, an induction plate, etc.) include: clicking the candidate word, double-clicking the candidate word, sliding a contact point along a certain direction after press the candidate word, long pressing the candidate word over a specified period, hovering a mouse over the candidate word over a specified period, right-clicking the candidate word by the mouse, or any kind of predetermined motion or mouse action. Still, for example, operations performed on an electronic device screen equipped with a keyboard (including hardware keyboard and software keyboard) or equipped with a key-press include: moving the cursor to the candidate word; pressing a specified key (e.g., Enter key, direction key, special function key, etc.) after moving the cursor to the candidate word; pressing specified combined keys (e.g., simultaneously press CTRL+NUMBER, or first press key A and then press key B within a specified period) after moving the cursor to the candidate word; moving the cursor to the candidate word and then hovering over the candidate word over a specified period; each candidate word corresponds to a key, e.g., four candidate words correspond to keys K 1 -K 4 respectively, where K 1 -K 4 may be shortcut keys of the device, or may be combination keys CTRL+1 to CTRL+5.
In terms of step 1103 , there are various ways for displaying a related word. For example, displaying a list of all related words horizontally in an area near the candidate word or in a specified area on the screen; displaying a list of all related words vertically in an area near the candidate word or in a specified area on the screen.
The step 1103 is optional. When the user inputs the related word in a shortcut way, the step 1103 for displaying the related word may be bypassed. For example, the plural form of the word may be selected by sliding a contact point rightward from the candidate word.
In terms of step 1104 , there are various ways for inputting a user desired related word. For example, click the listed related word; or press a confirmation key after the cursor is moved to the specified related word; slide on the candidate word for a direct selection with a mouse or contact point motion, e.g., the plural form of the word may be selected by sliding a contact point rightward from the candidate word; directly select the related word with a specified shortcut key, e.g., candidate words 1 - 4 correspond to shortcut keys K 1 -K 4 respectively.
Although the related word input procedure 1100 includes a series of steps performed in sequence, apparently, the procedure may include more or less steps, and the steps may be performed in series or in parallel (e.g., using a multithread processor), or several steps may be combined into one step. Moreover, in addition to the various ways for implementing each step mentioned above, it is readily appreciated by those skilled in the art that other ways (e.g., changing the key-press input into a voice input) may be adopted for implementing a certain step, while not compromising the essential of the related word input procedure according to present invention.
Embodiment Three
The present embodiment illustrates a method for predicting a subsequent input at the cursor position based on the user input and selecting a related word.
For example, in a text editing area 1200 shown in FIG. 12 a , when the user inputs a text 1201 “pro”, the input method may look up words with the initial “pro” in a dictionary and automatically predict the input word as “profit”, and display a rest part of the text 1202 “fit” in another form. In this example, “pro” is the user input, and “profit” is the predicted word. The predicted word and the candidate word in the Embodiment Two differs in that, only one predicted word is display at the same time, whereas one or more candidate words are generally displayed at the same time. Usually, the predicted word is the candidate word with highest word frequency.
However, the user may actually desire to input a word “productivity”. The user may change the predicted word by a specified operation (e.g., pressing an upward or downward direction key). For example, the user may press a downward key and change the predicted word to a word 1203 “product”, as shown in FIG. 12 b.
Next, the user finds that “productivity” is a related word of the predicted word “product”. Therefore, the user may switch among various related words (e.g., products, production, etc.) of “product” by another specified operation (e.g., pressing a leftward or rightward direction key), until “productivity” is reached, as shown in FIG. 12 c . At this point, the user may press a space key or an Enter key for confirmation.
Still, for example, in a text editing area 1300 shown in FIG. 13 a , when the user inputs a text 1301 “pro”, the input method may automatically predict that the input word is 1302 “profit”, and may display the predicted word 1302 in an area near the cursor (e.g., below the cursor).
However, the user may actually desire to input a word “productivity”. The user may then change the predicted word by a specified operation (e.g., pressing an upward or downward direction key). For example, the user may press a downward key and change the predicted word to a word “product”, as shown in FIG. 13 b.
Finally, the user finds that “productivity” is a related word of the predicted word “product”. Therefore, the user may switch among various related words (e.g., products, production, etc.) of “product” by another specified operation (e.g., pressing a leftward or rightward direction key), until “productivity” is reached, as shown in FIG. 13 c . At last, the user may press a space key or an Enter key for confirmation.
FIG. 14 is a flowchart illustrating a related word input procedure 1400 according to the third embodiment of the present invention. The procedure includes the following steps. Step 1401 : Display a user inputting text, and one or more predicted word of a certain inputting word in said inputting text. Step S 1402 : Select the predicted word based on the user input, and invoke a related word selection mode of the selected predicted word. Step 1403 (optional): Display one or more related words of the selected predicted word. Step 1404 : Input a user desired related word.
In terms of step 1401 , there are various ways for displaying a predicted word. For example, display a rest part of the predicted word following the user input, as shown in FIG. 12 a ; display the predicted word in an area near (above or below) the user input, as shown in FIG. 13 a ; display the predicted word at a fixed area in the screen.
In terms of step 1402 , there are various ways for selecting a predicted word based on the user input. For example, the user may click some keys (e.g., an upward or downward direction key) on a hardware keyboard or a software keyboard for switching the predicted word; the user may use a scroll wheel on the device (e.g., a scrolling key on some mobile phones) for switching the predicted word; use a specified motion or mouse action on a touch screen or a screen with the mouse system (e.g., sliding rightward within the screen area indicates switching to another predicted word).
In terms of step 1403 , there are various ways for displaying a related word. For example, displaying a list of all related words horizontally in an area near the predicted word or in a specified area on the screen; displaying a list of all related words vertically in an area near the predicted word or in a specified area on the screen; displaying a related word at the original position of the predicted word.
The step 1403 is optional. When the user inputs the related word in a shortcut way, the step 1403 may be bypassed. For example, the plural form of the word may be selected by sliding a contact point rightward from the predicted word.
In terms of step 1404 , the user may input a desired related word in various ways. For example, the user may click some keys (e.g., a leftward or rightward direction key) on a hardware keyboard or a software keyboard for switching the related word; the user may use a scroll wheel on the device (e.g., a scrolling key on some mobile phones) for switching the related word; use a specified motion or mouse action on a touch screen or a screen with the mouse system (e.g., sliding downward within the screen area indicates switching to another related word).
Although the related word input procedure 1400 includes a series of steps performed in sequence, apparently, the procedure may include more or less steps, and the steps may be performed in series or in parallel (e.g., using a multithread processor), or several steps may be combined into one step. Moreover, in addition to the various ways for implementing each step mentioned above, it is readily appreciated by those skilled in the art that other ways (e.g., changing the key-press input into a voice input) may be adopted for implementing a certain step, while not compromising the essential of the related word input procedure according to present invention.
All the foregoing embodiments are based English. It is apparent that the methods for inputting a related word described in the present invention are not limited to one language model. For example, in Chinese, “I” is relevant to “my”. In German, “vollkommen” is relevant to “Verkollkommnung”. In French, “roman” is relevant to “romantique”. Therefore, a person of ordinary skill in the art may implement the methods for inputting a related word in other languages.
It is appreciated by a person of ordinary skill in the art that various modifications, combinations, recombinations or equivalents may be made to the embodiments of the present invention according to design requirements or other factors, as long as these modifications, combinations, recombinations or equivalents fall within the scope of the appended claims and the equivalent scope of the claims. | The present invention provides a text input method, which is integrated in a text input program or device supporting word input (e.g., software/hardware keyboard, input method, etc.) and assists a user in easily inputting a word or a phrase (e.g., various tense forms of a verb, etc.) relating to a certain word. The user may fast input a specific word relating to the certain word by a specific operation (e.g., clicking a software or hardware key, moving a screen contact point, etc.) or by a combination of a plurality of operations. | 6 |
CROSS REFERENCE TO RELATED MATTERS
The following patents, helpful to an understanding of the present invention, are hereby incorporated by reference:
[1] U.S. Pat. No. 4,025,721, issued May 24, 1977; and
[2] U.S. Pat. No. 4,185,168, issued Jan. 22, 1980.
TECHNICAL FIELD
This invention relates to a method of and means for adaptively filtering screeching noise caused by acoustic feedback in communication systems such as hearing aids or public address systems.
BACKGROUND OF THE INVENTION
Hearing impaired persons fitted with hearing aids, as well as persons around them, are familiar with loud, unpleasant, and often uncomfortable, screeching noises that often eminate from a hearing aid when it is turned on, and at other times as well. Persons with normal hearing have experienced similar problems with public address systems. In both hearing aids and public address systems, hereinafter referred to as communication systems of the type described, which are used in acoustic environments, acoustic feedback is the culprit. That is to say, some of the acoustic energy radiated from the speaker of a communication system into the acoustic environment is picked up by the microphone of that same system, is amplified by the system's electronics, and then rebroadcast into the environment. Under some conditions, signal reinforcement, or bootstrapping, occurs; and the result is a screeching noise that is both loud, physically uncomfortable, and annoying to all those in the vicinity of the speaker.
Screeching noise caused by acoustic feedback is a major irritation to hearing aid users as well as to persons with unimpaired hearing in their vicinity, and to persons in the vicinity of a malfunctioning public address system. Conventionally, the user of a hearing aid controls screech caused by acoustic feedback by reducing the gain on the amplifier in the hearing aid, but this expedient solves the problem at the expense of a reduction in the level of amplification of information, which is the basis for wearing a hearing aid in the first place. In addition, manual adjustment of the volume of a relatively small hearing aid is usually difficult, or at least inconvenient. In public address systems, on the other hand, resort to rearranging the microphone is often the only practical way to alleviate screeching noise. Thus, the elimination of screeching noise in a communication system caused by acoustic feedback often requires manual intercession into the operation of such system which may be inconvenient or inappropriate. Apparatus that automatically, and adaptively, overcomes the problem of screeching noise caused by acoustic feedback would therefore be very desirable.
It is an object of the present invention to provide both a method of and apparatus for automatically and adaptively overcoming the problem of screeching noise caused by acoustic feedback in a communication system of the type described.
BRIEF DESCRIPTION OF INVENTION
The present invention is incorporated into a communication system of the type described which operates in an acoustic environment. The system includes a microphone component for inputting audio information, an amplifier component for amplifying audio frequency signals inputted into the microphone, and a speaker component for outputting amplified audio frequency signals into the environment which provides an acoustic feedback path between the speaker component and the microphone. According to the present invention, an identification circuit dynamically identifies those parameters associated with acoustic feedback, and a correction circuit, whose transfer function is established by the parameters identified by the identification circuit, and which is coupled to the amplifier component, cancels the effect of the acoustic feedback.
In order for the acoustic feedback parameters to be identified, the configuration of the communication system is altered from a conventional operational mode to a parameter identification mode. In its operational mode, the system is configured with the microphone coupled to the speaker through the amplifier of the system; and the speaker is coupled to the microphone through the acoustic medium of the environment. In its parameter identification mode, the amplifier is decoupled from the microphone and speaker and is replaced by an identifier circuit. By decoupling the amplifier according to the present invention, identification is performed in a manner that virtually ignores the amplifier and concentrates essentially only on the acoustics of the system. Identifying the parameters of the acoustics of the system is the goal of the present invention because it is these parameters that must be cancelled in order to eliminate acoustic feedback.
The identifier circuit, which is part of an identification circuit that also includes a pseudo-random noise generator, is a cross-correlation circuit that may be of type disclosed in Chapter 4 of the textbook Identification of Systems, D. Graupe, Krieger Publishing Company, Huntington, NY (1976) listed as reference [1] of U.S. Pat. No. 4,025,721 identified above. Such a cross-correlation circuit cross-correlates the signals that appear at each of two inputs to the circuit and produces either discrete or continuous time parameters as output. Instead of a cross-correlation circuit, the identifier circuit may utilize a least square minimization circuit (that minimizes a function of the squared integrated identification error), or a gradient, or a sequential gradient, minimization circuit (that minimizes the gradient of the squared integration identification error, e.g., using an iterative process in which minimization is done sequentially in time).
These last mentioned mimimization circuits are described in Chapters 5 and 7 of Identification of Systems. The parameters so obtained establish the transfer function of the correction circuit enabling the effect of acoustic feedback to be significantly reduced or eliminated.
In order to establish the configuration of the communication system, a two-state switch means, operated by switch control means, is interposed between the microphone and the amplifier, and between the speaker and the amplifier. In its first state, the switch means is effective to configure the system in its operational mode, i.e., the amplifier is interposed between the microphone and the speaker, and the identification circuit is not in the loop. When the switch means is in its second state, the system is configured in its parameter identification mode wherein the identifier circuit of the identification circuit replaces the amplifier, i.e., one input to the identifier circuit is connected to the microphone and the other input is connected to both the speaker and the noise generator. In this configuration, the output of the noise generator is injected both into the speaker and into one input of the identifier circuit. Some of the noise broadcast by the speaker is received by the microphone because of the acoustic coupling therebetween; and the received noise is applied to the other input of the identifier circuit.
The cross correlation between the noise directly injected into the identifier circuit, and the noise (and perhaps information that is uncorrelated with the noise) received by the microphone via the acoustic link between the speaker and the microphone, is a representation of a transfer function related to the individual transfer functions of the microphone, the speaker, and the acoustic link. In this way, the parameters associated with the acoustic feedback are dynamically identified by the identification circuit in prepration for establishing the transfer function of the correction circuit.
The identification process requires a finite time; and the switch control means maintains the switch means in its second state of a predetermined period interval of time. At the end of such time interval, the switch control means changes the state of the switch means from its second to its first state, and the configuration of the system is converted from its identification mode to its operational mode. At the same time, the identified parameters are applied to the correction circuit to establish a transfer function that is directly associated with the acoustic feedback as it existed during the time the system was operated in its identification mode. Both the correction circuit and the amplifier of the communication system are coupled between the microphone and speaker of the system in its operational mode, preferably in a simple feedback connection. Because the transfer function of the correction circuit is in accordance with the output of the identifier circuit during the identification mode, the presence of the correction circuit is effective to alter the system transfer function in a way that cancels the effect of acoustic feedback as long as it remains substantially the same as it was during the identification time interval.
As indicated above, the switch control means establishes the states of the switch means which, in turn, determine the configuration of the communication system. The switch control means senses turn-on of the system and monitors the gain of the amplifier or threshold increases in amplitude, or in the root-means square (RMS) amplitude of the output of the amplifier, or in the high frequency portion of such output. Such threshold increases are assumed to be caused by acoustic feedback. In response to system turn-on, or gain change, or a threshold change in the output of the amplifier, or in the high-frequency (e.g., above say 1200 Hz.) portion of the output of the amplifier, or at periodic intervals (e.g., every 60 seconds), the switch-control means forces the switch means into their second state and maintains them in such state for a predetermined period of time during which the system is configured in its identification mode. During this period of time, parameter identification takes place. At the end of the predetermined period of time, the switch control means is effective to return the switch means to their first state at which the communication system reverts to its operational mode. In this way, the present invention provides a dynamic and adaptive way to filter screeching noise caused by acoustic feedback from communication system without manual intercession.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention are illustrated in the accompanying drawings wherein:
FIG. 1 is a schematic representation of a prior art hearing aid that is representative of a communications system into which the present invention can be incorporated;
FIG. 2 is a schematic block diagram of the hearing aid shown in FIG. 1 illustrating the transfer functions of its components;
FIG. 3 is a block diagram of the present invention incorporated into a communication system such as a hearing aid housing or a public address system;
FIG. 4 is a block diagram of the device shown in FIG. 3 configured to operate in a parameter identification mode;
FIG. 5 is a schematic block diagram of the correction circuit shown in FIG. 3;
FIG. 6 is block diagram of an embodiment of logic circuit which provides for the sensing of gain changes in the amplifier means of the apparatus shown in FIG. 3;
FIG. 7 is a block diagram showing one type of noise generator shown in FIG. 3;
FIG. 8 is a block diagram showing electronic switch means by which the microphone and speaker are connected to the amplifier means of the system and the switch control means for controlling the switch means.
DETAILED DESCRIPTION
Referring now to FIG. 1 of the drawings, reference numeral 10 designates a prior art communication system such as a hearing aid or public address system. Communication system 10 comprises microphone component 12 for producing an audio output signal on line 13 in response to audio signals, figuratively identified by lines 14 and 15, in an acoustic environment within which the communication system is located. System 10 further includes amplifier component 16 for producing an amplified output on line 17 in response to an audio input signal on line 13. Finally, system 10 includes speaker component 18 for producing audio signals, designated figuratively by reference numeral 19, that are broadcast into the acoustic environment in response to an input signal on line 17. For the purpose of illustrating the prior art, the acoustical environment within which the communication system is located provides an acoustic link designated figuratively by reference numeral 20 between speaker 18 and microphone 12.
As a consequence of the arrangement shown in FIG. 1, audio information broadcast by speaker 18 may be received by microphone 12, amplified in amplifier 16, and supplied to speaker 18 such that reinforcement occurs. The result is the familiar screeching noise associated with acoustic feedback.
Reference is now made to FIG. 2 for the purpose of illustrating the problem of acoustic feedback in terms of the transfer function associated with each of the components shown in FIG. 1. Each of the components shown in FIG. 1, namely microphone 12, amplifier 16, speaker 18, and acoustic link 20 has associated with it a transfer function characteristic of the component. The transfer function of a component, as is well known, is the ratio of the Laplace transform of the output of the component to the Laplace transform of the input of the component. Expressed in this manner, the transfer function of a component is characteristic of the component regardless of the form of the input thereto.
In FIG. 2, the transfer function of the components shown in FIG. 1 are shown in corresponding blocks. That is to say, the transfer function of microphone 12 is G 1 (s) as indicated by block 12A, etc. The present invention contemplates the addition to the conventional circuitry in a communication system of a correction circuit, whose transfer function C(s) is such that the presence of the correction circuit in the communication system is effective to cancel the acoustic feedback link. Such a circuit is shown in FIG. 2 and is designated by reference numeral 21A. While correction circuit 21A is shown connected in feedback relationship to the amplifier component, it is also possible for the correction circuit to be connected serially, or in parallel, to the amplifier component but the resulting corrections and analyses are more complex.
By conventional circuit analysis, the transfer function of the entire communication system T(s) is defined as the Laplace transform of the output at point 22, in the circuit shown in FIG. 2, to the Laplace transform of the input at point 23 in the circuit. The circuit transform T(s) can be expressed as follows: ##EQU1## where G l (s) is the transfer function of microphone 12, G 2 (s) is the transfer function of amplifier 16, G 3 (s) is the transfer function of speaker 18, and H(s) is the transfer function of acoustic link 20.
From inspection of Eq. (1), the effect of acoustic link 20 can be eliminated form the transfer function of the system provided that the transfer function of correction circuit 21A is adjusted, or is established, such that:
C(s)+H(s)G.sub.1 (s)G.sub.3 (s)=0 (2)
In the event that Eq. (2) is satisfied, Eq. (1) reduces to:
T(s)=G.sub.1 (s)G.sub.2 (s)G.sub.3 (s) (3)
Eq. (3) represents the transfer function of the communication system when no acoustic link exists between the output and the input of the system. From inspection of Eq. (2), one can see that the product G l (s)G 3 (s)H(s) must be identified rather than the quantity H(s), and the transfer function of the correction circuit must be set in accordance with Eq. (2).
Basically, the present invention provides an acoustic feedback identification circuit for selectively identifying those parameters associated with acoustic feedback between the speaker and microphone components of a communication system, and an adaptive correction circuit component which is coupled to the amplifier component, and which has a transfer function established by the parameters identified by the acoustic feedback identification means. In order to achieve this end, the present invention also includes configuration means for interconnecting the components such that the acoustic feedback identification circuit first identifies the parameters associated with acoustic feedback between the speaker and the microphone, and then, automatically, and self adaptively, establishes the transfer function of the correction circuit such that the latter is effective to cancel acoustic feedback.
Apparatus according to the present invention is designated by reference numeral 30 in FIG. 3 to which reference is now made. This figure is similar to FIG. 2 in that the transfer functions of the components of the communication system are illustrated in FIG. 3. That is to say, the microphone component of the system is illustrated by block 12, the amplifier component is represented by block 16, the speaker of the system is represented by block 18, the acoustic feedback link is indicated by block 20, and the correction circuit is represented by block 21. Apparatus 30 also includes acoustic feedback identification means 31 and configuration means 32.
Configuration means 32 includes two-state switches S1 and S2, and switch control means 33 for establishing and maintaining the state of the switch means. In one state, the switch means is effective to interconnect the microphone to the speaker through the amplifier component thus establishing what is termed, herein, the operational configuration of the components. In the other state of the switch means, the components are connected in what is termed an identification configuration in which identification means 31 is substituted for amplifier component 16.
Identification means 31 comprises identifier circuit 34 (see details in FIG. 4) which, as explained below, cross correlates the signals appearing at first input 35 and second input 36, and produces an output signal at 37 which is applied to correction circuit 21A. In addition to identifier circuit 34, identification means 31 also includes pseudo-random noise generator 38 connected to the first input terminal 35 of the identifier circuit.
Switch S2 of configuration means 32 is an electronic switch but is shown schematically in FIG. 3 for the purpose of simplifying the explanation of the invention. As seen in FIG. 3, switch S2 has a first state in which the output of amplifier component 16 of the system is connected to the speaker (position B) and a second state at which the input to the speaker is connected to noise generator 38 (position A). The configuration means also includes switch S1, which, in its first state (position B) connects the output of the microphone component to the input of the amplifier component, and a second state (position A) in which the output of the microphone is connected to input 36 of identifier 34. In normal operation, configuration means 32 maintains switches S1 and S2 in their first state such that the communication system is configured in an operational mode and the circuit thus established resembles that shown in FIGS. 1 and 2.
As indicated previously, configuration means 32 also includes switch control means 33 for controlling the state of switches S1 and S2. In a manner described below, the switch control means is responsive to a threshold change in the gain of amplifier component 16 for switching switches S1 and S2 from their first to their second state for a predetermined interval of time. In addition, switch control means 32 is also responsive to a turn-on condition of the amplifier component for switching switches S1 and S2 from their first to their second state for a predetermined interval of time.
When switches S1 and S2 are in their second state, the output of microphone component 12 is supplied to input 36 of identifier 34, and the output of noise generator 38 is applied to first input 35 of identifier 34 and to speaker 18. Noise from generator 38 is thus broadcast by speaker 18 into the ambient environment within which the communication system is located, and some of this noise is picked up, via acoustic link 20, by microphone 12 in addition to whatever information, such as speech, is also present in the environment. Thus, the input to identifier 34 is noise received directly from generator 38 as well as noise transmitted via acoustic link 20 between the speaker and the microphone. In a manner explained in Chapter 4 of "Identification of Systems" by D. Graupe, Krieger Publishing Co., Huntington, N.Y., (1976), and described below, identifier circuit 34 cross correlates the signals appearing at the first and second inputs 35 and 36, respectively, of the identifier and produces parameters that identify the acoustic line. While the input to the identifier supplied by the microphone may contain some intelligence, there is no correlation between it and the noise, and for this reason the presence of the intelligence does not affect the operation of identifier circuit 34 in a significant manner.
The parameters thus identified by identifier circuit 34 are applied to correction circuit 21 in a manner that establishes a transfer function for the correction circuit which satisfies Eq. (2). A finite time is required for the identifier circuit to generate the parameters associated with the acoustic feedback link, generally less than one second. After identification is complete, switch control means 32 becomes effective to reconfigure the communication circuit from its identification mode back to its operational mode by changing the state of switches S1 and S2 from their second state to their first state. Thereafter, the transfer function of the communication system will satisfy Eq. (3) with the result that the transfer function of the system in its operational mode eliminates acoustic feedback. Thus, the present invention prevents the communication system from producing screeching noise associated with acoustic feedback.
Summarizing the operation of the present invention, powering up the communication is sensed by switch control means 33 and is effective to configure the communication system into its identification mode as shown in FIG. 3. In this mode, the amplifier component, and the correction circuit that is feedback-connected thereto, are effectively removed from the communication system and identifier circuit 34 substituted therefor. In this configuration, the identifier circuit produces parameters which establish the transfer function of the correction circuit in a manner that solves Eq. (2). After identification is complete, switch control means 32 is effective to change the state of switches S1 and S2 to their first state where the identification means is disconnected from the communication system which operates in a conventional manner in the sense that the output of the microphone is amplified by the amplifier component and applied to the speaker component.
The switch-control means is also responsive to a threshold change in the gain of the amplifier component for the purpose of switching the state of the switches S1 and S2 from their first to their second state for a predetermined period of time sufficient for parameter identification to occur. Thereafter, the switch control means is effective to reconfigure the system from its identification mode to its operational mode.
For an explanation of the identification process carried out by the identification circuit in FIG. 3, reference is made to FIG. 4 which shows the configuration of the communication system during its identification mode. That is to say, the output of microphone component 12 is applied to the second input 36 of identifier circuit 34 and the output of noise generator 38 is applied to first input 35 of the identifier circuit. Nose from the generator is also applied to speaker component 18 whose is output is linked by the acoustic environment to microphone component 12. For reference purposes, the acoustic link between the speaker component and the microphone component is designated by reference numeral 20. Intelligence picked up by microphone component 12 is indicated at 40 in FIG. 4.
Identifier 34 is constructed in accordance with chapter 4 of Identification of System, D. GRAUPE, Krieger Publishing Company, Huntington, NY (1976), listed as reference [1] in the reference of U.S. Pat. No. 4,025,721. Thus, the signal received by identifier circuit 34 from microphone 12 is applied in parallel to a series of multipliers designated M 1 , M 2 , . . . M n . The output of noise generator 38 is applied in parallel to a series of delay circuits D 1 , D 2 , . . . D n ; and the output of corresponding delay circuits is applied, individually, to the multipliers. The outputs of each of the multipliers is integrated by integrators I 1 , I 2 , . . . I n for a predetermined period of time, typically about one second, producing, as shown in FIG. 4, a series of discrete time parameters. If the inputs to identifier circuit 34 are designated x(t) and y(t), the discrete output parameters may be identified as φ xy (φ 1 ), φ xy (φ 2 ), . . . φ xy (φ n ).
Chapter 4 in the reference referred to above also discloses a way in which the parameters can be continuous time parameters instead of discrete time parameters. Thus, an identifier according to the present invention can produce either discrete time parameters, or continuous time parameters. In either case, all of the parameters are pole parameters; namely, they are autoregressive.
The discrete time parameters produced as the output of identifier circuit 34 are applied to correction circuit 21 in the manner shown in FIG. 5. During operation of the communication system in its operational mode, the output of amplifier component 16 is applied to the input of correction circuit 21, and this input is designated by z(t). As shown in FIG. 5, the input signal z(t) is applied in parallel to delay circuits d 1 , d 2 , . . . d n where the delays of these delay circuits respectively correspond to the delays associated with identifier circuit 34. The outputs of the delay circuits in correction circuit 21 are individually multiplied by multipliers m 1 , m 2 , . . . m n as shown in FIG. 5 and applied to adder circuit 41, which produces output signal C(t) that is fed back into the input of amplifier component 16. In this way, correction circuit 21 is configured by the parameters identified by identifier circuit 34 to have a transfer function that satisfies Eq. (2). As a result, the acoustic feedback link does not affect the communication circuit during its operational mode.
One embodiment of a suitable pseudo-random noise generator is illustrated in FIG. 7 as a pseudo-random binary noise generator circuit. This circuit is described in reference [1] referred to previously. Essentially, a clock signal is applied in parallel to a series of delay circuits, the output of which is combined, in an exclusive-OR circuit, to produce an essentially "white" noise signal. Other types of noise generators that produce "white" noise can be used with the present invention, however. Instead of using a noise-generator, as such, the noise may be pre-recorded and stored in memory. In such case, the noise generator is the memory and the circuitry for reading out the memory.
An embodiment of configuration means 32 (FIG. 3) used with the present invention is shown in FIG. 8. Here, switch S1 is constituted by a pair of pass transistors 50 and 51, and switch S2 is constituted by a pair of pass transistors 52 and 53. When pass transistors 50 and 52 are enabled by a high level of node 54, the switches configure the communication system in its operational mode because the output from the microphone component is applied, via conducting pass transistor 50, to the input of amplifier component 16, and the output of the amplifier component is applied to the speaker by way of conducting pass transistor 52. On the other hand, when node 55 is high and node 54 is low, pass transistors 51 and 53 conduct, and pass transistors 50 and 52 are rendered non-conductive. The conduction of transistors 51 and 53 configure the communication system in its identifier mode because the output from the microphone component is applied, via conduction of transistor 51, to the input of identifier circuit 34 (i.e., "x"); and the output of identifier circuit 34 (i.e., "y") is applied to the speaker component by way of conducting transistor 53.
The voltages at nodes 54 and 55 are controlled by the resetting of counter 56. In operation, a reset signal produced by OR-gate 57 resets counter 56. The resetting of this counter causes the voltage at node 55 to go high and the voltage at node 54 to go low. As a consequence, the switch control means configures the communication system into its identification mode. The system remains in this mode until counter 56 reaches a predetermined number, counting from zero being commenced by the application of the output of AND gate 58 to which clock pulses are applied. The time required for the counter to count from zero to the preselected number is dependent upon the amount of time required for identifier 34 to identify the parameters associated with the acoustic feedback link. In any event, once the counter reaches this predetermined number, the output thereof switches the voltage at nodes 54 and 55 such that the voltage at node 54 becomes high and the voltage at node 55 becomes low thereby causing the switch control means to convert the communication system from its identification mode back to its operational mode.
OR-gate 57 produces an output when either of two situations occur: powering up the amplifier by closing on/off switch 59, or by a signal r(t) applied to OR-gate 57. When switch 59 is closed, the voltage at node 60 begins to rise from ground level at a rate depending upon the time constant associated with capacitor 61 and the resistance in the circuitry of the power supply of the communications system until a threshold level is reached at which Schmidtt trigger 62 is activated producing a step-voltage output that is applied to OR-gate 57. In response, counter 56 is reset and the system is configured to its identification mode. Thus, after a small delay following powering up the system to allow the components to become operational, the switch control means is effected to configure the communication system into its identification mode.
The signal r(t) shown in FIG. 8 is produced by gainsensor circuit 40 in response to a threshold change in gain of the amplifier component of the communication system. Gain sensor circuit 40 for generating signal r(t) is shown in FIG. 6. As shown therein, circuit 63 senses threshold changes in the gain of pre-amplifier 16' that is the gain-adjustable part of amplifier component 16. Specifically, circuit 63 computes the ratio of the output b of preamplifier 16' to its input a, continuously applies the ratio to a comparator, and produces an output when the change in gain across the pre-amplifier exceeds a threshold. The divisional operation by which the ratio of the output to the input of the pre-amplifier is done in an analog manner as shown in FIG. 6, but the operation could also be done digitally if desired.
As shown in FIG. 6, the output of the pre-amplifier is applied to a convertor which converts the root=mean-square of the signal at the output of the pre-amplifier to a dc voltage proportional to the root-mean-square of the output signal and applies this to operational amplifier 64. The same procedures apply to the input signal of the preamplifier, but this is limited at 65, and applied to one side of divider circuit 66. The other side of this divider circuit is taken from the output of operational amplifier 64 as shown. Thus, the voltage appearing at node 67 is a voltage proportional to the ratio of the output of preamplifier 16' to its input, i.e., to the gain of the preamplifier. This voltage is converted into a digital signal at 68, and digitally processed at 69 where the difference between this gain value and its value as delayed by delay element 72, are subtracted in difference circuit 73. The output of difference circuit 73 is then passed through absolute value circuit 74 and the subsequent absolute value of the difference is applied to comparator 70. The comparator is also supplied with a threshold signal at 71 for the purpose of comparing changes in gain of the pre-amplifier to some fixed level. When this gain reaches the threshold, comparator 70 produces the gain change signal r(t).
The advantages and improved results achieved by the method and apparatus of the present invention are apparent from the foregoing description of the preferred embodiment of the invention. Various changes and modifications may be made without departing from the spirit and scope of the invention as described in the claims that follow. | A communication system, such as a hearing aid or a public address system, may include a microphone for inputting audio information to the system, an amplifier for amplifying audio frequency signals inputted to the microphone, and a speaker for outputting amplified audio frequency signals into the environment which provides an acoustic feedback path between the speaker and the microphone. The invention provides an identification circuit for dynamically identifying those parameters associated only with acoustic feedback, and a correction circuit whose transfer function is established in accordance with the parameters identified by the identification circuit. The transfer function of the correction circuit is such that the effect of acoustic feedback is cancelled from the transfer function of communication system. The identification circuit is constructed and arranged to identify said parameters in response to a turn-on of the system, or to an automatically-sensed threshold change in gain of the amplifier. | 7 |
BACKGROUND AND SUMMARY OF THE INVENTION
The development of superconducting electrical generators has led to the use of airgap armature windings. These airgap armature windings are distinguishable from conventional stator windings by their structure which includes a support mechanism which does not include insertion in a slotted core. Conventional stators employ a generally rigid cylindrical core which is constructed from a plurality of stacked laminations. Each lamination has a plurality of teeth which, when stacked together, result in axial grooves in the inner cylindrical periphery of the core. By inserting the stator windings within these grooves, support is provided for the stator coils.
In contradistinction to the above described conventionally constructed stator, superconducting generator stators support the stator winding in generally rigid nonconductive material which is typically cylindrically shaped and which encase the conductive stator coils. This material typically has less mechanical strength than that provided by the laminated core and, therefore, the stresses to which the coils are subjected must be held to values within this lesser strength.
There are two major sources of mechanical stress in a superconducting generator stator, one due to thermal expansion and another caused by electromagnetic forces which occur during transient faults. When a transient fault occurs following a sustained operation which has produced thermal expansion of the stator components, the total stresses on the stator structure could be approximately equivalent to the sum of these two conditions and could approach or exceed the strength of the materials used to support the airgap armature winding.
Since the materials which are presently used in the support structure of airgap armature windings are of limited strength, a means for minimizing the stresses on them is required. The present invention provides a way of avoiding the additive stresses, particularly their radial components, resulting from both the thermal expansion and transient fault forces described above.
A generator stator made in accordance with the present invention incorporates an outer support structure around the airgap armature structure. Both are generally cylindrical and are associated in a coaxial and concentric assembly. A gap, or interface space, is provided between these two members which is generally cylindrical. Grooves are shaped in both the inner surface of the outer support structure and the outer surface of the airgap armature structure. These grooves are aligned to form a channel which is intersected by the above mentioned interface gap.
Within the channel, an interface support structure is disposed. It consists of a porous bar which is impregnated with a liquid, such as transformer oil, and encapsulated by an impermeable covering, such as plastic. Although a single interface support structure is described herein, it should be understood that a plurality of interface structures may be used, each being disposed in a separate channel.
The porous bar, which can be a fiber composite, is deformable under a sustained force but provides a rigid support capable of withstanding sudden forces of short duration, such as those caused by transient faults. The bar's ability to withstand short duration impulses enables the support system to provide stiffness which resists sudden deflections whereas the bar's gradual deformation under long duration forces, such as those caused by thermal expansion, enables it to avoid built up stresses caused by this expansion.
Since transient faults in an electrical generator typically produce forces which are tangential to the stator coil structure, the present invention is most advantageously positioned to extend axially along the interface gap. However, it should be understood that the porous bar of the present invention can be configured in any direction which extends perpendicular to the direction of anticipated forces.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be more completely understood from a reading of the description of the preferred embodiment in conjunction with the figures, in which:
FIG. 1 is a schematic end view of an exemplary superconducting generator employing the present invention;
FIG. 2 is a more detailed sectional view of the present invention shown in FIG. 1; and
FIG. 3 is a graph of the deflection/load relationship of the present invention under both sudden and long duration forces.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates generally to a support structure of electrical generators and, specifically, to viscoelastic means for providing support to an airgap armature of a superconducting generator.
FIG. 1 depicts an end view of a superconducting generator 10. The rotor member 12 is supported at its ends (not shown in FIG. 1) in a manner which maintains its concentricity with the airgap armature 14. The airgap armature 14 shown in FIG. 1 represents a generally rigid nonconductive material which is disposed around a generally cylindrical stator coil structure (not visible in FIG. 1).
The stator coil structure of a superconducting generator is typically an interleaved pancake assembly as shown and described in U.S. Pat. No. 4,151,433 issued to Flick on Apr. 24, 1979 and U.S. Pat. No. 4,292,558 issued to Flick, et al. on Sept. 29, 1981. The coil assembly is encased in a generally rigid non-conductive structure which provides it with both electrical insulation and mechanical support. Structures of this type are shown and described in copending patent applications Ser. No. 324,295 filed on Nov. 15, 1981 and Ser. No. 226,335 filed on Jan. 19, 1981, both of which are assigned to the assignee of the present application.
The airgap armature structure 14 is disposed in concentric and coaxial relation with an outer structure 16 with an interface space 17, or gap, therebetween. The outer cylindrical surface of the airgap armature structure 14 is provided with a groove 18 which, in the preferred embodiment, runs axially along the armature's periphery. A similar groove 20 is provided in the inner cylindrical surface of the outer structure 16. When tangentially aligned, as shown in FIG. 1, these two grooves, 18 and 20, cooperate to form a channel which runs axially between the outer structure 16 and airgap armature structure 14, intersecting the interface space 17.
The grooves, 18 and 20, are configured to form the channel which is shaped to receive a porous bar 22 which is disposed therein. The bar 22 is impregnated with a fluid, such as transformer oil, which fills the bar's internal voids. The oil impregnated porous bar 22 is enclosed in an impermeable covering 24 which can be an elastomer, such as plastic. The covering must be nonrigid and capable of containing the above mentioned bar 22 and oil. Although only one interface support structure is shown in FIG. 1, it should be understood that a plurality of them can be spaced around the airgap armature structure 14 in the interface space 17.
Although many porous materials can be used to manufacture the porous bar 22, oil permeable transformer board is advantageous because of its easy availability and known characteristics. The calculated and empirical values of its viscoelastic stiffness is reported in "Dynamic Response of Power Transformer Windings and Clamps under Axial Short Circuit Forces", Ph.D. Thesis by M. R. Patel, Rensselear Polytechnic Institute, June, 1972, in pages 1567 to 1576 of "Dynamic Response of Power Transformers under Axial Short Circuit Forces", by M. R. Patel, IEEE Transactions on Power Apparatus and Systems, Volume PAS-92, 1973 and in pages 721 to 730 of "Dynamic Stiffness and Damping of Transformer Pressboard during Axial Short Circuit Vibrations", by D. O. Swihart and D. V. Wright, IEEE Transactions, Volume PAS-95, 1976. Patel, in the 1972 and 1973 documents described above, shows that the compressive modules of oil impregnated pressboard under suddenly applied power frequency loads is approximately seven times its modulus under gradually applied loads, whereas the Swihart and Wright document gives the viscoelastic properties of oil permeated transformer boards at various preloads and temperatures. It should be understood, however, that any other suitable material, such as fiber composite, could be used within the scope of the present invention.
The porous bar 22 serves the function of permitting deflections caused by slowly applied forces such as thermal expansion, thus avoiding the build up of stresses during normal operation. It also has the characteristic of withstanding deflections caused by sudden forces such as those caused by transient fault conditions. These dual functions prevent the additive effect of transient forces combined with thermally induced forces which could otherwise exceed the mechanical strength of the nonconductive materials used in the construction of the airgap armature structure 14 which is significantly less than that of the laminated core which is typically used in conventional, nonsuperconducting electrical generators as described above.
FIG. 2 is a longitudinal sectional view of the interface support device 30 which comprises the porous bar 22 and impermeable covering 24 shown in FIG. 1. In FIG. 2, the bar 22 is accompanied with a reservoir of oil 32 disposed around it within the covering 24. Conduits 34 and 36 are provided to permit a flow of oil 32 into and out from the impermeable covering 24.
When the dynamoelectric machine is initially started, its temperature gradually rises and its stator components expand. This causes the porous bar 22 of the interface support device 30 to be compressed slowly, squeezing some oil from its multiplicity of internal voids. The oil 32 flows axially toward the ends of the impermeable covering 24 and through the conduits 34 and 36 into the reservoir bottles 40 and 41.
If valves 44 and 45 are closed, this oil flow compresses and raises the pressure of the gas 48 which is located in the space above the oil 32 in the bottles 40 and 41. As the machine cools, this pressure forces the oil 32 back into the voids of the porous bar 22.
Depending on the specific requirements of the generator, the present invention can comprise the valves 44 and 45 or, alternatively be open to atmospheric pressure. Furthermore, the pressure of the gas 48 can be raised by an external pressure system or left at atmospheric pressure before startup and sealed to permit the oil flow to raise the gas pressure during operation.
It is important to understand that, regardless of the specific construction of the interface support device 30, it must be able to withstand sudden loads and also to permit deflection under slowly applied loads. This dual function releaves stresses which could otherwise build up in the stator structure due to thermal expansion, while also resisting possibly damaging deflections which can be caused by sudden transient faults.
These characteristics are illustrated in FIG. 3. The dual behavior of oil impregnated porous material, such as transformer board, is shown by the two curves, S and L. Curve S represents the device's behavior under short duration forces such as those caused by transient faults. As can be seen in FIG. 3, very high loads produce only slight deflections due to the material's high modulus in response to sudden forces. However, under long duration loads as depicted by curve L, the porous material deflects considerably more due to its lower modulus under these conditions. Typical long duration loads are those caused by thermal expansion of stator components.
It should be apparent that the present invention provides a support system capable of withstanding sudden forces without allowing significant deflections but, under slowly applied loads, deflect in a manner which reduces built up stresses. It should further be apparent that these characteristics prevent the deleterious additive effect of sudden forces caused by transient faults which occur after long duration thermal expansion has occurred during the normal operation of an electrical generator. Furthermore, it should be understood that, although the present invention has been described in considerable detail and specificity, other embodiments are within its scope. | A viscoelastic support system is disclosed which utilizes an oil impregnated porous material. The porous bar has mechanical properties which behave in significantly different manners under sudden long duration loads. It withstands sudden forces with little deflection but deflects significantly in response to slowly applied forces. These dual characteristics avoid the harmful effects of additive stresses which could otherwise result from sudden loads caused by transient faults which occur following thermal expansion which has produced built up stresses following normal operation. | 8 |
TECHNICAL FIELD
The present invention relates to a terminal knitting texture and clothing such as top underwear and bottom underwear provided with the terminal knitting texture and is intended to prevent the terminal thereof from adversely affecting the appearance thereof and curling outward by forming the terminal as single knit so that the terminal is thin.
BACKGROUND ART
A welt portion such as the terminal of hems of socks, a waist hem and sleeve hems of an undershirt, and a waist hem and leg hems of shorts, and the like is mostly formed as a pouchy double welt by folding the welt portion. In this case, the terminal is thick and thus a difference in level is generated between the terminal and a portion of the body continuous with the terminal. The difference in level appears through an outerwear. A phenomenon so-called “difference in level adversely affects appearance” is liable to occur. Therefore it is preferable to form the welt portion as thinly as possible as a single welt. But when the welt portion is thin, there arises a problem that the welt portion is liable to curl outward and turn up.
That is, when the welt portion is formed as the double welt, the welt portion little curls but there arises a problem of the generation of the difference in level. On the other hand, when the welt portion is formed as the single welt, the difference in level is not generated, but there arises a problem that the welt portion is liable to curl.
Therefore conventionally there is a demand that the welt portion is formed as the single welt so that the terminal is thin and yet does not curl.
In compliance with the above-described demand, the welt portion proposed as disclosed in Japanese Patent Application Laid-Open No. 2002-146609 (patent document 1) is formed without folding the welt portion, namely, not as the double welt, but formed as the single welt consisting of the double knit fabric formed by weaving an elastic yarn. In the above-described double knit fabric, as shown in FIG. 8(A) , loops R are formed on the knit stitch S 1 and the purl stitch S 2 with a yarn supplied to the needles N 1 of the row A and the needles N 2 of the row B. Therefore the double knit fabric has an advantage that the tensile force of the right side surface and that of the wrong side are balanced with each other and that the knit fabric does not curl to the right side thereof. Compared with the case in which the welt portion is knit like a pouch, the single welt allows knitting steps to be simple and the knit fabric to be thin. But the proposed single welt consists of the double knit fabric which is thicker than the single knit fabric and does not solve the problem that the difference in level is liable to be generated at the terminal.
When the welt portion is formed as the single welt consisting of the single knit fabric, the knitting speed is about three times faster than the double knit. Thus the single welt enhances productivity and is capable of thinning the welt portion. But as shown in FIG. 8(B) , in the single knit fabric, the loops R are formed on only the knit stitch S 1 with a yarn supplied to the needles N 3 arranged side by side in a row. Thus as described above, the single knit fabric is liable to curl on the knit stitch side and turn up outward.
To solve the above-described problem, the present applicant proposed terminal knitting texture in which the welt portion is formed as the single welt consisting of the single knit, as disclosed in Japanese Patent Application Laid-Open No. 2004-124291 (Patent Document 2). As shown in FIG. 9 , in the set up area 2 of the terminal knitting texture where knitting is started, the courses composed of the mixture of knit and miss are knit with an elastic yarn. The welt knitting area 3 continuous with the set up area 2 has a plurality of courses knit with a ground yarn. In each of a plurality of the courses of the welt knitting area 3 , miss and tuck are combined with knit. The positions of the knit, the miss, and the tuck are so dispersed that the tensile force of the knit stitch and that of the purl stitch are balanced with each other to prevent the knit stitch side from curling.
Because the above-described terminal knitting texture consists of the single knit, the terminal knitting texture is capable of solving the problem of “difference in level adversely affects appearance” and in addition, the tensile force of the knit stitch and that of the purl stitch are balanced with each other in the welt knitting area 3 . Therefore it is possible to prevent curling from being generated on the knit stitch side. In addition, because the courses of the set up area 2 composed of the mixture of the knit and the miss are knit with the elastic yarn, it is possible to impart an appropriate degree of a tightening force to the terminal and yet prevent the set up area 2 from curling outward.
The above-described terminal knitting texture of the patent document 2 consists of the single knit so that the terminal knitting texture is thin and yet can be prevented from curling at the welt portion thereof. But the terminal knitting texture has room for improvement in enhancing fitting feeling of a user at the terminal thereof and the feeling of touch when the user wears clothing having the terminal knitting texture by imparting a proper degree of a tightening force to the user's body.
Patent document 1: Japanese Patent Application Laid-Open No. 2002-146609
Patent document 2: Japanese Patent Application Laid-Open No. 2004-124291
SUMMARY
Problems to be Solved by the Invention
The present invention has been made in view of the above-described problems and has for an object thereof to provide a terminal knitting texture in which a welt portion consisting of single knit fabric is prevented from curling and which is capable of making a user feel that the terminal knitting texture fits to a user's body to a high extent by imparting a proper degree of a tightening force thereto and further making the user have an agreeable feel.
Means for Solving the Problems
To achieve the above-described object, the present invention provides a terminal knitting texture, started to be knit at the terminal side, which is formed as a single welt consisting of single knit,
wherein a plurality of courses of a set up area where knitting is started is composed by knitting the set up area at not all wales, and the set up area is knit with a first-kind knitting yarn consisting of a single covering yarn having a thick elastic core yarn in such a way that the first-kind knitting yarn does not let the set up area curl outward; and
in a welt knitting area continuous with the set up area, courses knit with the first-kind knitting yarn are combined with courses knit with a knitting yarn having a lower stretch force than that of the first-kind knitting yarn.
As described above, because in the set up area in which knitting is started, not all the wales are knit but a plurality of courses is continuously knit with one knitting yarn, it is possible to prevent the set up area from curling. The terminal knitting texture consists of the single knit. Thus even though the first-kind knitting yarn consisting of the thick elastic core yarn and having a higher stretch force is used as the knitting yarn, it is possible to prevent the set up area from being thick but keep the set up area thin and impart a proper degree of a tightening force to a user's body and yet prevent the set up area from curling.
In the welt knitting area continuous with the set up area, the courses knit with the first-kind knitting yarn are provided. Thereby it is possible to impart a proper degree of a tightening force to the user's body and easily prevent the welt knitting area from curling outward. Further in addition to the courses knit with the first-kind knitting yarn, the courses knit with the knitting yarn having a lower stretch force than that of the first-kind knitting yarn are provided alongside the courses knit with the first-kind knitting yarn. Thereby the welt knitting area has a lower tightening force than that of the set up area, is capable of applying a low degree of a sense of oppression to the user's body, and make the user comfortable to wear.
It is preferable that the number of the courses in the welt knitting area is set larger than that of the courses in the set up area.
More specifically, the set up area includes a first set up part having a plurality of courses disposed at the terminal side where knitting is started and a second set up part, having a plurality of courses, which is disposed continuously with the first set up part,
wherein the first set up part has two to three courses; and each of the courses is composed of repeated one-wale knit and two-wale miss or repeated one-wale knit and three-wale miss, and knitting positions are shifted from one another in the wale direction; and
the second set up part has three to six courses; and each of the courses is composed of repeated one-wale tuck and two-wale miss or repeated one-wale tuck and three-wale miss.
As described above, the first set up part disposed at the terminal where the knitting is started has two to three courses. Each of the courses is composed of repeated one-wale knit and two-wale miss or repeated one-wale knit and three-wale miss. The knitting yarn is supplied every two or three needles. Thereby the first set up part is capable of imparting an appropriate tightening force to the user's body and preventing the tensile force of a knit stitch from being too high. In addition, by shifting the knitting positions from one another in the wale direction, it is possible to prevent the tensile force from being partially generated.
As described above, the second set up part has three to six courses. Each of the courses is composed of repeated one-wale tuck and two-wale miss or repeated one-wale tuck and three-wale miss. Similarly to the first set up part, the second set up part is capable of imparting an appropriate tightening force to the user's body by supplying the knitting yarn every two or three needles.
Preferably the welt knitting area has courses each composed of repeated one-wale tuck and one-wale to three-wale miss and courses each composed of all-wale knitting, wherein subsequently to continuously arranged two to three courses each composed of all-wale knit, one course composed of repeated tuck and miss is provided;
the courses each composed of the repeated tuck and miss are knit with the first-kind knitting yarn; and the courses each composed of the all-wale knit are knit with a second-kind knitting yarn consisting of a single covering yarn provided with an elastic core yarn thinner than that of the first-kind knitting yarn or/and a knitting yarn having a lower stretch force than that of the second-kind knitting yarn.
As described above, by continuously forming two to three courses knit at all the wales with the knitting yarn having a lower stretch force, it is possible to make the tightening force of the welt knitting area lower than that of the set up area and thus decrease a sense of oppression and thereby make the user comfortable to wear. By using the second-kind knitting yarn consisting of the single covering yarn for the courses each composed of the all-wale knitting, the welt knitting area is agreeable to the feel.
In this case, even though the tensile force of the knit stitch is increased by the plain knitting texture, it is possible to effectively prevent the welt knitting area from curling outward and keep a proper degree of a tightening force of the welt knitting area, because the knitting yarn having a low stretch force is used for the courses composed of the all-wale knit.
The number of the courses of the welt knitting area is not limited to a specific number, but may be increased or decreased according to the function and design of clothing so that the length of the welt knitting area is adjusted. The number of the courses of the set up area may be increased to not less than 20 courses, not less than 50 courses or 100 to 300 courses.
As the first-kind knitting yarn, consisting of the single covering yarn having a higher stretch force, which is used for both the set up area and the welt knitting area, it is favorable to use a yarn composed of a polyurethane elastic core yarn having 70 to 200 decitex and nylon 6 or nylon 66 wound round the polyurethane elastic core yarn.
If the thickness of the polyurethane elastic core yarn is less than 70 decitex, the tightening force of the first-kind knitting yarn consisting of the single covering yarn is so low that there is a case in which the tightening force thereof is lower than the curling force of the welt portion. If the thickness of the polyurethane elastic core yarn is more than 200 decitex, the balance between the tightening force of the set up area and that of the welt knitting area is lost and the tightening force of the terminal knitting texture is so high that the user may feel uncomfortable to wear. It is especially favorable that the thickness of the polyurethane elastic core yarn is 100 to 160 decitex.
As the knitting yarn for the plain knitting texture for use in the courses, of the welt knitting area, which are knit at all the wales thereof, one or a plurality of kinds of the following knitting yarns (1) through (3) having a stretch force lower than that of the first-kind knitting yarn is used:
(1) The second-kind knitting yarn consisting of the single covering yarn composed of the polyurethane elastic core yarn having 10 to 40 decitex and the nylon 6 or the nylon 66 wound round the polyurethane elastic core yarn
(2) Wooly nylon
(3) A blended yarn consisting of cuprammonium rayon and the nylon 66
In consideration of the appearance and function of clothing provided with the terminal knitting texture, there are a case where only the second-kind knitting yarn of (1) is used; a case where the second-kind knitting yarn of (1) and the wooly nylon of (2) as a plating are used; and a case where instead of the second-kind knitting yarn of (1), the wooly nylon of (2) or the blended yarn (3) consisting of the cuprammonium rayon and the nylon 66 is used.
In the second-kind knitting yarn of (1) consisting of the single covering yarn, if the thickness of the polyurethane elastic core yarn is less than 10 decitex and even though the plain knitting texture which is used for the courses, of the welt knitting area, which are knit at all wales thereof is formed, the tightening force of the welt knitting area is so low that there may be a case in which the user cannot feel comfortable to wear. On the other hand, if the thickness of the polyurethane elastic core yarn is more than 40 decitex, the second-kind knitting yarn does not have a low power, but has a tightening force so high that the user feels uncomfortable to wear and in addition, the tensile force of the knit stitch is so high that outward curling may be generated. It is most favorable that the thickness of the polyurethane elastic core yarn is 15 to 25 decitex.
By using the wooly nylon of (2), it is possible to adjust the degree of the elongation of the welt knitting area and improve the appearance and touch of the clothing provided with the terminal knitting texture. Considering the balance between the stretch force of other yarns and that of the wooly nylon, it is preferable to use the wooly nylon having a thickness of 10 to 80 decitex.
By using the blended yarn of (3) consisting of the cuprammonium rayon and the nylon 66, it is possible to enhance the moisture absorbing/release property of the blended yarn owing to the blending of the cuprammonium rayon with the nylon 66. The preferable mixing ratio of the blended yarn is so selected that the moisture absorbing/release property of the cuprammonium rayon is not damaged. Thus it is preferable to use the blended yarn having 40 to 90 decitex.
It is preferable that the knit fabric is a tubular knit fabric knit by using a single cylinder. The tubular knit fabric of the single knit can be formed into underpants, socks, a body and sleeves of an undershirt, and the like without sewing the knit fabric. Thus the tubular knit fabric contributes to an increase of productivity.
The present invention provides clothing having the terminal knitting texture formed as the single welt consisting of the single knit. The terminal knitting texture is especially preferably used as an innerwear and socks. More specifically, as top clothing, an undershirt, a T-shirt, a tank top, a camisole, and the like are listed. The hems of the sleeve and body of the top clothing are formed as the single welt consisting of the terminal knitting texture. As bottom clothing, shorts, underpants, leggins, a girdle, leg wear, stockings, pantyhose, socks, and the like are listed. The waist hem, sleeve hems, and the like of the bottom clothing are formed as the single welt consisting of the terminal knitting texture.
By forming the waist hem, sleeve hems, and leg hems of the clothing as the single welt consisting of the single knit, the hem, cuff, and top thereof are thinly formed. Therefore the difference in level is little generated, which prevents the terminal of the innerwear from generating the phenomenon that the terminal thereof adversely affects the appearance. Because the set up area is knit with the first-kind knitting yarn consisting of the single covering yarn provided with the thick elastic core yarn and having a higher stretch force, it is possible to impart a proper degree of a tightening force to the user's body and prevent the set up area from curling outward and thus the terminal from turning up outward.
The welt knitting area is formed in combination of the courses knit with the first-kind knitting yarn consisting of the single covering yarn having a higher stretch force and the courses knit with the knitting yarn having a lower stretch force than that of the first-kind knitting yarn. Therefore the welt knitting area is capable of applying a proper degree of the tightening force to the user's body, making the user feel comfortable to wear, and giving a soft feel thereto, and preventing the welt knitting area from curling outward.
EFFECTS OF THE INVENTION
As described above, in the present invention, in a plurality of the courses of the set up area in which knitting is started, knitting is performed at not all the wales, but knit and miss are mixedly performed. Therefore it is possible to prevent the set up area from curling outward. Further the terminal knitting texture is knit with the first-kind knitting yarn consisting of the single covering yarn provided with the thick elastic core yarn and having a higher stretch force. Thus it is possible to impart a proper degree of the tightening force to the user's body and provide the user with a comfortable feeling in wearing and yet prevent the set up area from curling outward.
The welt knitting area continuous with the set up area is formed in combination of the courses knit with the first-kind knitting yarn having a higher stretch force and the courses knit with the knitting yarn having a lower stretch force than that of the first-kind knitting yarn. Therefore the welt knitting area is capable of applying a proper degree of the tightening force to the user's body, giving a soft feel thereto, and preventing the welt knitting area from curling outward.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view of a tubular knit fabric having the terminal knitting texture of the invention,
FIG. 2 is an explanatory figure showing a knit fabric of first embodiment,
FIG. 3 shows the knit fabric of the first embodiment,
FIG. 4 is an explanatory figure showing a knit fabric of second embodiment,
FIG. 5 is an explanatory figure showing a knit fabric of third embodiment,
FIG. 6 is an explanatory figure showing a knit fabric of fourth embodiment,
FIG. 7 is a schematic view of underpants of fifth embodiment,
FIG. 8(A) shows a part of a conventional knit fabric, and FIG. 8(B) shows a part of another conventional knit fabric, and
FIG. 9 is an explanatory figure showing a conventional knit fabric.
DESCRIPTION OF EMBODIMENTS
The embodiments of the terminal knitting texture and clothing provided with the terminal knitting texture of the invention are described below with reference to the drawings.
FIG. 1 shows a knit fabric 1 of first embodiment knit by a single cylinder type circular knitting machine having 4 feeders with 4 inch diameter. In the drawing, the upper side is the starting side of knitting, and from the top a set up area 2 , a welt knitting area 3 , and a body knitting area 4 continues and at the bottom, a double welt knitting area 5 is provided.
FIGS. 2 and 3 show a fabric texture of the welt knitting area 3 wherein a mark (◯) under needles 10 - 1 in the 1st row through 10 - n in Nth row denotes a case when the needle 10 is fed with a yarn which is called knit, a mark (x) denotes a case when the needle is skipped and not fed with a yarn which is called miss, and a mark (Δ) denotes a case when the needle having knitted in the previous course is fed with a yarn which is called tuck.
For the set up area 2 at the start of knitting, the first-kind knitting yarn consisting of the single covering yarn 11 composed of the polyurethane elastic core yarn of 130 decitex and the nylon 66 of 28 decitex wound around the polyurethane elastic core yarn. By continuously feeding the single covering yarn 11 from a feeder, three courses from 1st course C 1 through 3rd course C 3 which consist a first set up part 2 a , and six courses from 4th course C 4 through 9th course C 9 which consist a second set up part 2 b are knit.
In this embodiment, in the course of the first set up part 2 a , 1-wale knit→2-wale miss→1-wale knit→2-wale miss is repeated. In the course of the second set up part 2 b , 1-wale tuck→2-wale miss→1-wale tuck→2-wale miss is repeated.
In particular, as shown in FIGS. 2 and 3 , the needle 10 - 1 of 1st row is positioned knit ◯, the needles 10 - 2 and 10 - 3 of 2nd and 3rd rows are positioned miss x, the needle 10 - 4 of 4th row is positioned knit ◯, the needles 10 - 5 and 10 - 6 of 5th and 6th rows are positioned miss x so that one-wale knit and two-wale miss is repeated.
In 2nd course C 2 and 3rd course C 3 , one-wale knit and two-wale miss is repeated similarly in 1st course, but in 2nd course, the needles 10 - 3 and 10 - 6 of 3rd and 6th rows are positioned knit, and in 3rd course, the needles 10 - 2 , 10 - 5 and 10 - 8 of 2nd, 5th and 8th rows are positioned knit. In short, the knit positions of all courses are shifted in the wale direction so that the position in one course where is the miss positions in the other courses is the knit position.
As described above, in the first set up part 2 a of the set up area 2 , one-wale knit and two-wale miss is repeated in one course, and one-wale tuck and two-wale miss is repeated in the second set up part 2 b in knitting. Besides, the set up area 2 including the first and second set up parts 2 a and 2 b is knit with the elastic first-kind knitting yarn consisting of the single covering yarn 11 composed of thick polyurethane elastic core yarn so that the area is free from curling outward.
Additionally, the knit positions of all courses are shifted in the wale direction so that the position in one course where is the miss positions in the other courses is the knit position. Therefore, tension is balanced and moderate tightening force is universally and equally applied to the portion in the peripheral direction, which makes the clothing comfortable to wear.
In courses C 10 , C 13 and C 17 of the welt knitting area 3 continuing from the set up area 2 , 1-wale tuck→1-wale miss→1-wale tuck→1-wale miss is repeated in knitting by feeding from one feeder, the first-kind knitting yarn with a higher stretch force which consists of the single covering yarn 11 composed of the polyurethane elastic core yarn of 130 decitex and nylon 66 of 28 decitex wound around the polyurethane elastic core yarn.
In other courses C 11 , C 12 , C 14 , C 15 , C 16 , C 18 , C 19 and C 20 of the welt knitting area 3 , the second-kind knitting yarn with a lower stretch force consisting of the single covering yarn 12 of the polyurethane elastic core yarn of 20 decitex and nylon 66 of 28 decitex wound around the polyurethane elastic core yarn is fed from another feeder and knit at all the needles.
In particular, as shown in FIGS. 2 and 3 , on 10th course C 10 , the needle 10 - 1 of 1st row is positioned tuck Δ, the needle 10 - 2 of 2nd row is positioned miss x, the needle 10 - 3 of 3rd row is positioned tuck Δ, the needle 10 - 4 of 4th row is positioned miss x, so that one-wale tuck and one-wale miss by the single covering yarn 11 is repeated.
Then, on 11th course and 12th course, all the needles 10 - 1 through 10-n are positioned knit ◯ where the single covering yarn 12 having a lower stretch force is knit. After these two continuous courses, follows 13 th course C 13 repeating 1-wale tuck and 1-wale miss, same as that on 10th course C 10 . Further, the patterns of three courses of knit only and one course repeating 1-wale tuck and 1-wale miss follows.
The length of the welt knitting area 3 may be a necessary length. Therefore, when the welt knitting area 3 is necessary to be shorter, the number of repeating course may be lessened and when the welt knitting area 3 is necessary to be longer, the number may be increased.
As described above, in the welt knitting area 3 , after the continuous two courses C 11 and C 12 of only knit by the second-kind knitting yarn 12 having a lower stretch force, one course repeating 1-wale tuck and 1-wale miss with the first-kind knitting yarn 11 having a higher stretch force follows, then three courses of only knit by the second-kind knitting yarn 12 follow. Subsequently, by repeating the above sequence, the tightening force may become weaker than that of the set up area so that feeling of oppression decreases to improve comfortability of wearing and the fabric is effectively prevented from curling outward. Besides, the welt knitting area 3 is knit only by the first-kind and second-kind knitting yarn consisting of the single covering yarn similar to the set up area 2 , which can make the feel of the area comfortable.
FIG. 4 shows second embodiment of the invention.
The difference from the first embodiment is that in the portion of continuous three courses of knit only, the middle course is knit with a blended yarn 13 of cuprammonium rayon and nylon instead of the second-kind knitting yarn 12 .
That is, on the courses C 10 , C 13 and C 17 , 1-wale tuck→1-wale miss→1-wale tuck→1-wale miss is repeated by feeding from one feeder, the first-kind knitting yarn with a higher stretch force consisting of the single covering yarn 11 composed of polyurethane elastic core yarn of 130 decitex and nylon 66 of 28 decitex wound around the polyurethane elastic core yarn.
On the courses C 11 , C 12 , C 14 , C 16 , C 18 and C 20 , the second-kind knitting yarn with a lower stretch force consisting of the single covering yarn 12 of the polyurethane elastic core yarn of 20 decitex and nylon 66 of 28 decitex wound around the polyurethane elastic core yarn is fed from another feeder and knit at all the needles.
Besides, on the courses C 15 and C 19 , the blended yarn 13 of cuprammonium rayon and nylon 66 is fed from further another feeder and knit at all the needles in one course.
That is, in the area of the continuous three courses of knit, the cuprammonium rayon blended yarn course is laid between the second-kind yarn courses.
As described above, the two continuous courses C 11 and C 12 of knit only by the second-kind knitting yarn with a lower stretch force are provided, then the three courses C 14 and C 16 of knit only by the second-kind knitting yarn and C 15 of knit only by the cuprammonium rayon blended yarn continuously follow, so that the tightening force may become weaker than that of the set up area to decrease feeling of oppression, which improves comfortability of wearing.
Besides, the course of knit only is repeated two or three times continuously, then one course of 1-wale tuck and 1-wale miss knit by the first-kind knitting yarn with a higher stretch force follows so that the moderate tightening force can be applied and the fabric can be effectively prevented from curling outward.
And yet, in the area of continuous three courses of knit only, the middle course is knit by the cuprammonium rayon blended yarn so that moisture absorption-release capability increases and feeling of wearing improves at the terminal portion which closely contacts the skin.
Additionally, since other composition is same as the first embodiment, the explanation is omitted here.
FIG. 5 shows third embodiment of the invention.
In the third embodiment, the circular knitting machine having 4 feeders with 4 inch diameter is used for knitting, and the single covering yarn 11 composed of polyurethane elastic core yarn of 130 decitex and nylon 66 yarn of 28 decitex wound around the polyurethane elastic core yarn is used as the first-kind knitting yarn 11 with a higher stretch force, and the second-kind knitting yarn 12 consisting of the polyurethane elastic core yarn of 20 decitex and nylon 66 yarn of 28 decitex wound around the polyurethane elastic core yarn is used as the knitting yarn with a lower stretch force.
As shown in FIG. 5 , the first set up part 2 a consists of two courses and the second set up part 2 b consists of three courses.
All the continuous courses of knit only in the welt knitting area 3 consist of three courses and all of the continuous three courses (C 7 , C 8 , C 9 ) are knit with the second-kind knitting yarn.
Besides, the courses C 10 and C 14 between the first course C 6 of the welt knitting area 3 and the three courses of knit only are knit by the first-kind knitting yarn with a higher stretch force where 1-wale tuck and 3-wale miss are repeated.
Also in the third embodiment having the above composition, the moderate tightening force is applied so that comfortability of wearing is obtained, the feel of the texture improves, and the texture is effectively prevented from curling outward.
Additionally, in the welt knitting area 3 consists of continuous three courses of knit only knit by a third-kind knitting yarn where a course knit with the blended yarn of cuprammonium rayon and nylon 66 intervenes in the middle of the three courses so that moisture absorption-release capability of cuprammonium rayon improves and it has the advantage of preventing the texture from becoming sticky at the terminal knitting texture area which closely contacts the skin.
FIG. 6 shows fourth embodiment of the invention.
In the fourth embodiment, the terminal knitting texture from the set up course to the welt knitting area is knit by a single circular knitting machine having 4 feeders with 7 inch diameter utilizing 308 needles of every two needles among 616 needles. That is, half of the whole needles such as every two needles 10 - 1 in 1st row, needle 10 - 3 in 3rd row, needle 10 - 5 in 5th row, needle 10 - 7 in 7th row, and so on are used for knitting.
Besides, the first-kind knitting yarn 11 consisting of the single covering yarn composed of the polyurethane elastic core yarn of 156 decitex and nylon 66 yarn of 78 decitex wound around the polyurethane elastic core yarn is used as the first-kind knitting yarn having a higher stretch force.
And the second-kind knitting yarn 12 consisting of the polyurethane elastic core yarn of 20 decitex and a knitting yarn 14 of wooly nylon of 66 decitex as a plating for the second-kind knitting yarn 12 are used as the knitting yarn having a lower stretch force.
To put it concretely, as shown in FIG. 6 , the first set up part 2 a of the set up area 2 consists of two courses and knit by repeating 1-wale knit and 3-wale miss. The second set up part 2 b consists of three courses and knit by repeating 1-wale tuck and 3-wale miss.
In the welt knitting area 3 , the courses C 6 , C 8 , C 9 , C 11 , C 12 , C 14 and C 15 are knit only by the above-mentioned knitting yarn 14 .
As described above, after knitting the course C 6 of knit only by the knitting yarn 14 , knitting one course of repeating 1-wale tuck and 1-wale miss with the first-kind knitting yarn 11 having a higher stretch force, then the pattern of knitting two continuous courses of knit only and one course of repeating 1-wale tuck and 1-wale miss is repeated.
Also in the fourth embodiment, the moderate tightening force is applied so that wearing comfortability is obtained, the feel of the texture improves, and the texture is effectively prevented from curling outward.
FIG. 7 shows fifth embodiment of the invention.
The fifth embodiment shows underpants 20 formed by the two tubular knit fabrics 1 of FIG. 1 . The two tubular fabrics 2 are arranged side by side and the upper adjacent portions of the two tubular fabrics 2 to be a rise are cut and sew to form the underpants 20 . As for this underpants 20 , the both leg hems are formed single welt with the set up area 2 being placed at the bottom end, the welt knitting area continues from the set up area 2 , the body knitting area 4 continues from the top of the welt knitting area to the waist hem, then the waist hem at the top end is the double welt knitting area 5 .
The leg hems of the underpants 20 is single welt so that a difference in level to affect the appearance is prevented. Besides, the set up area 2 is knit by the elastic first-kind knitting yarn consisting of the single covering yarn 11 composed of the thick polyurethane elastic core yarn and not all the wales are knit so that the fabric is prevented from curling outward and moderate tightening force is applied and wearing comfortability is obtained.
In the welt knitting area 3 , the courses knit by the first-kind knitting yarn with a higher stretch force consisting of the single covering yarn composed of the thick elastic core yarn and the courses knit by the second-kind knitting yarn with a stretch force lower than that of the former knitting yarn are combined. So that, the welt knitting area 3 may apply moderate tightening force to improve wearing comfortability but also apply soft feeling, and further prevent the fabric from curling outward.
If, in the above-mentioned welt knitting area 3 , also combining the courses knit by the cuprammonium rayon blended yarn as the knitting yarn having a stretch force lower than that of the first-kind knitting yarn, moisture absorption-release capability is increased.
Additionally, if, in the above-mentioned welt knitting area 3 , combining the courses knit by the wooly nylon yarn as the knitting yarn having a stretch force lower than that of the first-kind knitting yarn, texture characteristics improves, and the tension and appearance are balanced. In place of the wooly nylon, a knitting yarn having the similar effect, such as a cotton blended knitting yarn or the like, is applicable.
If applying the single welt of the present composition in place of the double welt knitting area 5 to the waist of the underpants 20 of the present embodiment, the similar characteristics and function may be obtained.
The invention is not limited to the above-mentioned underpants but may also be applicable to the case where sleeves of the top inner are formed by the tubular knit fabrics with hems being a single welt terminal knitting texture by the above-described single knit, or the case where the body of the undershirts is formed by the larger diameter tubular knit fabric with a hem being a single welt terminal knitting texture by the above-described single knit, the sleeve hems, body hem, and waist hem as well as the leg hems of the above-described underpants may be so thin as not to adversely affect the appearance, and besides as not to occur the outward curling. Additionally, the moderate tightening force is applied to obtain comfortability in wearing. | A terminal knitting texture for a single welt consisting of a single knit that starts knitting on a terminal side, wherein a plurality of courses in an antirun area at knit starting are knit without being knit at all the wales, and are knit by using first-kind knitting yarns consisting of single covering yarns provided with thick elastic core yarns in the antirun area so as to provide knitting not causing outward curls with the first-kind knitting yarns in the antirun area. In a welt knitting area continuous to the antirun area, a course knitted with the first-kind yarns is combined with a course knitted with knitting yarns lower in stretching/shrinking force than the first-kind yarns. | 3 |
FIELD OF THE INVENTION
The present invention relates generally to fasteners for plastic bags that are opened and closed by a slider, and, more particularly, to leak resistant fasteners.
BACKGROUND OF THE INVENTION
Plastic bags are a popular household item used for a variety of uses such as storage of food. The addition of reclosable fasteners or zippers to these bags has further enhanced their utility and the addition of a slider has made the fasteners easier to open and close.
Although sliders have made opening and closing the fasteners easier, some of the slider operated fasteners have leakage across the fastener when the fastener is closed. This is caused by a separation member or finger on the slider that extends between sides of the fastener. Even when the fastener is completely closed, a portion of the separation member extends into the fastener preventing closure of the fastener at that location. One solution to this leakage has been to remove a portion of a fastener track at the location of the slider in the fastener closed position. When the slider is in this location, the separation member is in this portion of the fastener track and the fastener is completely closed. Precise sizing and locating the removed portion is difficult and failure to remove the correct amount and in the correct location can result in leaking and possible operation failure of the slider.
Another solution to the problem of leakage is a slider with a pivoting separation member. When the slider is moved to close the fastener, the separation member pivots out of the fastener. When the slider is reversed to open the fastener, the separation member pivots down into the fastener. An example of this slider is disclosed in U.S. Pat. No. 5,871,281. These sliders are complex to design and manufacture and are costly. In addition, the fact that the separation member must pivot to operate impacts the reliability of the slider. There is a need for a low cost, highly reliable slider and reclosable fastener arrangement that is leak resistant.
SUMMARY OF THE INVENTION
The present invention is directed to a slider that when used to open and close a fastener on a plastic bag provides a leak resistant closure. The slider has a top, depending side walls, a front or nose portion with a ramp on the nose portion, a rear portion, and a separation member or finger formed on the underside of the top extending from the nose portion toward the rear portion. The ramp can instead be incorporated into the shape of the separation member. The leak resistant feature is accomplished by withdrawing the operable portion of the separation member from cooperating features of the fastener. The separation member has a wide portion and a narrow portion. The fastener includes a pair of tracks and each track has an interlocking profile. Each track has two ends with a termination on each end. As the slider closes the fastener, the wide and narrow portions of the separation member move within the fastener with the wide portion holding the profiles open. As the slider is moved to close the fastener, the fastener passes along the separation member from the wide portion to the narrow portion and this along with body of the slider moves the profiles together interlocking the profiles. This action is reversed during the fastener opening movement of the slider. One example of this opening and closing is described in U.S. Pat. No. 5,007,143 which is incorporated by reference herein. When the slider reaches the termination at the end of the fastener, the ramp on the slider engages and travels up the termination. As this occurs, the slider is pivoted up which moves the wide portion of the separation member out of from between the fastener allowing the profiles to interlock up to the termination. The shape and positioning of the ramping surfaces and the relative location of slider retention shoulders control the change in orientation of the slider and the stiffness of the fastener is also a factor. The ramp can include a lock such as an indention which snap locks onto the termination and reduces the likelihood of the slider accidently being moved to open the fastener enough to allow leakage.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description in conjunction with the drawings in which:
FIG. 1 is an enlarged perspective view of a slider constructed in accordance with the principles of the present invention;
FIG. 2 is a side elevation view of the slider illustrated in FIG. 1,
FIG. 3 is a front view of the slider on a fastener;
FIG. 4 is a cross sectional view of the slider and fastener of the present invention in the fastener closed configuration;
FIG. 5 is a side elevation view of the slider and fastener with the slider locked on an end termination clip;
FIG. 6 is a view similar to FIG. 5 with the slider on an terminal end of the fastener;
FIG. 7 is a perspective view of an alternative embodiment of the slider;
FIG. 8 is a cross sectional view of an alternative embodiment of a fastener slider arrangement;
FIG. 9 is a partial cross sectional view of a fastener slider arrangement illustrating the forces on and action of the slider during parking;
FIG. 10 is a cross sectional view of a slider on a fastener; and
FIG. 11 is a cross sectional view of a slider on a fastener illustrating the reaction of the slider and fastener during parking of the slider.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1, there is illustrated a slider 10 that when combined with a fastener 12 (FIGS. 4 and 5) eliminates the need for a slider parking notch to provide a leak resistant closure of the fastener 12 . A parking notch is a notch cut in the tracks of prior art fasteners in which a slider is located in a fastener closed position such that a separation finger on the slider is out of engagement with tracks on the fastener allowing the fastener to be fully closed. As will be described in detail hereinafter, the need for a parking notch is eliminated by docking or parking the slider 10 on an fastener end termination such as an end termination clip 14 (FIG. 5) which lifts at least a portion of a separation finger or member 16 (FIG. 3) on the slider 10 out from between the fastener 12 allowing complete closure of the fastener 12 .
To understand how a leak resistant fastener and slider arrangement is accomplished reference is first made to the slider 10 (FIGS. 1 - 3 ). The slider 10 is of the type described in U.S. Pat. No. 5,007,143 and this patent is incorporated by reference in its entirety. The slider 10 includes a top 18 with a forward portion or nose 20 and a rear portion 22 . A pair of sides or side walls 24 and 26 depend downwardly from the top 18 . At the lower end of each side wall 24 and 26 are shoulders 28 and 30 (FIGS. 3 and 4 ), respectively, which cooperate with the separation finger 16 to assist in opening and closing the fastener 12 .
The nose 20 of the slider 10 extends forward of the top 18 and has an inclined ramp 32 on the front under side of the nose 20 . An indention or lock 34 (FIG. 2) is formed on the under side of the slider nose 20 behind the ramp 32 . The lock 34 snaps onto an enlarged end 36 of the termination clip 14 after the ramp 32 has passed over the end 36 in the fastener closed position (FIG. 5 ).
The separation finger 16 has a first wide portion 40 (FIG. 3) and a second narrow portion 42 (FIG. 4 ). The separation finger 16 with the first and second portions 40 and 42 interact with first and second portions 44 and 46 (FIGS. 6 and 7) of the fastener 12 to lock and unlock first 48 and second 50 profiles on the fastener 12 thereby opening and closing the fastener 12 in the manner described in U.S. Pat. 5,007,143. More specifically, the wide portion 40 of the separation finger 16 in cooperation with the shoulders 28 and 30 spread the first and second portions 44 and 46 which separates the first and second profiles 48 and 50 thereby opening the fastener 12 (FIG. 6) as the slider 10 is moved. To close the fastener 12 , the slider 10 is moved in the reverse direction and the narrow portion 42 of the separation finger 16 cooperates with the shoulders 28 and 30 and the sides 24 and 26 of the slider 10 to bring the first and second portions 44 and 46 together which brings together and locks the first and second profiles 48 and 50 (FIG. 7 ).
To close the fastener 12 completely, at least the wide portion 40 of the separation finger 16 is removed from between the first and second portions 44 and 46 . This is accomplished by docking or parking the nose 20 of the slider 10 on the end 36 of the termination clip 14 (FIG. 5 ). As the slider 10 closes the fastener 12 and approaches the termination clip 14 , the ramp 32 engages the end 36 of the clip 14 causing the nose 20 and that end of the slider 10 to rock or rotate upwardly in the direction of the arrow 52 in FIG. 5 . As this action occurs, the wide portion 40 of the separation finger 16 is moved up and out from between the fastener portions 44 and 46 . Since only the narrow portion 42 of the separation finger 16 is between the first and second portions 44 and 46 , the first and second profiles 48 and 50 lock along the entire length of the fastener 12 up to the termination clip 14 . Upon complete closure of the fastener 12 , the slider 10 is locked on the termination clip 14 by the lock 34 snapping onto the end 36 of the termination clip 14 (FIG. 5 ).
To open the fastener 12 , the slider 10 is grasped and moved away from the termination clip 14 . As the slider 10 begins to move, the lock 34 moves off of the end 36 of the termination clip 14 and the ramp 32 slides over the end 36 . As this occurs, the wide portion 40 of the separation finger 16 moves between the first and second fastener portions 44 and 46 to separate the first and second profiles 48 and 50 and open the fastener 12 .
Although the fastener 12 is terminated by a clip 14 in the embodiment illustrated in FIGS. 1-5, other forms of terminating the ends of the fastener 12 will also provide the desired result. For example, FIG. 6 illustrates a fastener 112 that is terminated by an end weld 114 . The end weld 114 may be formed by heated bars pressed against the end of the fastener 112 , ultrasonic welding or other ways known in the art. As the slider 10 approaches the end weld 114 , the wide portion 40 of the separation finger 16 encounters increased resistance as it attempts to spread the first and second fastener portions 44 and 46 which are tightly bound in a closed configuration by the end weld 114 . The convergence of the first and second fastener portions 44 and 46 behind the separation finger 16 and the transition into the end weld 114 form a natural ramp on which the ramp 32 and nose 20 of the slider 10 ride. This action rocks the slider 10 in the direction of the arrow 119 (FIG. 6) moving the wide portion 40 of the separation finger 16 from between the first and second fastener portions 44 and 46 as in the embodiment of FIGS. 1-5. This action is reversed as the slider 10 is pulled away from the end weld 114 to open the fastener 112 .
If desired, the nose 20 with the ramp 32 can be eliminated from the slider 10 . Such a slider 110 is illustrated in FIG. 7 . Except for a nose and ramp, the slider 110 is identical to slider 10 . Both the sliders 10 and 110 function to close a zipper 12 completely. As each slider 10 and 110 approaches a zipper end termination 14 or 114 , an elastic twisting deformation of the zipper profiles 48 and 50 occurs. The deformation is caused by abrupt change in the orientation of the profiles 48 and 50 from spread apart to interconnected. The deformation of the profiles by the slider 10 or 110 increases the magnitude of the reaction force against the separation finger 16 . The deformed profiles 48 and 50 form a ramp which shifts the contact point with the slider 10 or 110 resulting in a reaction force with an upward component in the direction of arrow 112 (FIGS. 8 and 9 ). This upward force causes a rotational moment 114 (FIGS. 9 and 11) on the slider 10 or 110 about the shoulders 28 and 30 in a direction that lifts the separation finger 16 out from between the profiles 48 and 50 . Referring to FIG. 9, the distance D between the upward reaction force 112 to the shoulders 28 and 30 affects the magnitude of the moment indicated by the arrow 114 acting to lift or disengage the separation finger 16 from the profiles 48 and 50 .
Lifting of the separation finger 16 occurs due to a clearance 116 (FIG. 10) between the slider 110 or 10 and the profiles 48 and 50 . A shown in FIG. 9, the upward reaction force 112 rotates the slider 10 , 110 relative to the fastener 12 to the extent allowed by the clearance 116 . Because the slider 10 , 110 is rigid, additional relative motion, if required, will only occur through elastic deformation of the portion of the profiles 48 and 50 within the slider 10 , 110 . The beam stiffness of the profiles 48 and 50 and the unsupported lengths D 1 and 116 (FIG. 11) determine how much force is required to lift or move the separation member 16 out of the profiles 48 and 50 . This rocking of the slider 10 , 110 can be accomplished by the engagement of the ramp 32 with the end termination 14 , 214 or the weld 114 .
While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. | A fastener for plastic bags opened and closed by a slider includes first and second track members with each having one of a pair of interlocking profiles. The fastener has opposite ends with terminations. A slider is mounted on the fastener and has a separation member with a wide portion and a narrow portion positioned in the fastener. The slider, upon complete closure of the fastener, rides up onto a termination moving the wide portion of the separation member out from between the fastener allowing the profiles to lock along the entire length of the fastener. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of U.S. patent application Ser. No. 11/571,603, filed Feb. 1, 2007, now U.S. Pat. No. 7,839,022; which claims the benefit of International Application Ser. No. PCT/AU2005/001017, filed Jul. 12, 2005; which claims the benefit of Australian Provisional Patent Application Ser. No. 2004903833, filed Jul. 13, 2004, the disclosures of which applications are incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates to solar cell technology and in particular to maximum power tracking converters. The present invention has particular but not exclusive application for use in vehicles that are at least in part electrically powered by solar cells. Reference to solar powered vehicles is by means of example only and the present invention has application in other areas.
BACKGROUND OF THE INVENTION
[0003] A solar cell is a device able to convert incident light to electrical power. Many solar cells are typically grouped to form an array of solar cells. To collect the electrical power from the solar cells, groups of cells are either directly connected in series or in parallel. Where the cells are connected in series, they must have identical currents but if the cells are connected in parallel they must operate with identical voltages. An individual cell will produce maximum power at a unique cell voltage and current which will vary from cell to cell. The combination of voltage and current that allows a cell to produce its maximum power is termed the maximum power point. The maximum power point varies with cell illumination and temperature. Connection of the cells in series forces cells to have identical current while connection in parallel forces cells to have identical voltage. Direct connection in series or parallel results in failure to collect all the available electrical power from the solar cells in the array and at least some of the cells will operate at a condition other than at their maximum power points.
[0004] To obtain the maximum available power from a group of solar cells connected in an array or sub-array, a maximum power tracking device is used. Maximum power tracking devices are DC to DC power converters that allow an array or sub-array to operate at their maximum power point. A DC to DC converter can transform a power input at a certain voltage and current to be transformed to a DC power output at a differing voltage and current. A key feature of all maximum power trackers is a control device that determines the point of maximum power for the connected solar cells and acts to adjust the DC to DC converter performance to adjust the cell voltage or current to extract the maximum available power.
[0005] However there are a number of problems or disadvantages associated with the use of a single maximum power device to control the voltage or current of an array or sub-array of solar cells.
[0006] Where solar cells are used to power vehicles, the vehicles are usually aerodynamically designed with curved surfaces and also have limited surface area in which to mount the solar cells. Consequently arrays of cells are mounted on the curved surfaces but the variation of the angle of incidence of light on the different cells within the array on the curved surface causes variation in the available optical power. Furthermore, cells in an array may be subjected to variable light levels due to shadowing by foreign objects such as trees and buildings between the cell and the source of illumination.
[0007] Because of differences in optical illumination, cell temperatures may vary within arrays causing some cells to be hotter than other cells. Arrays may be cooled partially by air flow or by the use of a cooling fluid in an illumination concentrator system. These mechanisms however may not provide uniform cooling to all cells.
[0008] The available power from each cell within an array will vary due to the variations in illumination and temperature. In these cases, the maximum power conditions of different cells within the array will differ at any one point of time. Furthermore the maximum power conditions of some cells within the array will vary differently over time compared with others. As well these variations are not predictable. In addition changes to the maximum power conditions of cells can vary rapidly thereby requiring a relatively quick response time.
[0009] Currently maximum power tracking devices are directly electrically connected to an array of solar cells. A single maximum power tracking device is currently used to control the available power from an array of between ten to several hundred cells.
OBJECT OF THE INVENTION
[0010] It is an object of the present invention to provide an alternate maximum power tracking device that overcomes at least in part one or more of the above mentioned problems or disadvantages.
SUMMARY OF THE INVENTION
[0011] The present invention arises from the realization that each cell at any one particular time point will have a unique maximum power point defined by a specific cell voltage and specific current at which the cell will produce its maximum available power. Furthermore the invention was developed from the realization that it is not possible for every cell in an array to operate at its maximum power point if the array is formed by the direct electrical interconnection of cells. With this in mind and taking advantage of recent advances in low voltage electronics, maximum power tracking devices for very small groups of directly connected cells or for single solar cells were developed to provide a solution to optimizing the electrical power from the array.
[0012] In one aspect the present invention broadly resides in a system for providing power from solar cells including one or more solar generators wherein each of said solar generators has one to nine solar cells;
[0013] a maximum power tracker operatively associated with each solar generator, each of said maximum power tracker includes a buck type DC/DC converter without an output inductor, each of said maximum power trackers are operatively connected in series with each other;
[0014] an inductor operatively connected to the series connected maximum power trackers; and
[0015] means for providing electrical power from the inductor to load means, wherein each of said maximum power trackers is controlled so that the operatively associated solar generator operates at its maximum power point to extract maximum available power.
[0016] The maximum power tracker preferably includes an energy storage capacitor and a control means for adjusting the buck type DC/DC converter duty cycle so that a connected solar generator operates at its maximum power point.
[0017] Preferably the control means makes observations of solar generator voltage, and observations of the change in energy storage capacitor voltage during the buck converter switch off time and observations of the duration of the buck converter switch off time to infer solar generator power to adjust the buck converter duty cycle to extract maximum power from the connected solar generator.
[0018] In one preferred embodiment, the switching operations of the DC/DC converter are synchronized in frequency by the use of a synchronizing signal.
[0019] Preferably each solar generator includes one solar cell. Preferably each solar generator includes one solar cell and each solar cell is connected to its own dedicated maximum power tracker so that the tracker responds to its connected solar cell.
[0020] Preferably the system uses a single inductor.
[0021] Load means includes devices that use or store the electrical power.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order that the present invention can be more readily understood and put into practical effect, reference will now be made to the accompanying drawings wherein:
[0023] FIG. 1 is a diagrammatic view of a simplified Buck type DC/DC converter with solar generator and load;
[0024] FIG. 2 is a diagrammatic view of an alternative embodiment of a simplified Buck type DC/DC converter with solar generator and load;
[0025] FIG. 3 is a diagrammatic view of a solar generator with a Buck type DC/DC converter without an inductor;
[0026] FIG. 4 is a diagrammatic view of an alternative embodiment of a solar generator with a Buck type DC/DC converter without an inductor;
[0027] FIG. 5 is a diagrammatic view of the interconnection of a plurality of Buck type DC/DC converters without inductors, corresponding plurality of solar generators, one inductor and a load; and
[0028] FIG. 6 is a diagrammatic view of a preferred embodiment of the single cell MPPT converter;
[0029] FIG. 7 is a graphical representation of the control signals and gate signals for MOSFETs;
[0030] FIG. 8 is a graphical representation of a no load 2 kHz waveforms, top MOSFET gate waveform; top MOSFET gate drive referred to ground, bottom MOSFET gate waveform to ground, output terminal to ground (from top to bottom);
[0031] FIG. 9 is a graphical representation of an unloaded 20 kHz waveforms, Traces top to bottom, output terminal, bottom MOSFET gate, top MOSFET gate, all referred to ground;
[0032] FIG. 10 is a graphical representation of a loaded 20 kHz waveforms, traces top to bottom, output terminal, bottom MOSFET gate, top MOSFET gate, all referred to ground;
[0033] FIG. 11 is a graphical representation of input voltage, current and power at 10 kHz (from top to bottom);
[0034] FIG. 12 is a graphical representation of output current, voltage and power at 10 kHz (from top to bottom);
[0035] FIG. 13 is a table of equipment for efficiency measurement; and
[0036] FIG. 14 is a table of converter efficiency at different frequencies.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] With reference to FIG. 1 there is shown a simplified buck type DC/DC converter 10 connected to a solar generator 11 and load 12 . The solar generator 11 can be a solar cell or several cells. The buck type DC/DC converter 10 includes a capacitor 13 which serves as an energy storage element, a controlled switching device 14 , a diode or a controlled device acting as a synchronous rectifier 15 and an output inductor 16 . An alternative arrangement for the buck type DC/DC converter 10 is shown in FIG. 2 .
[0038] A buck type DC/DC converter can be controlled to operate the solar generator at its maximum power point while producing an adjustable level of output current. The solar generator and maximum power tracker will be referred to as a solar generator/MPPT. Many solar generators/MPPT can be series connected. Each DC/DC converter will then have an identical output current but they can be individually controlled to allow each solar generator to operate at their maximum power point.
[0039] A conventional buck converter uses an output inductor to provide energy storage that is necessary for current filtering. An important feature of this invention is that the many inductors would normally be required, one for each solar generator/MPPT, and this can be replaced by a single inductor which will perform the energy storage and filtering function for many series connected solar generator/MPPT. The MPPT device can be produced as an inductor free device.
[0040] FIG. 3 shows an inductorless DC/DC buck converter with a solar generator while
[0041] FIG. 4 shows an alternate embodiment.
[0042] Many solar generators/MPPT devices that utilize inductor free DC/DC buck converters can be series connected with a single inductor to supply power to an electrical load. The series connection of the solar generators/MPPT devices forces each inductorless DC/DC buck converter to supply an identical output current. Each converter operates with a constant current load.
[0043] The controlled switching device operates alternates between an open and closed state. The average portion of time that the switch is closed is the switch duty cycle. Closure of the controlled switching device causes the load current to be supplied from the solar generator and the energy storage capacitor. When the controlled switch is open, the load current transfers to the diode or synchronous rectifier device while the solar generator current replenishes the charge within energy storage capacitor.
[0044] The duty cycle of the controlled switching device will determine the average current withdrawn from the energy storage capacitor. The energy storage capacitor will adjust its voltage in response to the difference in the current supplied by the solar generator and the current withdrawn to by the controlled switch. The switching device will be controlled by a device that adjusts the controlled switch duty cycle to maintain the solar generator voltage at the maximum power point.
[0045] With respect to FIG. 5 there is shown a solar generator 20 connected to a capacitor 21 , diode 22 and control switch 23 . The capacitor 21 , diode 22 and control switch 23 forms the inductorless DC/DC converter 24 . Several solar generators 20 are connected in series via their dedicated inductorless DC/DC converters 24 . Each solar generator 20 has its own inductorless DC/DC converters 24 . After the last inductorless DC/DC converters 24 , there is an inductor 25 to filter the current prior to reaching the load 26 . The inductor 25 can be smaller in terms of magnetic energy shortage measured as ½ LI 2 where L is the inductance value in Henry and I is the inductor current, in Amperes, than the total combined set of inductors that are normally used with each buck DC/DC converter. The use of a smaller inductor and only one inductor reduces cost and weight and increases the efficiency in providing maximum power from the solar cells. In the preferred embodiment the solar generator consists of a solar generator which is a single high performance solar cell.
[0046] With reference to FIG. 6 , there is shown a DC to DC converter 30 in the formed by MOSFETs Q 1 and Q 2 ( 31 and 32 respectively), and the energy storage capacitor 33 . No filter inductor is required. In this preferred embodiment MOSFET Q 1 ( 31 ) is a synchronous rectifier implementation of the diode device and MOSFET Q 2 ( 32 ) is the buck converter controlled switch element. In the preferred embodiment the output terminals of the solar generator/MPPT device are the drain terminal of Q 1 , point X and the junction of the source terminal of Q 1 and the drain terminal of Q 2 , point Y.
[0047] The control element of the maximum power device is a microprocessor. In this preferred embodiment, an ultra-low power Texas Instruments MSP430 microprocessor 34 which is capable of operation at a supply voltage of 1.8V. This allows direct operation from a dual junction cell which typically produces 2V. If other cell types are used with lower cell voltages, a power conditioning device may be required to develop a higher voltage supply to allow the control element to be operated from a single cell. For example, silicon cells typically produce 0.4V and a voltage boosting converter would be required to generate a voltage high enough to operate a microprocessor control element.
[0048] An alternate embodiment is possible where the solar generator/MPPT device output terminals are the junction of Q 1 and Q 2 , point Y, and the source of Q 2 . In this case Q 1 is the controlled switch element and Q 2 is the diode element implemented as a synchronous rectifier.
[0049] The gate drive voltage for the MOSFETS Q 1 and Q 2 is derived by charge pump circuit. In the preferred implementation a multiple stage charge pump circuit formed by diodes D 1 to D 4 , devices 35 - 38 , and their associated capacitors 39 - 42 .
[0050] The MOSFETS Q 1 and Q 2 are driven by a gate driver circuit. In the preferred embodiment a comparator, 43 , forms the driver circuit. As this circuit delivers a higher gate to source voltage to device Q 2 than Q 1 , Q 2 achieves a lower turn on resistance. In the preferred embodiment Q 2 is the controlled switching device as this arrangement minimizes power losses.
[0051] Resistors 44 and 45 form a voltage divider network which is used to perform voltage observations of solar generator voltage using a analogue to digital converter within the microprocessor 34 . An important feature of the maximum power tracking method is the measurement of cell voltage magnitude, the and measurement of the change in cell voltage during periods when the controlled switch, 32 , is open and the measurement of the time that the controlled switch is open to infer cell power. This may be used as an input to a maximum power tracking method that will control the DC-DC converter duty cycle to allow the solar generator to operate at maximum power.
[0052] In order to secure high efficiency in the solar generator/MPPT, low switching frequencies are preferred. In the preferred embodiment switching frequencies will be below 20 kHz. At very low switching frequencies the ripple voltage on capacitor C 1 will increase. The voltage ripple will cause the cell to deviate from its maximum power point. An optimum switching frequency range will exist. In the preferred embodiments the switching frequency will be adjusted to maximize the energy delivered by the solar generator/MPPT.
[0053] A plurality of solar generator/MPPT may be configured within a large array to switch at the same frequency and with a relative phase relationship that provides improved cancellation of switching frequency voltage components in the output voltage waveforms of the solar generator/MPPT combinations. This allows a smaller inductor to provide filtering of the load current. Such synchronization may be provided by auxiliary timing signals that are distributed within an array or by other means.
[0054] In some embodiments the solar generator/MPPT devices within an array may not switch at the same frequency. The combined output voltage of large number of asynchronously switching series connected buck converters will follow a binomial distribution. The average output voltage of the group of n solar generator/MPPT devices, with an input voltage V in and a duty cycle d, increases linearly with n while the switching ripple or the distortion voltage, V dist , rises as √n.
[0000] V dist =V in √{square root over ( n ( d−d 2 ))} (1)
[0055] Likewise the average volt second area, A, for a shared filter inductor follows an √n relationship.
[0000]
A
=
n
V
in
f
(
d
-
d
2
)
(
2
)
[0056] In a non synchronized embodiment, a larger inductor is required than in an optimally synchronized embodiment. The required inductor is still significantly smaller than the combined plurality of inductors that would be required for conventional buck converters.
[0057] A prototype converter was developed to first examine the conversion efficiency of the DC to DC converter stage and its suitability for use with a dual junction single solar cell, with an approximate maximum power point at 2V and 300 mA. For these tests the MSP340 was programmed to drive the charge pump circuitry and to operate the buck converter stage at a fixed 50% duty ratio. The experimental circuit is as in FIG. 6 . A fixed 2V input source voltage was applied and a load consisting of a 2 500 μH inductor and a 1.6Ω resistor was applied. A dead-time of 0.8 μS is inserted in each turn-on and turn-off transient to prevent MOSFETs shoot through conduction events.
[0058] As gate charging loss was a significant loss contributor, a range of operating frequencies was trialled. FIG. 7 shows the control waveforms at 20 kHz. The waveforms show the dead times between the top and bottom signals at turn-on and turn-off. All waveforms in this figure are ground referred. The measured no load loss in this condition was 6 mW which is approximately twice the expected figure. The gate drive loss is fully developed at no load and we may have additional loss in the charge pump circuitry. FIG. 8 shows gate waveforms at 2 kHz but a differential measurement is made of V gs1 to show the lowering of the gate source voltage to approximately 4V due to elevation of the source at the device turn-on.
[0059] The waveforms at 20 kHz without load are shown in FIG. 9 . Note that the load connection is across terminals X and Y. The lower MOSFET has the higher gate drive voltage and a lower R dson . FIG. 10 shows the loaded waveforms. Note the conduction of the MOSFET inverse diodes in the dead time as seen by the 2 μS wide peaks on the leading and trailing pulse top edges on the top trace. The transfer of current to these diodes generates an additional conduction loss of 24 mW which reduces efficiency at higher frequencies.
[0060] Given circuit losses are around a few percentage points of rating, precise voltage and current measurements are needed if power measurements are used to determine efficiency. A complication is that the output is inductorless and both the output voltage and current contain significant switching frequency components. It is likely that a significant amount of power is transferred to the combined R-L load at frequencies other than DC.
[0061] In order to determine the efficiency of this converter, a new high end oscilloscope was used to measure the input and output power. The internal math function was employed to obtain the instantaneous power from the current and voltage, the mean value of which indicates the average power. The current probe was carefully calibrated before each current measurement, to minimize measurement errors. FIG. 13 shows the details of the equipment used in a table format. FIGS. 11 and 12 show the input and output voltages, current and power. The mean value of measured power is displayed at the right column of the figures.
[0062] The efficiencies of the converter obtained are shown in a table in FIG. 14 . It is seen that the measured efficiency is slightly lower than estimated especially at higher frequencies. One reason is the loss during the dead-time. The on-state voltage drop of the diode is much higher than the MOSFET, and therefore reduces the efficiency of the converter. At 10 kHz the dead time loss accounts for 12 mW of the observed 30 mW. The results do confirm that the circuit is capable of achieving high efficiencies especially if the switching frequency is low.
Variations
[0063] It will of course be realized that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.
[0064] Throughout the description and claims this specification the word “comprise” and variations of that word such as “comprises” and “comprising,” are not intended to exclude other additives, components, integers or steps. | The present invention is a system for providing power from solar cells whereby each cell or cell array is allowed to produce its maximum available power and converted by an operatively connected DC/DC converter. Each cell or cell array has its own DC/DC converter. In one form the system for providing power from solar cells includes one or more solar generators wherein each of said solar generators has one to nine solar cells; a maximum power tracker operatively associated with each solar generator, each of said maximum power tracker includes a buck type DC/DC converter without an output inductor, each of said maximum power trackers are operatively connected in series with each other; an inductor operatively connected to the series connected maximum power trackers; and means for providing electrical power from the inductor to load means, wherein each of said maximum power trackers is controlled so that the operatively associated solar generator operates at its maximum power point to extract maximum available power. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved gas boiler, and more particularly to a gas boiler which has a simple internal pipeline structure, is easy to install, and can be manufactured at a low cost.
2. Description of the Prior Art
Gas boilers of a variety of types have been continuously proposed hitherto for producing hot water and room heating. FIG. 10 illustrates the internal structure of a conventional gas boiler 10 which generally includes a water tank 20, a circulation pump 30, a three-way valve 40, a gas-heated heat exchanger 50, and a box accommodating a printed circuit board (hereinafter simply referred to as "PCB box") 70.
Conventional gas boiler 10 additionally includes a water valve 55, a supplementary water valve 57, a fan 60, a gas valve 74, a plurality of pipelines (not shown), and a plurality of electric wires (not shown).
Referring to FIG. 10, gas boiler 10 has a rear plate 12 consisting of steel. Rear plate 12 is joined with a front cover (not shown). Water tank 20 for retaining the heating water is placed on the upper left portion of rear plate 12. A water level sensing unit 80 is installed at the upper portion of water tank 20. Also, a bypass pipe 90 is installed at the upper right portion of water tank 20, which is connected to the upper left portion of heat exchanger 50 arranged to the right of water tank 20.
A heating water tank (not shown) and a combustion chamber 54 are equipped within heat exchanger 50. A gas supply pipe 72 is connected to the lower portion of heat exchanger 50, which supplies a gaseous fuel such as liquefied natural gas (hereinafter referred to as "LNG") or liquefied petroleum gas (hereinafter referred to "LPG") from an external gas source to heat exchanger 50. A gas valve 74 for adjusting the quantity of the LNG or LPG supplied to heat exchanger 50 is positioned in the middle of gas supply pipe 72. Fan 60 underlies heat exchanger 50.
Meanwhile, an overflow pipe 24, a heating water return pipe 26, a first heating water inlet pipe 28 and a supplementary water supply pipe 58 are connected to the bottom portion of water tank 20.
Here, heating water return pipe 26 is a flow path of the heating water returning from a heating place.
First heating water inlet pipe 28 for recirculating the heating water extends from the lower portion of water tank 20 to be connected to circulation pump 30. Circulation pump 30 is driven by an electric motor (not shown) to raise a pressure of the heating water and circulate the heating water. A second heating water inlet pipe 32 is connected to the upper portion of circulation pump 30. Second heating water inlet pipe 32 extends from circulation pump 30 to be connected to the heating water tank of heat exchanger 50. A pump drain pipe 34 is connected to the lower portion of circulation pump 30. A drain cock 35 is installed to the center of pump drain pipe 34.
Supplementary water supply pipe 58 is connected to a water supply pipe 56. A supplementary water valve 57 is furnished to the middle of supplementary water supply pipe 58, which adjusts the quantity of the supplementary water supplied into water tank 20 via supplementary water supply pipe 58. Water supply pipe 56 provides fresh water and extends from the water source outside gas boiler 10 to enter into the heating water tank of heat exchanger 50. Water valve 55 is mounted in the middle of water supply pipe 56, which adjusts the quantity of the fresh water supplied via water supply pipe 56.
In the upper left portion of heat exchanger 50, water supply pipe 56 is connected to a hot water supply pipe 59, which extends from the left upper portion of heat exchanger 50 to the exterior of gas boiler 10, and supplies the hot water indirectly heated to have a raised temperature within heat exchanger 50 to a user.
Three-way valve 40 is disposed to the right of water supply pipe 56. Three-way valve 40 controls the flow of the heating water. An internal circulation pipe 42 and a heating water supply pipe 52 are connected to the upper portion of three-way valve 40. Internal circulation pipe 42 is connected to first heating water inlet pipe 28 which connects water tank 20 and circulation pump 30. Heating water supply pipe 52 extends from the heating water tank of heat exchanger 50 to be connected to three-way valve 40 via the bottom side of fan 60. A heating water discharge pipe 44 for discharging the heating water from heating water supply pipe 52 to the heating place is connected to the lower portion of three-way valve 40. PCB box 70 is situated to the right of gas valve 74. The printed circuit board within PCB box 70 controls the operation of gas boiler 10.
The operation of conventional gas boiler 10 constructed as above will be briefly described in connection with the flow of the fluid.
The heating water which returns into gas boiler 10 after executing the room heating is introduced into water tank 20 via heating water return pipe 26. The heating water introduced into the interior of water tank 20 blends with the fresh water supplemented into water tank 20 via supplementary water supply pipe 58, and is provided to the interior of circulation pump 30 via first heating water inlet pipe 28.
The heating water introduced into circulation pump 30 is pressed by the pumping operation of circulation pump 30 to flow into the heating water tank of heat exchanger 50 via second heating water inlet tube 32. The heating water admitted into the heating water tank is heated by a gas burner (not shown) disposed in combustion chamber 54 of heat exchanger 50. The heating water,whose the temperature is raised by the heating, flows into three-way valve 40 via heating water supply pipe 52 extending from the right upper portion of the heating water tank.
At this time, if the operational mode of gas boiler 10 is the a heating mode, three-way valve 40 opens heating water discharge pipe 44 in accordance with a control signal from the printed circuit board to discharge the heating water. The heating water discharged as above is directed to the heating place via the heating water supply pipeline. The heating water which release the heat returns to water tank 20 via heating water return pipe 26. The heating water admitted in water tank 20 is successively subjected to the above-stated circulation procedure.
In contrast to the above operation, when the operational mode of gas boiler 10 is the hot water mode, three-way valve 40 shuts off heating water discharge pipe 44 in accordance with the control signal from the printed circuit board. Therefore, the heating water having the raised temperature drifts within circulation pump 30 via internal circulation pipe 42. The heating water, which has a raised temperature and is introduced into circulation pump 30 is in turn provided to the heating water tank of heat exchanger 50 via second heating water inlet pipe 32 together with the heating water returning from the heating place by means of the pumping operation of circulation pump 40. The heating water admitted into the heating water tank is heated by the gas burner arranged within combustion chamber 54 as mentioned above. The heating water heated in this manner is introduced into three-way valve 40 via heating water supply pipe 52. Thereafter, the heating water is subjected to the aforestated circulation procedure to drift just within gas boiler 10.
On the other hand, apart from the circulation of the heating water, the fresh water is provided into the heating water tank of heat exchanger 50 via water supply pipe 56. The fresh water flows via water supply pipe 56, which is arranged as a coil within the heating water tank. At this time, the fresh water is changed into hot water of a high temperature by indirectly receiving the heat transmitted from the heating water which has been heated by the gas burner. The hot water prepared as above is guided to the user via hot water supply pipe 59 extending from water supply pipe 56 on the left of heat exchanger 50. Therefore, the hot water is constantly supplied while gas boiler 10 is operating.
However, in conventional gas boiler 10 as described above, there is a long and complicated pipeline for mutually connecting water tank 20, circulation pump 30, three-way valve 40 and heat exchanger 50. This intricate pipeline impedes the free arrangement of the components during the assembling of the gas boiler. Moreover, because a copper pipe is adopted in consideration of corrosion and a hydraulic pressure in the pipeline of the gas boiler, the long pipeline becomes a factor of consuming a much higher manufacturing cost as such. Furthermore, when a breakdown occurs and repaired, the complicated pipeline requires considerable manpower and time for separating and replacing respective pipes.
U.S. Pat. No. 5,248,085, issued to Niels D. Jensen on the date of Sept. 28, 1993 may be given as one example of simplifying the internal construction of the gas boiler. Here, a switch mechanism placed between a first heat exchanger and a second heat exchanger is formed together with a control mechanism, a shaft and a middle wall of a circulation pump housing to form one assembly unit, thereby simplify the internal construction of the gas boiler. However, the Niels D. Jensen's gas boiler constitutes the assembly unit regardless of the position of a water tank, the circulation pump and a three-way valve for contriving the simplification of the internal structure to thus fail in accomplishing an indeed simple structure of the complicated pipeline.
SUMMARY OF THE INVENTION
The present invention is devised to solve the foregoing problems. Accordingly, it is an object of the present invention to provide a gas boiler which has few internal pipelines, ensures a higher space utilization ratio, is easy to install, and reduces the manufacturing cost.
To achieve the above object, the present invention provides a gas boiler comprising:
a water tank;
a heat exchanger for heating a first water and a second water;
a three-way valve mounted to one side of the water tank;
a circulation pump mounted to one side of the three-way valve in opposition to the mounting position of the water tank and the three-way valve;
first guide means for supplying the first water to the heat exchanger and supplying the first water heated within the heat exchanger to a user;
second guide means for circulating the heated second water between the three-way valve and the heat exchanger by an operation of the three-way valve when an operational mode of the gas boiler is a hot water mode, and directing the heated second water to a heating place by the operation of the three-way valve when the operational mode of the gas boiler is a heating mode;
third guide means for guiding the second water returning from the heating place into the water tank;
fourth guide means for guiding the second water directed into the water tank into the circulation pump; and
a printed circuit board box having a printed circuit board therein for controlling the operation of the gas boiler.
The first guide means comprises a water supply pipe for supplying the first water from a first water supply source outside of the gas boiler to the heat exchanger, and a hot water supply pipe for supplying the first water heated within the heat exchanger. The water supply pipe comprises a water valve for controlling the quantity of the first water supplied into the heat exchanger. The second guide means comprises a second communicating pipe, a first heating water supply pipe, a second heating water supply pipe and a heating water discharge pipe, whereby the three-way valve shuts off the heating water discharge pipe to discharge the heated second water into the circulation pump via the second communicating pipe when the operational mode of the gas boiler is the hot water mode, and shuts off the second communicating pipe to discharge the heated second water to the heating place via the heating water discharge pipe when the operational mode of the gas boiler is the heating mode.
The second communicating pipe allows for fluid communication of the three-way valve and the circulation pump, the first heating water supply pipe allows for the fluid communication of the circulation pump and the heat exchanger, and the second heating water supply pipe allows for the fluid communication of the heat exchanger and the three-way valve.
The three-way valve comprises a three-way valve frame formed with a plurality of coupling holes for mating the three-way valve to the water tank and the circulation pump, a heating water supply hole, a ball space, a spherical ball placed within the ball space and a heating water discharge hole connected to the heating water discharge pipe. The ball shuts off the heating water discharge hole to discharge the heated second water into the circulation pump via the second communicating pipe in accordance with a control signal from the printed circuit board when the operational mode of the gas boiler is the hot water mode, and shuts off the second communicating pipe to discharge the heated second water via the heating water discharge hole in accordance with the control signal from the printed circuit board.
The water tank has a rectangularly-shaped section, and comprises an upper casing having a lower portion opened and a lower casing having an upper portion opened. The upper casing comprises a recess for accommodating the printed circuit board box therein. The recess is formed in one side of the upper casing. The upper casing comprises a first flange formed along a lower marginal periphery of the upper casing for coupling the upper casing to the lower casing, and the lower casing comprises a second flange formed along an upper marginal periphery of the lower casing for coupling the upper casing to the lower casing and a third flange horizontally extending from the second flange for coupling the lower casing to the three-way valve, whereby the first flange and the second flange are coupled altogether, and the third flange is coupled to the three-way valve.
The heat exchanger comprises a heating water tank for retaining the second water, a combustion chamber and a gas burner for heating the second water retained within the heating water tank.
The circulation pump comprises a circulation pump frame formed with a plurality of connecting holes for coupling the circulation pump to the three-way valve, a heating water inlet hole, a pump entrance and a pump drain pipe.
The third guide means is a heating water return pipe. The fourth guide means is a first communicating pipe. The first communicating pipe extends from one side of the water tank into the circulation pump by passing through the three-way valve.
As described above, in the gas boiler according to the present invention, the typical water tank is partitioned into the upper casing and lower casing to be arranged. Also, the lower casing, three-way valve and circulation pump are successively arranged in series in the transversal direction. The recess is formed in one side of the upper casing for placing the PCB box, and then, the internal pipeline is furnished within the gas boiler. Therefore, both first heating water inlet tube 28 for connecting water tank 20 and circulation pump 30, and internal circulation pipe 42 for connecting first heating water inlet tube 28 and three-way valve 40, which have been heretofore adopted in the conventional gas boiler, are removed. Furthermore, a wasteful space within the gas boiler can be reduced. In addition, the pipeline for connecting respective components can be relatively shortened to minimize the size of gas boiler and to reduce the cost of manufacturing the gas boiler.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail the preferred embodiment thereof with reference to the attached drawings in which:
FIG. 1 is a view showing the internal structure of a gas boiler according to the preferred embodiment of the present invention;
FIG. 2 is a view partially showing the structure of the gas boiler shown in FIG. 1, which is a plan view showing the lower casing, three-way valve and circulation pump;
FIG. 3 is a front view showing the lower casing, three-way valve and circulation pump shown in FIG. 2;
FIG. 4 is a right side view of the lower casing, three-way valve and circulation pump shown in FIG. 2;
FIG. 5 is a view showing the gas boiler taken along line V--V of FIG. 2, which is a vertical section view of the three-way valve showing the position of the ball of the three-way valve when the operational mode of the gas boiler is a heating mode;
FIG. 6 is a view showing the gas boiler taken along line VI--VI of FIG. 2, which is a vertical section view of the three-way valve showing the position of the ball of the three-way valve when the operational mode of the gas boiler is a hot water mode;
FIG. 7 is a vertical section view taken along line VII--VII of FIG. 2 for showing the circulation pump;
FIG. 8 is a vertical section showing the circulation pump taken along line VIII--VIII of FIG. 4;
FIG. 9 is a cross section view showing the heat exchanger taken along line IX--IX of FIG. 1; and
FIG. 10 is a view showing the internal structure of a conventional gas boiler.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of a gas boiler according to the present invention will be described with reference to the accompanying drawings.
Referring to FIG. 1, gas boiler 100 according to the preferred embodiment of the present invention includes a water tank 114, a circulation pump 130, a three-way valve 140 for controlling the flow of heating water, a gas-heated heat exchanger 150 and a PCB box 170 for controlling an operation of gas boiler 100.
Gas boiler 100 also has a water valve 155, a supplementary water valve 157, a feed fan 160, a gas valve 174, a plurality of pipelines (not shown) and a plurality of electric wires (not shown).
In FIG. 1, gas boiler 100 is equipped with a rear plate 112 composed of a sheet of steel plate. Rear plate 112 is joined with a front cover (not shown), and a stage 113 is formed along the marginal periphery thereof for facilitating the joining with the front cover. Water tank 114 for retaining the heating water is disposed to the left of rear plate 112. Water tank 114 sectionally has a rectangular shape, which includes an upper casing 120 and a lower casing 122.
A recess 121 is formed in the left side of upper casing 120. PCB box 170 is placed within recess 121. The lower portion of upper casing 120 is open to be communicated with lower casing 122. A first flange 123 is formed along the lower marginal periphery of upper casing 120 to couple with lower casing 122. A plurality of screw holes 101 are formed in first flange 123.
A water level sensing unit 180 is installed to the upper portion of upper casing 120. Water level sensing unit 180 forces a water level of the heating water retained within water tank 114 to maintain a proper height. Preferably, water level sensing unit 180 is a water gauge. Water level sensing unit 180 includes a fixture 182, a column 184 and a water level sensor 186. Fixture 182 is provided to the ceiling of upper casing 120. Column 184 extends from fixture 182 into the interior of water tank 114. Water level sensor 186 is attached to the end of column 184.
The upper portion of upper casing 120 is equipped with a bypass pipe 190 which is connected to the left upper portion of heat exchanger 150 situated in the right of upper casing 120. Bypass pipe 190 is a flow path for permitting water bubbles generated from the heating water of high temperature to drift within heat exchanger 150.
Heat exchanger 150, as shown in FIG. 9, includes a heating water tank 151 for retaining the heating water supplied from first heating water supply pipe 128, a combustion chamber 154 and a gas burner 153 for heating the heating water housed within heating water tank 151. A water supply pipe 156 introduced from the left lower portion of heat exchanger 150 is arranged within heating water tank 151 as a coil. Gas burner 153 is connected with a gas supply pipe 172. Gas supply pipe 172 provides gaseous fuel such as LNG or LPG from an external gas source (not shown) to gas burner 153.
As illustrated in FIG. 1, gas supply pipe 172 extends from the external gas source of gas boiler 100 to flow into combustion chamber 154. A gas valve 174 is disposed in the middle of gas supply pipe 174. Gas valve 172 adjusts the quantity of the gas supplied to gas burner 153 via gas supply pipe 172. Feed fan 160 is installed below heat exchanger 150. Feed fan 160 provides the air into heat exchanger 150 to serve for assisting the combustion of the gas and preventing a gas explosion within combustion chamber 154.
The upper plane of lower casing 122 is open to be communicated with upper casing 120. A second flange 125 is formed for fitting lower casing 122 to upper casing 120. A plurality of screw holes 103 are formed in second flange 125 to correspond to plurality of screw holes 101 formed in first flange 123. Upper casing 120 and lower casing 122 are coupled to each other by means of a plurality of screws 102 piercing through screw holes 101 and 103. Upper casing 120 and lower casing 122 are mated to each other sufficiently tight enough to prevent leakage of water and to endure the heating water pressure.
A heating water return pipe 126 and an overflow pipe 124 are installed at the lower portion of lower casing 122. Heating water return pipe 126 is a flow path of the heating water that returns from a heating place to lower casing 122. Overflow pipe 124 penetrates through the bottom of lower casing 122 to extend into upper casing 120. Overflow pipe 124 is installed for externally draining an expansion pressure of the heating water resulting from the heating. The upper end of overflow pipe 124 extends just below bypass pipe 190 such that the upper end is higher than the highest water level of the heating water within water tank 114.
Three-way valve 140 is mounted to the right of lower casing 122. Second heating water supply pipe 152 is connected to the upper portion of three-way valve 140. Second heating water supply pipe 152 extends from the left upper side of heating water tank 151 shown in FIG. 9 to be connected to the upper portion of three-way valve 140. A heating water discharge pipe 144 is connected to the lower portion of three-way valve 140. Also, three-way valve 140 is equipped with a three-way valve frame 142 for mounting three-way valve 140 to lower casing 122 and circulation pump 130.
Circulation pump 130 is driven by an electric motor (not shown) to raise a pressure of the heating water and circulate the heating water. First heating water supply pipe 128 connects circulation pump 130 and heat exchanger 150. A pump drain pipe 134 is connected to the lower portion of circulation pump 130. A drain cock 135 is installed to pump drain pipe 134. Also, circulation pump 130 is provided with a circulation pump frame 132 for mounting circulation pump 130 to three-way valve 140.
Water supply pipe 156 is perpendicularly arranged to the right of circulation pump 130 for supplying fresh water into gas boiler 100. Water supply pipe 156 extends from a water source outside gas boiler 100 to be admitted into heating water tank 151 (refer to FIG. 9) of heat exchanger 150 after passing through the right of circulation pump 130. Water valve 155 is installed to the middle of water supply pipe 156. Water valve 155 adjusts the quantity of the fresh water introduced to heat exchanger 150 via water supply pipe 156. Water supply pipe 156, running heating water tank 151 of heat exchanger 150, is arranged as a coil to extend to the upper right portion of heat exchanger 150. Water supply pipe 156 is connected to a hot water supply pipe 159 at the upper right portion of heat exchanger 150. Hot water supply pipe 159 externally extends downward under feed fan 160 mounted below heat exchanger 150.
On the other hand, supplementary water supply pipe 158 is installed between upper casing 120 and water supply pipe 156. Supplementary water supply pipe 158 enables the supplying of the fresh water which is the supplementary water into water tank 114. Supplementary water valve 157 is installed in the middle of supplementary water supply pipe 158. Supplementary water valve 157 adjusts the quantity of the fresh water supplied into water tank 114 via supplementary water supply pipe 158.
Hereinafter, the construction of lower casing 122, three-way valve 140 and circulation pump 130 will be described in detail with reference to FIGS. 2 to 9.
First, in FIG. 2, lower casing 122 has second flange 125 formed along the upper marginal periphery of lower casing 122. Second flange 125 contains a plurality of screw holes 103 corresponding to plurality of screw holes 101 formed in first flange 123 (refer to FIG. 1). Lower casing 122 has a third flange 129 horizontally extending from the right marginal periphery of second flange 125 to be coupled with three-way valve 140 which places in the right of lower casing 122. Third flange 129 contains a plurality of screw holes 105 for coupling lower casing 122 and three-way valve 140. A heating water return inlet 127 is provided in the lower portion of lower casing 122, to which heating water return pipe 126 (refer to FIG. 1) is connected. Meantime, overflow pipe 124 penetrates through the bottom of lower casing 122 to extend into upper casing 120.
Three-way valve 140 is mounted to the right of lower casing 122, which is substantially identical to three-way valve 40 adopted to conventional gas boiler 10. Three-way valve 140 is equipped with three-way valve frame 142 for mounting three-way valve 140 to lower casing 122. A plurality of screw holes 106 corresponding to plurality of screw holes 105 in third flange 129 of lower casing 122 are formed in the lower portion of three-way valve frame 142 to allow three-way valve 140 to couple with lower casing 122. Lower casing 122 and three-way valve 140 are coupled by means of plurality of screws 104 penetrating through plurality of screw holes 105 and 106. A plurality of screw holes 107 are formed in the right marginal periphery of three-way valve frame 142 to allow three-way valve 140 to couple with circulation pump 130. As illustrated in FIGS. 5 and 6, a heating water supply hole 146 is provided in the upper portion of three-way valve 140, which is connected to second heating water supply pipe 152. A heating water discharge hole 148 is formed in the lower portion of three-way valve 140 to be connected with heating water discharge pipe 144.
As indicated by a dotted-line shown in FIG. 3, a ball space 300 is provided in the center of three-way valve 140, in which a spherical ball 310 is placed for selectively shutting off heating water supply hole 146 and heating water discharge hole 148, as required. Lower casing 122 and three-way valve 140 are connected by a first communicating pipe 200 which extends from lower casing 122 and passes through ball space 300 within three-way valve 140 prior to being connected to the center of a second communicating pipe 400 of circulation pump 130 on the right of three-way valve 140.
As illustrated in FIGS. 2, 7 and 8, circulation pump 130 is formed with second 10 communicating pipe 400 communicated with three-way valve 140 and a heating water inlet hole 136 connected to first heating water supply pipe 128. A pump entrance 138 for admitting the heating water is formed in the center of circulation pump 130. Circulation pump 130 includes a circular circulation pump frame 132 for mounting circulation pump 130 to three-way valve 140. A plurality of screw holes 109 are formed in the left marginal periphery of circulation pump frame 132 for coupling circulation pump 130 to three-way valve 140. Plurality of screw holes 109 correspond to plurality of screw holes 107 formed in the right marginal periphery of three-way valve frame 142. Three-way valve frame 142 and circulation pump frame 132 are coupled with plurality of screws 108 penetrating through plurality of holes 107 and 109. Pump drain pipe 134 is connected to the lower portion of circulation pump frame 132, and drain cock 135 is installed to pump drain pipe 134. Drain cock 135 adjusts the quantity of the heating water discharged from circulation pump 130 to a ditch via pump drain pipe 134 for substituting the heating water.
In the above description, three-way valve 140 is substantially identical to three-way valve 40 which has been adopted in conventional gas boiler 10. Three-way valve 140 is operated by a control signal from a printed circuit board within PCB box 170 of gas boiler 100.
An operation of gas boiler 100 according to the preferred embodiment of the present invention constructed as above will be described in connection with the flow of fluid.
To begin with, the heating water returning to gas boiler 100 since the temperature thereof is lowered after executing room heating is admitted into water tank 114 via heating water return pipe 126. The heating water admitted into water tank 114 blends with the supplementary water which is the fresh water introduced into water tank 114 via supplementary water supply pipe 158 connected to water supply pipe 156 to be supplied to second communicating pipe 400 via first communicating pipe 200.
The heating water entering in second communicating pipe 400 drifts within circulating pump 130 via pump entrance 138 of circulation pump 130. Within circulation pump 130, the heating water is pressed by the pumping operation of circulation pump 130 to be supplied into heating water tank 151 of heat exchanger 150 via first heating water supply pipe 128. The heating water flowing into heating water tank 151 is heated by gas burner 153 in combustion chamber 154 of heat exchanger 150. That is, gas burner 153 ignites the LNG or LPG supplied via gas supply pipe 172 to heat the heating water. The heating water having the temperature raised by the heating is admitted to three-way valve 140 via second heating water supply pipe 152 extending from the left upper portion of heating water tank 151.
Three-way valve 140 opens heating water discharge hole 148 to discharge the heating water when an operational mode of gas boiler 100 is the heating mode. In more detail with reference to FIG. 5, spherical ball 310 placed in ball space 300 of three-way valve 140 shuts off second communicating pipe 400 in accordance with the control signal from the printed circuit board. By doing so, the heating water admitted into three-way valve 140 from second heating water supply pipe 152 is discharged via heating water discharge pipe 144 after passing through ball space 300 of three-way valve 140. The heating water discharged as above is transferred to the heating place 500 via the heating water pipeline. The heating water releasing the heat in the heating place 500 returns into water tank 114 via heating water return pipe 126. The heating water introduced into water tank 114 is successively subjected to the above-described circulation procedure.
On the other hand, different from the circulation of the heating water, the fresh water is supplied into heating water tank 151 of heat exchanger 150 via water supply pipe 156. The fresh water flows via water supply pipe 156 arranged as the coil within heating water tank 151. At this time, the fresh water is changed into the hot water of high temperature by indirectly receiving the heat from the heating water heated by gas burner 153. The hot water prepared as above is guided to the user via hot water supply pipe 159 extending from water supply pipe 156 on the right of heat exchanger 150. Therefore, the heating water and hot water are simultaneously supplied when gas boiler 100 is in the heating mode state.
Separate from the above operation, when the operational mode of gas boiler 100 is in the hot water mode, three-way valve 140 shuts off heating water discharge pipe 148 as shown in FIG. 6 to drift the heating water only within gas boiler 100. More specifically, ball 310 of three-way valve 140 shutting off second communicating pipe 400 is moved in accordance with the control signal from the printed circuit board to shut off the upper end of heating water discharge hole 148. Thus, the heating water having the raised temperature flows into circulation pump 130 via second communicating pipe 400 and pump entrance 138 of circulation pump 130. The heating water having the raised temperature introduced into circulation pump 130 is then provided into heating water tank 151 of heat exchanger 150 via first heating water supply pipe 128 by the pumping operation of circulation pump 130 together with the heating water returning from the heating place. The heating water admitted into heating water tank 151 is heated by gas burner 153 arranged within combustion chamber 154 as mentioned above. The heating water heated in this manner is introduced into three-way valve 140 via second heating water supply pipe 152. Thereafter, the heating water is subjected to the aforestated circulation procedure to drift just within gas boiler 100.
Meanwhile, the hot water is supplied apart from the circulation of the heating water. That is, as described above, the fresh water introduced into heating water tank 151 of heat changer 150 via water supply pipe 156 passes through water supply pipe 156 arranged as the coil within heating water tank 151. At this time, the fresh water is changed into the hot water of high temperature by indirectly receiving the heat from the heating water heated by gas burner 153. The hot water prepared as above is guided to the user via hot water supply pipe 159 extending from the right of heat exchanger 150. Therefore, the hot water is solely supplied independent of the heating operation when gas boiler 100 is in the hot water mode.
In the gas boiler according to the preferred embodiment of the present invention constructed as above, lower casing 122 of water tank 114, three-way valve 140 and circulation pump 130 are successively arranged in a row, and recess 121 is formed in one side of upper casing 120 to accommodate PCB box 170 therein. Then, the internal pipeline work of gas boiler 100 is executed, so that first heating water inlet pipe 28 for connecting water tank 20 and circulation pump 30 in conventional gas boiler 10 is removed, and internal circulation pipe 42 for connecting first heating water inlet pipe 28 and three-way valve 40 is subsequently removed. Thus, wasteful space within gas boiler 10 can be reduced. In addition, the length of other pipelines for connecting respective components is relatively shortened. By doing so, the gas boiler's size can be minimized and the manufacturing cost of the gas boiler is reduced.
While the present invention has been particularly shown and described with reference to a particular embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be effected therein without departing from the spirit and scope of the invention, which is defined by the appended claims. | Disclosed is a gas boiler which has a simple structure, which is easy to be installed, and which is manufactured at a low cost. The typical water tank is partitioned into an upper casing and a lower casing which are capable of communicated with each other. A three-way valve and a circulation pump are mounted to the lower casing in a row in the horizontal direction, and the plurality of pipelines are arranged by using the above serial arrangement as a reference. A recess for retaining a printed circuit board box is formed in one side of the upper casing. The three-way valve is coupled to the lower casing and circulation pump is to the three-way valve. Therefore, the size of the gas boiler is minimized and the manufacturing cost thereof is economized. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to heat exchangers and to solar energy collectors and in particular to a method for fabricating solar energy collector panels of the flat-plate type.
2. Prior Art
An urgent, current need exists for alternative energy supplies to fill the gap between industrial, commercial and residential energy needs and the ability of dwindling supplies of fossil fuels to satisfy those needs. Nuclear fission offers near-term relief, but supplies of fissionable material are also limited and, in addition, nuclear energy production is accompanied by as yet unsolved problems of waste disposal, plant and fuel transportation security risks, and high capital costs.
Since a large amount of energy produced is used for heating homes, and commercial and industrial buildings, and for heating water supplies for bathing, washing and similar activities, elimination or reduction of the energy required for those activities from the current energy distribution channels would mean that current energy sources can be stretched over a longer period of time and used in ways for which they are most efficient; i.e., petroleum reserves could be applied to transportation needs while coal and uranium reserves could be used to produce electricity for use in lighting, industrial processes, communications and similar areas for which electricity is ultimately required.
It has been proposed to use the sun's energy for this purpose, and indeed solar energy is being used on a limited basis for residential heating and has been so used for quite some period of time. More widespread use is required for this alternative to produce any appreciable reduction in overall energy needs, but widespread use on a residential basis is generally hampered by the high capital costs of collection and storage apparatus since the cost must generally be bourne by the individual homeowner. Although it may be shown that savings in other costs over a period of time will equal or exceed the cost of purchasing and installing solar collector equipment, the large capital outlay requirement is nonetheless a serious deterrent to widespread use of solar energy.
Of the proposed solar energy collection schemes, the most commonly used and, generally speaking, the most convenient and efficient is the flat-plate collector. Although more exotic schemes are available, the flat-plate collector is generally considered best for reasons of initial cost and compatibility with existing architectural styles, and compatibility with existing home systems.
Of the many flat-plate collectors designed, most employ a thin sheet of copper to which is bonded a copper tubing which meanders over the surface of the sheet to achieve maximum thermal conductivity between all areas of the sheet and the walls of the tubing. Common additions include darkening of the surface of the sheet to achieve higher energy absorption, and, insulation of the back of the collector plate and glazing of the front to prevent excessive heat loss.
A drawback of the flat-plate collector, and of many other engineering situations as well, lies in the oft-encountered dilemma that if the device works efficiently it is expensive to produce, while if it is inexpensively produced, it works inefficiently.
The primary cost of the solar collector lies in its raw materials, but substantial labor costs are encountered and must be reckoned with in the manufacturing process. Of these, the cost associated with achievement of a close thermal bond between the copper tubing and the copper sheet loom large. At the same time, failure to devote sufficient attention to thermal bonding will result in an inefficient collector design since less than maximum transfer of heat energy will occur between the sheet and the tubing.
The most common solution is to position the copper tubing against the copper sheet and then to solder, braze or otherwise bond the two together. If thermally conductive bonding material is used, the bonding material as well as the contact between sheet and tubing will provide a thermal path, and if sufficient filleting of the gap between the curving side of the tube and the sheet is produced, the energy transfer may be quite efficient. Producing maximum transfer efficiency does consume a large amount of bonding material, however, and is at best an uncertain and difficult-to-control process. In addition, use of soldering or brazing requires large amounts of heat to be applied, thereby necessitating that the bonding process take place before insulation is added to the collector. This additional step in processing adds to the handling requirement and therefore to the cost of producing the plates.
It has been proposed to eliminate or reduce the problems of bonding while achieving high thermal efficiency by curving the sheet to conform to the tubing, and previous attempts to secure a close thermal bond by means of forming a conductive copper plate around a copper tube have been described in patents issued to several applicants. In each case the method described involves separate formation of a groove generally conforming to the outline of the tubing which is then placed inside the groove. Various other procedures are used to cause the tubing wall to collapse inward, causing portions of the tubing to expand outward against the backing plate or to cause the backing plate to fold slightly around the tubing. In a patent issued to Sandburg U.S. Pat. No. 2,666,981, for example, the groove is formed in a backing plate by a cooperating roller and die, the roller having a protrusion which forms a groove against a mating die surface. Once the groove is formed, a second step also involving a roller flattens the groove slightly, causing partial collapsing of the side walls from a straight configuration into arcuate configuration. Into the groove is then placed a tubing having a diameter slightly smaller than the width of the groove. In a fourth step, the top of the tube is pressed with a third roller which urges the sides of the tubing outward against the arcuate wall of the groove in the backing plate which is held firmly affixed in a die.
A second patent issued to Sandburg 2,585,043 describes a heat exchanger which is manufactured by first providing a grooved backing plate having raised ridges on each side of the length of the groove. After a tube has been formed and is accommodated into the groove, portions of the raised ridge are deformed by pressing them against a backing die causing the ridges along the groove to overlap the edge of the round tube, thereby entrapping the tube at the bottom of the groove.
In a related method patent, O'dell 1,971,723 describes a method for securing automobile top covers which provides a groove in a metal surface having an arcuate bottom and sides essentially circular and a split tube which fits within the tube. The automobile top cover is placed over the groove and the split tube forced into the groove entrapping the cover between the groove and the metal surface. Then, to secure the top cover permanently, the split tube is compressed forming a flat surface even with the surface of the metal surface and causing the top cover to be compressed against the arcuate sides of the groove. Since greater than 180° of arc is provided, a portion of the metal surface wraps around the compressed split tube thereby retaining it. The split in the tube allows accommodation for movement of the side wall of the tubes without causing deformation of the metal surface.
All of the above-described processes suffer form the common requirement of careful, labor-intensive steps to ensure good thermal bonding. Of those processes which employ some form of groove adapted to receive the copper tubing, all require multiple press operations employing expensive dies. In all cases, the shape of the tubing must be carefully matched to the groove to achieve proper fit. Slight variances in one or the other will result in poor fit and loss of thermal efficiency, or in extreme cases, scraping of the non-fitting parts. The roller die employed in the first Sandberg invention is not amenable to use in forming sinuous patterns in the copper sheet since only straight grooves can apparently be formed.
It is desirable therefore to provide a method for manufacturing solar collector panels which avoids the above problems and which results in a collector panel which is thermally efficient and inexpensive of both labor and materials.
SUMMARY OF THE PRESENT INVENTION
Accordingly, it is an object of the present invention to provide a method for manufacturing heat exchangers which is economical in use of materials.
It is another object of the present invention to provide a method for manufacturing heat exchangers which avoids labor intensive operations.
Yet another object of the present invention is to provide a method for manufacturing heat exchangers which are thermally efficient.
Yet still another object of the present invention is to provide a method for manufacturing heat exchangers which provides for a large percentage of contact between the backing plate and the copper coolant tubing.
Yet still another object of the present invention is to provide a method for manufacturing heat exchangers which is rapid.
Yet still another object of the present invention is to provide a design for heat exchangers which are easily mass produced.
Yet still another object of the present invention is to provide a method for manufacturing heat exchangers which is producible without requirement of great investment in capital equipment.
Yet still another object of the present invention is to provide a method for manufacturing heat exchangers which are durable.
Briefly, the present invention accomplishes these and other objects by providing a method employing soft, thin copper sheeting and soft, thin-wall copper tubing. The copper tubing is formed into a suitable geometry, generally a serpentine shape for overlay on the copper sheet. The copper sheet is provided with a backing of high density foam insulation which is chosen to yield at moderate applied forces when pressure is applied. The three layers of tubing, the copper sheet, and the foam backing are passed between the nap of two high pressure rollers. As the copper tubing is passed between the rollers, it becomes crushed slightly against the resistance offered by the thin copper sheet and its foam backing. The copper sheet in turn is deformed into approximately the shape of the copper tubing which is pressing against it. The foam insulation is similarly deformed and being a non-resiliant type of foam does not attempt to spring back to its original position. When the assembly has been entirely passed through the roller press, an assembly is produced which provides for close thermal contact between the copper tubing and the copper plate as well as a conforming foam insulation on the back panel.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects are achieved by the present invention by means which are best understood by making reference to the drawings wherein:
FIG. 1 is a top view of a solar collector panel made in accordance with the present invention, prior to passage of the assembly through the rollers.
FIG. 2 is a sectional view of the assembly depicted in FIG. 1 through section 2--2.
FIG. 3 depicts the passage of the assembly through a roller press.
FIG. 4 is a sectional view of the assembly taken at section line 4--4 after the passage of the assembly through the roller press.
FIG. 5 is a detail view of one portion of the tubing enclosed dotted lines in FIG. 4.
FIG. 6 depicts the tubing shown in FIG. 5 after being subjected to different processing.
FIG. 7 shows the assembly in completed form.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, there is shown a top view of a solar collector panel 10 in the initial stages of fabrication in accordance with the present invention. The copper tubing 15 has been formed into a sinuous pattern, visible in FIG. 1, covering most of the area of the copper sheet 13. Inlet 16 and outlet 17 ports extend beyond the edge of the copper sheet for connection to coolant lines.
The copper sheet 13 is initially laminated to a layer of insulating foam 11, visible in the section view FIG. 2. In turn, the foam is laminated to a backing panel 12 made of pressed wood.
Following lamination of the copper sheet/foam/backing panel assembly, and formation of the tubing into a sinuous pattern, the tubing is placed on the copper sheet and is positioned and held in contact with the sheet by a suitable fixture.
FIG. 3 depicts the passage of the tubing and copper sheet through the rollers 31 and 32 of a roller press. The backing panel 12 supports the foam 11 causing the pressure to be more evenly distributed throughout the back of the assembly, thereby preventing the foam from being crushed by high local pressures.
On the top of the assembly, the tubing 15 is shown deforming the surface of the copper sheet producing a groove in the sheet which conforms to the shape of the tubing 15. As the length of the assembly 10 passes through the rollers 31 and 32, the entire length of the tubing 15 becomes pressed into the surface of the copper sheet.
Referring now to FIG. 4, there is shown a cross-sectional end view through section 4--4 of FIG. 3 of the collector panel 10 after passage through the roller press has been completed. The depth of penetration into the copper sheet may be regulated by varying certain parameters as will be described below.
Referring now to FIG. 5, there is shown a detail view of the portion of FIG. 4 enclosed in dotted lines. The tubing 15 is seated in the groove 19 formed in the copper sheet 13 by processing in accordance with the present invention. An additional desirable feature is illustrated by the dark area 18 between the tubing 15 and the sheet 13, which represents bonding material of an adhesive type or a eutectic alloy type such as solder or brazing compound. It will be desirable in most cases to provide such a bond between tubing 15 and sheet 13 to enhance the thermal efficiency of the collector panel and to retain the tubing securely.
If the fillet is made of solder or brazing material, the temperature limitations of the foam must be given due consideration. It is an advantage of the present invention that a minimum amount of filleting material is required due to the close contact between the tubing and the copper sheet. Since the material required is minimal, only minimal heat is required to be applied to the assembly. Thus, it is possible to solder or braze even though the lamination of the copper to the foam is done before the brazing process. In practice, some damage to the foam does result but its effect is negligible.
In FIG. 6, a variant of the technique described is illustrated. The tubing 15 in this case has been subjected to greater pressure causing the top of the tube to flatten slightly and producing an approximately elliptical shape. The tubing 15 has been forced almost level with the surface of the copper sheet 13 so that a larger percentage of its external area is in contact with the sheet. Where maximum thermal efficiency is required, this technique may be employed, but for most purposes it is not required.
FIG. 7 shows a cross-sectional view of a complete solar collector panel 10 made in accordance with the present invention. Glazing 71 has been added to enhance collector efficiency as is well known in the art. Extruded aluminum brackets 72 and 73 are adapted to hold the glass 71 and the backing plate 12. Apertures are provided at appropriate locations for clearance around inlet 16 and outlet 17 ports.
In practising the present invention, it will be desirable to choose materials for their mechanical as well as their thermal properties. The tubing 15 must be relatively strong in comparison to the yield strength of the foam-backed copper sheet 13, while the copper sheet should be as thin as is reasonably possible without becoming subject to rupture under the pressure of the tubing being forced into its surface. Minimum thickness will produce minimum manufacturing costs and insures that the copper sheet forms easily around the copper tubing as well. In the commercial units, a soft copper sheet of .010" has been found to be suitable.
The tubing 15 is preferably made of copper although other materials may be useful in some applications. Copper is preferred because of its twin desirable properties: it has high thermal conductivity and is easily formed into patterns. The sinuous pattern shown is an efficient one since it results in coverage of all useable area of the copper sheet without excessive waste. However, other patterns may be employed without departure from the teaching of the present invention.
Spacing of adjacent runs should be made with consideration being given to the trade-off between cost and efficiency. If a single run were used, for example, the cost of the collector would be minimum but its efficiency would be poor since, in areas distant from the tubing, the temperature of the copper sheet will rise to a point at which the heat loss through the sheet and through the surrounding air and materials equals the heat gained by solar absorption. The heat loss into surrounding air and materials represents wasted energy, so far as the collector is concerned, and the efficiency of the collector is diminished.
Varying tube dimensions and yield strengths may be selected for varying requirements. To produce the approximate results of FIGS. 4 and 5, soft copper tubing having an O.D. of one-half inch and an I.D. of three-eighth inches, and a nominal wall thickness of one-sixteenth inch is employed. Variations in thickness of the copper sheet and the stiffness of the foam will, of course, produce varying results.
The frame of the collector is preferably made from a material having requisite mechanical strength and the ability to withstand exposure to the environment described above, including the ability to withstand continuous exposure to the sun's rays. A desirable material is aluminum from which extruded forms having accomodation for the backing plate, the copper foil and glazing if so desired, are easily and inexpensively manufactured. A glazed collector has greatly improved efficiency over the unglazed type, particularly in areas in which high wind currents create a great amount of convection cooling of the collector's surface.
Selection of a suitable foam material must be done in conjunction with the selection of the copper sheet. It is desired to have a combination of the two which will yield in the area immediately beneath the tubing, but will resist general collapsing of the foam in areas not directly beneath the tubing. At the same time, it should be chosen to have desirable insulating properties to avoid loss of collected heat energy through the back plane of the collector. In many applications the foam will also be continuously exposed to extremes of hot and cold temperature thereby implying an ability to withstand that exposure as a requisite characteristic of the foam also.
A good choice for this material is TRYMER CPR 9545, manufactured by Upjohn, which is employed in the commercial version of the collectors manufactured in accordance with the present invention in 1 inch thickness slabs.
In producing the shape depicted in FIG. 6, reliance is placed on the characteristic of non-resilient foam that density is increased as the foam is compressed beyond the elastic limit of the cell structure. The density of the foam in the area surrounding the depression caused by the tubing being urged into the copper foil therefore increases as the displacement of the tubing increases with respect to the original surface of the copper sheet. As the density increases, the resistance offered to the bottom of the copper tubing by the copper sheet is likewise increased causing the copper tubing to be subjected to compressive forces between the bottom of the groove and the roller 31. As the forces reach the yielding strength of the copper tubing it begins to deform causing a flattening of the tube into an elliptical cross section and causing the sides of the groove to expand outward from the original circular shape. By proper selection of foil thickness, tubing hardness, and the foam density, the process may be caused to yield the proper amount of deformation of the copper tubing and in the proper amount of deformation of the copper sheet so that the maximum percentage of the surface of the copper tubing is in contact with the surface of the copper sheeting.
While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptions, and modifications may be made therein without departing from the spirit of the invention or the scope of the following claims. | A sinuous pattern of soft copper tubing is pressed against a laminated assembly consisting of a thin sheet of copper laminated to a layer of insulating foam which is in turn laminated to a backing plate of pressed wood. As the pressure is increased, the tubing deforms the copper sheet in conformity with the shape of the copper tubing. The foam resists deformation of the sheet in areas not directly beneath the copper tubing resulting in a well-defined trough adapted to receive the copper tubing which deforms it. The copper tubing and sheet are then bonded together resulting in a thermally efficient, inexpensively produced collector panel. | 5 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 61/337,748, filed Feb. 11, 2010.
FIELD OF THE INVENTION
The present invention relates generally to medical devices and methods for sealing and closing passages formed through tissue. More specifically, the present invention relates to apparatuses or devices for sealing or closing an opening formed through biological tissue to control, prevent or stop bleeding or other biological fluid or tissue.
BACKGROUND
In many medical procedures, such as, for example, balloon angioplasty and the like, an opening can be created in a blood vessel or arteriotomy to allow for the insertion of various medical devices which can be navigated through the blood vessel to the site to be treated. For example, after initial access with a hollow needle, a guidewire may first be inserted through the tissue tract created between the skin, or the epidermis, of the patient down through the subcutaneous tissue and into the opening formed in the blood vessel. The guidewire is then navigated through the blood vessel to the site of the occlusion or other treatment site. Once the guidewire is in place, an introducer sheath can be slid over the guide wire to form a wider, more easily accessible, tract between the epidermis and the opening into the blood vessel. The appropriate medical device can then be introduced over the guidewire through the introducer sheath and then up the blood vessel to the site of the occlusion or other treatment site.
Once the procedure is completed, the medical devices or other equipment introduced into the vessel can be retracted through the blood vessel, out the opening in the blood vessel wall, and out through the tissue tract to be removed from the body. The physician or other medical technician is presented with the challenge of trying to close the opening in the blood vessel and/or the tissue tract formed in the epidermis and subcutaneous tissue. A number of different device structures, assemblies, and methods are known for closing the opening in the blood vessel and/or tissue tract, each having certain advantages and disadvantages. However, there is an ongoing need to provide new and improved device structures, assemblies, and/or methods for closing and/or sealing the opening in the blood vessel and/or tissue tract.
Arteriotomy closure after diagnostic and/or interventional catheterization procedures has been addressed by a number of devices in addition to standard manual compression. One of the most successful approaches has been the use of a collagen plug placed external to the artery, held in place by a biodegradable polymer (such as PLGA) anchor inside the artery, with these two components held together by a suture which passes through the arteriotomy. The components are essentially cinched together to stabilize the components in place with arterial wall tissue pinched between the plug and anchor to maintain approximation for a period of time before sufficient clotting, tissue cohesion, and/or healing occurs to prevent significant bleeding complications. While this approach has had success, there are drawbacks with these devices. The primary problems are that bleeding complications still occur, arterial occlusion problems occur, and there are many steps required to properly implant these devices which require effort by the practitioner, training, and careful attention to various manually-performed steps to reduce the occurrence of complications. One step common to most of the prior approaches has been trimming of the cinching suture at the conclusion of the procedure. This is typically performed by pulling tension on the suture manually, depressing the skin manually, and trimming the suture manually. The suture is trimmed close to the depressed skin so that when the skin is released, the ends of the suture are underneath the surface of the skin. This is important to reduce infections which would be more likely if the suture extends to the skin because this would maintain an access path from outside the body through the normally protective skin layer to the tissues underneath. This is typically not a difficult procedure, but nevertheless represents steps which are presently performed manually, taking more time than necessary, and must be done carefully to trim the suture to the correct length. It may be desired to trim the suture a bit farther underneath the skin than is easily accomplished by this method; this may be desired to minimize infection risks, for example. The present invention overcomes these problems by providing an apparatus which automates the suture cutting, and can easily cut the suture at a location deeper under the skin if desired, providing a faster procedure and an improved safety margin for trimming location.
Prior art devices require complex techniques that require many steps to properly implant these devices. This requires training and careful attention to various manually-performed steps to reduce the occurrence of complications. The present invention overcomes these problems by providing an apparatus which automates the implantation procedure, thereby providing more reliable sealing, and reducing the complexity of using the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an introducer sheath 200 passing through a vessel wall 201 ;
FIG. 2 is a schematic view of a device sheath 210 with a vascular closure device loaded therein inserted into the introducer sheath of FIG. 1 ;
FIG. 3 is a schematic view of the introducer sheath 200 and device sheath 210 combination during a step of a process of deploying the vascular closure device;
FIG. 4 is a schematic view of the introducer sheath 200 and device sheath 210 combination during a step of a process of deploying the vascular closure device;
FIG. 5 is a schematic view of the introducer sheath 200 and device sheath 210 combination during a step of a process of deploying the vascular closure device;
FIG. 6 is a schematic view of the introducer sheath 200 and device sheath 210 combination during a step of a process of deploying the vascular closure device;
FIG. 7 is a schematic view of the introducer sheath 200 and device sheath 210 combination during a step of a process of deploying the vascular closure device;
FIG. 8 is a schematic view of a deployed vascular closure device;
FIG. 9 is an isometric view of the proximal portion, including the handle, of a device sheath;
FIG. 10 is a cross-sectional view of a device sheath with a vascular closure device loaded therein;
FIG. 11 is a cross-sectional view of the device sheath of FIG. 10 inserted into an introducer sheath;
FIG. 12 is a cross-sectional view of the device sheath and introducer sheath of FIG. 11 during a step of a process of deploying the vascular closure device;
FIG. 13 is a cross-sectional view of the device sheath and introducer sheath of FIG. 11 during a step of a process of deploying the vascular closure device;
FIG. 14 is a cross-sectional view of the device sheath and introducer sheath of FIG. 11 during a step of a process of deploying the vascular closure device;
FIG. 15 is an exploded view of certain interior components of an introducer sheath;
FIG. 16 is an exploded view of the proximal portion of an introducer sheath;
FIG. 17 is a view of a deployed vascular occluder device;
FIG. 18A is a side view of a suture cutting mechanism with a suture therein;
FIG. 18B is a side view of a suture cutting mechanism with a cut suture therein;
FIG. 19A is a side schematic view of a suture cutting mechanism with a suture therein; and
FIG. 19B is a side schematic view of a suture cutting mechanism with a partially cut suture therein.
DESCRIPTION
The following summary is provided to facilitate an understanding of some of the innovative features unique to the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
The present disclosure relates generally to medical devices and more particularly to methods and devices for closing and/or sealing punctures in tissue. In one illustrative embodiment, a device is provided for delivering and deploying an anchor, plug, filament and locking mechanism adjacent to the opening in the vessel wall and/or tissue tract. In some cases, the anchor may be automatically seated against the vessel wall. In some cases, the plug is compressed and the filament is trimmed automatically. In some cases, the anchor is seated, the plug is compressed and the filament is trimmed automatically.
The invention pertains to apparatuses and methods for implantation and deployment of an anchor-plug-cinch vascular closure device. The implantation and deployment apparatus may comprise an automated plug deployment mechanism having actuation means, drive mechanism, automatic sheath retraction mechanism, automatic anchor seating mechanism, automatic cinching mechanism, optional cinching speed control means, and automated suture trimming or release. The mechanism provides automatic cinching of an extravascular plug towards an intravascular anchor with controlled plug compression. The cinching motion can be controlled to a variable rate by various means such as orifice flows or springs or electro-magnetic-mechanical speed governing to provide for reduced actuation forces to minimize damage to the plug material and the anchor. For example, a gradual acceleration or deceleration period, with different velocity or driving force than other portions of the cinching travel, can be used to avoid tearing the plug, or bending or breaking the anchor. Various steps in the deployment process are accomplished automatically in the desired sequence while minimizing required user action.
The anchor-plug-cinch vascular closure device comprises an anchor, a plug, and a cinch and is similar to those described in of application Ser. No. 12/390,241, filed Feb. 20, 2009, which is incorporated by reference in its entirety herein. The implanted components (anchor, plug, cinch) are preferably degradable so that over time they are degraded or eroded and no longer present in the body. For example, the anchor can comprise PLGA, PLLA, or PGA, but other degradable or erodable polymers can be utilized for this purpose, such as polyesters, polysaccharides polyanhidrides, polycaprolactone, and various combinations thereof, especially if a different strength—degradation time profile is desired. The cinch can comprise these materials as well; for example, a biodegradable suture can be utilized as a tension member. One or more cinching or locking elements, such as a sliding cinch disk or knot, can be utilized to secure the cinch; a bonding or latching mechanism can also be utilized to secure the cinch. The plug preferably comprises a material which swells significantly to fill space in the tissue adjacent to the artery, such as by elastic expansion, fluid absorption, chemical reaction, and so forth, so that it provides improved hemostasis. The plug can comprise the aforementioned materials as well, but collagen, gelatin, PEG, and related materials and combinations can be used also. Dense collagen material has been used for this purpose, but is relatively stiff and provides little swelling. High void-volume gelatin foam or collagen foam, PEG, and similar materials offer more compressibility for smaller-profile introduction, and/or greater swelling for improved hemostasis. Other materials can be utilized which provide for control of hydration, or thrombogenicity, to improve the function of the plug; various combinations of these can be utilized, generally degradable or erodable materials are preferred.
The implantation and deployment apparatus provides automated deployment of the anchor-plug-cinch vascular closure device. The implantation and deployment apparatus comprises elongated components for introduction of the anchor, plug, and cinch into the body, including an insertion sheath and dilator, with an orientation indicator, a hub with a hemostatic valve and an elongated thinwalled tube formed with a distal bevel to accommodate the anchor at the desired deployment angle for proper approximation to the artery. A locating mechanism is incorporated, such as a bleed path in the insertion sheath and dilator for locating the sheath at the desired location in the artery.
The implantation and deployment apparatus further comprises a device sheath which passes through the insertion sheath and is affixed to a handle. The anchor of the anchor-plug-cinch vascular closure device is disposed in or adjacent to the distal end of the device sheath for introduction into the body. The anchor is affixed to the distal end of an elongated portion of the cinch mechanism (herein referred to as the “suture”). The suture extends through the device sheath. The plug is disposed proximal to the anchor and within the device sheath and is captured or retained by the suture. A cinching or locking element (herein referred to as the “cinch disk”) is disposed adjacent and proximal to the plug and within the device sheath. The implantation device also includes a push rod (typically tubular) which passes through the proximal portion of the device sheath to the plug. During the deployment procedure, the push rod, suture, plug, device sheath, and anchor pass through the insertion sheath so that the anchor just passes out the end of the insertion sheath but other components largely do not.
The handle is affixed to the device sheath and comprises a body portion, a hub connector portion, an actuation portion (optionally automatic), an automatic anchor seating mechanism, a sheath retraction mechanism (optionally automatic), an automatic cinching mechanism, and optionally comprises a suture trimming mechanism (optionally automatic); other grasping, orienting, indicating, and control elements can be incorporated.
The hub connector portion attaches to the insertion sheath hub, in a single orientation so that the relative orientation of the handle (and device sheath) and the insertion sheath (and bevel) are maintained when attached.
The actuation portion provides for arming the device and/or triggering the actions of the device. The actuation portion can include a lock or latch which is actuated by user manipulation. The actuation portion can include a latch or button which triggers the various retractions and cinching and other actions of the device in sequence. The actuation can be by application of force such as by pulling back on a portion of the delivery system after the anchor is in place in the vessel. The actions can all occur in sequence from a single trigger, or multiple triggering manipulations can be used to cause multiple sequences of device actions or single actions. Whether by manual or automatic retraction, the device is retracted until the anchor is seated snugly against the vessel wall.
The suture is attached to the automatic anchor seating mechanism. The automatic anchor seating mechanism can be activated by attachment of the hub connector portion of the handle body to the insertion sheath hub; the mechanism then retracts the suture and anchor (and may also retract other components such as the device sheath, plug, and cinch disk) relative to the introduction sheath a predetermined distance proximally to snug the anchor up against the beveled end of the insertion sheath. The automatic anchor seating mechanism can incorporate a speed limiting feature if desired to slow the movement and give the anchor sufficient time to move into alignment with the insertion sheath bevel, such as by incorporating a dashpot or other inertial or frictional mechanism; a moderate strength spring, for example, can retract the suture at an appropriate speed. The anchor seating mechanism has sufficient travel to accommodate any elongation of the suture.
The sheath retraction mechanism provides an appropriate sheath to anchor gap to allow proper deployment of the plug. Displacement can be provided to produce the desired sheath to anchor gap by paying out a predetermined length of suture, by sliding of a suture mounting element, by retraction of the device sheath hub relative to the introduction sheath hub, or by other means. Actuation of the sheath retraction mechanism can be automatically triggered, for example, by application of an appropriate retraction force by the user to pull the anchor against the vessel wall. One or more latches can be provided so that upon completion of the movement of the automatic anchor seating mechanism, automatic sheath retraction mechanism, or other mechanisms, the mechanism latches so to prevent further unwanted movement even if force is applied.
The automatic cinching mechanism advances the cinch disk, advances and axially compresses the plug (which deploys by radially expanding) and cinches the plug against the anchor. The cinching mechanism can be automatically triggered, for example, at the completion of the sheath retraction mechanism travel, or by application of an appropriate retraction force higher than the force which triggered the sheath retraction mechanism, or by manually pressing a button or releasing a latch, or by other means. The cinching mechanism also advances the cinch disk which maintains the implanted device in a cinched configuration after the procedure. When the cinching mechanism is completely actuated, the suture can be cut or otherwise released by an automatic suture cutting or release mechanism, which releases the suture from device so that the handle, device sheath, push rod, and insertion sheath can be withdrawn, leaving the anchor, plug, suture, and cinch disk in place. If an automatic suture cutting or release mechanism is not utilized, the skin is depressed an the suture trimmed to length manually so that it does not extend out past the skin.
The hub connector portion of the handle and/or the insertion sheath hub preferably have orientation features such as asymmetric shapes or pins or slots, etc., which allow the hub connector portion of the handle to mate with the insertion sheath hub in only one orientation, and which facilitate the attachment of the two pieces. Other shapes than those indicated in the drawings for the hub can be utilized, such as, for example, varying aspect ratios, angles, insertion depth, male/female, D- or squared- or rounded-components, convex/concave.
Some internal features and mechanisms which perform the described functions are not indicated in the figures to better illustrate the overall function of the invention. Such internal mechanisms can include, for example, springs, latches, levers, pulleys, strings, friction fits, dashpots, gas reservoirs.
In the embodiment described below with references to FIGS. 1-8 , certain conventions are used. Figures schematically illustrate the steps. (In the figures, the bevel is not shown, and the orientation is perpendicular to the artery for simplicity of illustration. Some latches are indicated diagrammatically as dots.)
The preferred method of achieving arteriotomy closure comprises the following steps. The steps are typically, but not necessarily, performed in the order listed. Certain steps can be combined or performed separately by configuration of the internal mechanisms. Preferably, steps are performed automatically as indicated. Alternatively, certain steps could include manual actuations, although this is less advantageous.
FIG. 1 is a schematic illustration of an insertion sheath 200 . The insertion sheath 200 is inserted over a guidewire after an interventional procedure (such as an angioplasty or stent deployment procedure). The insertion sheath 200 preferably includes a distal hemostatic seal (not shown) and a position indicator near the distal tip of the insertion sheath, which may provide an inlet for a bleed path which may flow through the insertion sheath to indicate the position of the insertion sheath relative to the vessel wall opening or other suitable indicator. Such features are described in the '241 application incorporated by reference above.
The insertion sheath preferably includes an insertion sheath tube 202 and an insertion sheath hub 204 . In this embodiment, the insertion sheath 200 has a spring 206 or other force mechanism which can move the insertion sheath tube 202 distally relative to the insertion sheath hub 204 when the latch 208 is released in a subsequent step.
The distal end of the insertion sheath tube 202 is preferably beveled as shown at 203 and a corresponding indicator is placed on the proximal portion of the tube or on the hub so that the orientation of the bevel can be known by observation of the proximal portion of the insertion sheath. The bevel is omitted in other figures for ease of illustration.
In this step, the interventional procedure sheath is exchanged with the insertion sheath 200 and dilator over a guidewire. The insertion sheath 200 is positioned and oriented to the proper bevel angle using the orientation indicator and the distal end of the insertion sheath is positioned a predetermined distance inside the artery and past the artery wall 201 by using the bleed path or other indicator to indicate position. The insertion sheath is then held to retain proper position and the dilator and guidewire are removed.
The second step is shown schematically with reference to FIGS. 2 and 3 . In this step a device sheath 210 is inserted into the insertion sheath 200 until the distal portion of the insertion sheath 200 is fed through the haemostatic valve and the device sheath 210 engages the hub 204 of the insertion sheath 200 and preferably clicks into place. The device sheath has the anchor 212 , plug 214 , cinch disk 216 and suture 218 preloaded. The suture is attached to the device sheath at the proximal end 220 of the device sheath.
The device sheath 210 has a device sheath tube portion 222 and a handle portion 224 . The handle includes an outer portion 226 that is disposed over a first frame 228 . The outer portion 226 is shown in its further distal position relative to the first frame 228 and may be slid proximally relative to the first frame 228 . This proximal motion is opposed by a spring 230 disposed between the outer portion 226 and the first frame 228 .
The device sheath 210 also includes a second frame 232 disposed within the first frame 228 . This second frame 232 is initially fixed relative to the device sheath tube 222 and the components internal to the second frame 232 (discussed below) and may be moved relative to the first frame 228 and outer portion 226 . A spring 234 is held between the proximal end of the second frame 232 and a pushing plate 236 . At this point, the pushing plate 236 is still fixed to the second frame 232 . The pushing plate is attached to a pushing tube 238 . The pushing tube 238 has a compression plate 240 at its distalmost end, which abuts the cinch disk 216 .
The anchor 212 is seated against the beveled edged 203 of the insertion sheath tube 202 by pushing the device sheath 210 against the insertion sheath 200 . The device sheath tube 222 has a shoulder 242 that hits against the insertion sheath tube 202 to check the proximal movement of the device sheath tube 222 . As the device sheath 210 is still being moved distally relative to the insertion sheath 200 , this movement breaks a connection 244 between the device sheath tube 222 and the second frame 232 . The anchor 212 is fixed to the second frame 232 by the suture 218 at the proximal end 220 , and the anchor 212 therefore pushes the device sheath tube 222 proximally until the distal ends of the insertion sheath tube 202 and the device sheath tube 222 are proximate each other, as shown in FIG. 3 . The components are sized such that at this point, the anchor 212 is properly seated against the beveled distal tip 203 of the insertion tube 200 . When the device sheath tube 22 and the insertion sheath tube 202 are positioned so that the distal ends are proximate each other, the device sheath tube and insertion sheath tube are also fixed with respect to one another at latch 246 .
The second frame 232 continues to move proximally until it latches to the first frame 228 at latch point 248 , at which point the first frame and second frame are fixed relative to each other.
The device sheath 210 is move distally until the first frame 228 latches against the insertion sheath hub 204 at latch point 250 , which fixes the first frame and insertion sheath hub relative to each other.
Once the anchor 212 is seated against the distal end of the insertion sheath tube 202 , the whole device ( 200 and 210 ) may be pulled proximally by pulling on the outer portion 226 . This first seats the anchor plug 212 against the artery wall 201 , as shown in FIG. 4 . The function of the spring 230 disposed between the first frame 228 and outer portion 226 may be seen at this point. This spring 230 functions to control the amount of force transmitted from the outer portion 226 to the first frame 228 .
It is helpful to recall that at this point in the process, the first frame 228 is fixedly connected to the insertion sheath hub 204 and to the second frame 232 . The internal components not yet discussed are fixedly attached to the second frame 232 . The insertion sheath tube 202 is fixedly attached to the device sheath tube 222 . Finally, the insertion sheath tube 202 is also still attached to the insertion sheath hub 204 .
When the device ( 200 and 210 together) is pulled proximally by pulling on the outer portion 226 , the anchor plug 212 positioned against the artery wall 201 prevents the device from being pulled from the patient's body. A force builds up in the mechanism. When a predetermined level of force is reached, the connection 208 between the insertion sheath hub 204 and the insertion sheath tube 202 is broken. This releases the spring 206 disposed between the insertion sheath tube 202 and hub 204 . This spring 206 expands to drive the insertion sheath tube 202 (and connected device sheath tube 222 ) proximally relative to the insertion sheath hub 204 . This operates to retract the distal ends of the insertion sheath tube 202 and device sheath tube 222 from around the distal portion of the plug 214 , as shown in FIG. 5 .
The operator continues to pull the device ( 200 and 210 ) proximally by pulling on the outer portion 226 , which further compresses the spring 230 between the outer portion 226 and the first frame 228 to provide a greater force. This causes a second connection point 254 to release, between the second frame 232 and the pushing plate 236 . This allows spring 234 to expand to advance to the pushing plate 236 distally. As the pushing plate 236 is connected through the pushing tube 238 to compression plate 240 and as the suture is still connected at 220 to the second frame 232 , this motion advances the cinch disk 216 to compress and deploy the plug 214 . This is illustrated in FIG. 6 .
There are several further components that may be attached to the pushing plate 236 and pushing tube 238 . A suture cutting mechanism 256 may be friction fit to the pushing plate 236 . Suture cutting mechanisms will be discussed more fully below, but for the purposes of this embodiment, it is sufficient to say that the suture cutting mechanism includes a long pull wire 258 with a blade at 260 at the distal end. The blade at the distal end is disposed in or proximate to a shearing block 262 , which is fixed within the pushing tube 238 . The suture or filament is threaded through the shearing block 262 and/or blade 260 such that relative movement of the shearing block 262 and blade 260 may cut the suture.
Once the connection point 254 is released, the spring 234 at the proximal end of the second frame 232 pushes the pushing plate 236 distally to advance the cinch disk 216 to compress and deploy the plug 214 as described above. This spring 234 continues to expand and forces the suture cutting mechanism 256 against a stop 264 . This stop 264 is shown as part of the second frame 232 . At this point, the spring 234 forces the push plate 236 proximally relative to the suture mechanism 256 . Because the suture mechanism 256 is fixed to the blade 260 by the pull wire 258 and because the shearing block 262 is fixed within the push tube 238 which is still being pushed by the push plate 236 , relative movement between the blade 260 and the shearing block 262 is created, which cuts the suture 218 . This is illustrated schematically in FIG. 7 .
The device ( 200 and 210 ) is still pulled proximately by the outer portion 226 . As the device is no longer attached to the anchor 212 , this serves to retract the device from the body, leaving the anchor 212 , plug 214 , cinch disk 216 and suture 218 distal portion cinched to the artery wall to provide hemostasis, as illustrated in FIG. 8 .
Since many of the actions occur automatically, the procedure is streamlined from a user perspective. The user steps condense to the following:
1. Swap the interventional sheath for the insertion sheath 200 and position the insertion sheath 200 using bleed indicator.
2. Hold the insertion sheath position, and insert the device sheath 210 until it engages the insertion sheath hub 204 (the anchor 212 automatically seats against the insertion sheath bevel 203 ).
3. Retract the device handle 224 to deploy the device and remove the delivery system (the sheath retraction, cinch mechanism, and suture cutting all happen automatically in sequence).
Prior art devices and procedures have more steps which must be performed by the user because certain automatic features incorporated into the present invention have previously been done manually by the user. The prior art is therefore more complicated to use. Also, the present invention accomplishes certain actions in an automatically controlled manner, making the performance of the device more reliable, less affected by the orientations, forces, and movement speeds applied by the user. For example, prior art devices typically do not have automatic seating of the anchor against the insertion sheath bevel. Also, prior art devices typically do not have automatic tension and compressive forces applied to the plug. Also, prior art devices typically do not cut the suture automatically upon proper plug deployment. These and other features streamline the use of the device and provide improved reliability over the prior art.
A second embodiment is illustrated with respect to FIGS. 9-17 . One difference between this embodiment and the previous embodiment is that the step of seating the anchor plug against the distal end of the insertion sheath tube is less automatic.
FIG. 9 is a view illustrating the proximal portion of a second embodiment. In FIG. 9 , the proximal portion of the device sheath 10 and the proximal portion of the insertion sheath 12 are shown. The device sheath is slid into the insertion sheath tube 16 but is not yet engaged with the device sheath.
The device sheath may optionally include a button 14 or other trigger mechanism, which is pushed to allow the automated process to start. Such a button 14 may be useful to prevent premature deployment of the process.
The insertion sheath 12 preferably includes a distal hemostatic seal (not shown) and a position indication near the distal tip of the insertion sheath, which may provide an inlet for a bleed path which may flow through the insertion sheath to indicate the position of the insertion sheath relative to the vessel wall opening or other suitable indicator. Such features are described in the '241 application incorporated by reference above.
In the first step, the insertion sheath is inserted over a guidewire after an interventional procedure (such as an angioplasty or stent deployment procedure). This step is not illustrated in these figures.
FIG. 10 is a cross-sectional view of a device sheath similar to that of FIG. 9 prior to the insertion of the device sheath into the insertion sheath. The anchor 18 , plug 20 , suture 22 and cinch disk 24 are preloaded in the device sheath and the proximal end of the suture is fixed to the second frame 36 . (An optional plug component 26 is shown in this figure). The anchor is kept in an insertion orientation by an orientation tube 28 . The device sheath tube 30 is fixed to the outer portion 32 by a fixation disk 34 or other suitable mechanism.
With reference to FIGS. 11 and 12 , the steps of inserting the anchor through the artery wall and seating the anchor against the distal end of the insertion sheath tube are described.
While the artery wall is not illustrated in these figures, it is contemplated that prior to FIG. 11 , the insertion sheath is already properly positioned through the artery wall. When the device sheath 10 is inserted into the insertion sheath 12 , the insertion sheath pushes the orientation tube 28 distally. The insertion sheath tube 16 keeps the anchor 18 in an insertion orientation until it deploys through the distal tip of the insertion sheath as illustrated in FIG. 11 . The orientation tube 28 is then housed within the device sheath hub 38 throughout the remainder of the procedure.
The device sheath is inserted until an insertion sheath collar 40 is locked to the device sheath by a detent (not shown) or other mechanism. This is the state in FIG. 11 .
The insertion sheath is then held in place by an operator holding onto hub 42 and the device sheath 10 is retracted proximally by the operator. This moves the collar 40 relative to the hub 42 until the collar is locked in a second position by a detent 44 or other mechanism, as shown in FIG. 12 . Because the insertion sheath tube 16 is fixed to the hub 42 , and the anchor, plug, cinch disk, suture and device sheath tube 30 are fixed relative to the device sheath, this moves those components relative to the insertion sheath tube 16 to seat the anchor 18 against the distal end of the insertion sheath tube as shown in FIG. 12 .
The operator releases the insertion sheath, and continues to withdraw the device sheath proximally. This first seats the anchor 18 against the inner wall of the artery and next starts to move the internal components of the device sheath distally relative to outer portion 32 .
Some of those internal components can be better seen with reference to FIG. 15 , which is an exploded view. Second frame 36 , spring 46 , first tube 48 , second tube 50 and pusher plate 52 are illustrated. These components may also be seen in cross-section in FIG. 12 , for example.
In the step of FIG. 12 , these internal components are positioned as follows. Tabs 54 of second frame 36 are in holes 56 of first tube 48 . These two components are fixed relative to each other throughout the procedure. Tabs 56 of first tube 48 are positioned through holes 60 of second tube 50 and the proximal ends of tabs 56 are disposed in slot 58 of pusher plate 52 . This is a circumferential slot. The spring is captured between second frame 36 and pusher plate 52 . The distal end of first tube 48 is somewhat proximal the distal end of second tube 50 .
When the operator continues to withdraw the device (moving from FIG. 12 to FIG. 13 ), these internal components move distally relative to outer portion 32 . The distal end of second tube 50 hits a stop at 60 . The first tube is forced to continue moving distally by its connection to the second frame until its distal end also hits the stop at 60 .
The effect of this relative movement between first and second tubes 48 and 50 is to force tabs 48 to ride up on ramps 62 . This forces the proximal end of the tabs 48 radially apart, which moves them out of slot 58 . This releases spring 46 .
First tube 48 also includes tables 68 . These tabs 68 engage detents 64 and 66 as the internal components move proximally within outer portion 32 . These tabs thereby prevent the internal components from being moved distally one the detents have been reached. Detents 66 are engaged by tabs 68 when the proximal edge of the second tube 50 reaches the stop at 60 . Detents 64 are engaged by tabs 68 when the proximal edge of the second tube reaches the stop at 60 .
In FIG. 14 , one can see the effect of releasing spring 46 . Spring 46 drives pusher plate 52 distally, which pushes pusher tube 70 , 72 to drive pushing end/shearing block 74 against cinch disk 24 . This compresses the plug 20 .
Also included in this embodiment are components related to the suture cutting mechanism. A suture cutting mechanism block 76 is connected by a tube 78 (located between the suture and the pusher tube) to a cutting block 80 . The suture is threaded through the cutting block 80 and the shearing block 74 . Block 76 is friction fit to pusher plate 52 . When the proximal end of block 76 reaches stop 82 , the block 76 is driven into a cavity 84 of the pusher plate 52 . Because the pusher plate is connected by pusher tube 70 , 72 to pushing end/shearing block 74 , and block 76 is connected by tube 78 to cutting block 80 , a relative movement is created between the shearing block 74 and the cutting block 80 , which cuts the suture.
At this point the device may be withdrawn, and the anchor, suture, plug and cinch disk are installed to create hemostasis.
Another embodiment of the invention is described with reference to FIGS. 18 a and 18 b . These figures illustrate the distal portion of an automatic suture cutter device 90 . The device 90 includes a shearing block 92 and a cutting element 94 . The shearing block includes a face 96 that abuts a corresponding face 98 of the cutting element. The faces 96 and 98 may be flat or may have another complementary shape. A lumen 100 is disposed in the shearing block 92 . The lumen 100 has a first opening 102 on the face 62 and a second proximal opening 104 . Lumen 102 angles away from opening 102 to create a sharp edge on the proximal side of the opening 102 . The cutting element 94 includes a corresponding lumen 106 with an opening 108 on face 98 and another opening (not shown) on the other side of the cutting block. Lumen 106 angles away from opening 108 to create a sharp edge on the distal side of opening 108 .
The cutting element 94 and the shearing block are initially aligned such that openings 102 and 108 are aligned. A suture 110 is threaded through the openings. The cutting element may then be retracted to cut the suture. The angled edges of the openings 106 and 108 act as a scissors to shear the suture.
The cutting element may include a proximal hole 112 to receive the suture and may be attached to a tube or wire 114 , which can be acted on to actuate the cutting mechanism. The shearing block 92 may include a central opening in the distal face through which the suture may be threaded. Both the shearing block and the cutting element are confined within a tube; this allows movement of the cutting element relative to the shearing block only along the direction of the arrow.
This suture cutting device may readily be incorporated into one or both of the embodiments described above. For example, shearing block 96 may correspond to shearing block 74 of the previous embodiment and cutting element 94 may correspond to cutting block 80 . The suture cutting may be triggered automatically as described above.
Another embodiment 120 of an automatic cutting mechanism is shown with respect to FIGS. 19 a and 19 b . This embodiment includes a tube 122 that has a suture lumen 124 and a cutting wire lumen 126 . A shearing block 128 is fixed to the tube and includes a first lumen 130 for the suture and a second lumen 132 for the cutting wire 134 . The first and second lumens cross in the shearing block. The cutting wire 134 has a distal end disposed in the cutting block and preferably has a loop (seen in cross section) with a cutting edge 136 on the inside of the loop. The loop is sized such that in a first position (shown in FIG. 19 a ), the cutting wire can be positioned so that it does not impinge on lumen 130 . When it is desired to cut the suture, the cutting wire 134 may be retracted proximally to sever the suture.
In this example, the shearing block has an angled hole through which the suture passes. The suture can move freely through the hole in either direction as needed by the delivery motions of the device. The cutting edge of the cutting element is initially positioned so that the suture is not contacted by the cutting edge until desired. The following figure illustrates the suture passing through the shearing block and other components. In this position, the suture is free to move relative to the cutter apparatus. The shearing block location within the device sheath, and the length of the cutting element, is chosen to cut the suture at a location long enough to minimize any risk of unintended suture release from the cinch disk, but short enough to be sufficiently far underneath the skin to minimize any risk of infection. Reduced length of suture also reduces the inflammatory response which occurs during biodegradation of a degradable suture.
The shearing block can be fixed at a particular location in the device sheath to allow enough space for the implantable portions, but little excess space. Alternatively, the shearing block can be advanced, such as together with the cinching movement, to follow the cinch disk and minimize the excess length of suture. The shearing block and cutting element can be advanced or retracted together at various stages in the deployment of the vascular closure device to provide for proper coordinated function of the deployment system. The following figure illustrates the cutter apparatus advanced along the suture; such advancement may be used during plug compression during vascular closure device deployment. The handle can have interacting features so that after the cinching movement occurs, the cutting element is automatically moved to cause the cutting of the suture. Alternatively, a manual actuator for the cutting element can be provided. The cutting movement of the cutting element can be either inward or outward, depending on the geometry of the cutting edge and shearing block. The present example shows the cutting element pulled back to cause the cutting of the suture.
After the suture is cut, the cutter mechanism is removed from the body; this motion may be combined with removal of the device sheath, handle, or other elements of the system. The removal may also be combined with retraction of the cutting element which produces the cutting, in an orderly or automatic manner. The following figure illustrates the cutting apparatus being removed after the suture has been cut. Other elements of the vascular closure device are not shown in these illustrations, but include an anchor, plug, and cinch disk, for example.
The suture cutter must be sufficiently flexible to allow for access and use; as examples, the cutter assembly extension can be made of a polymer, or slotted metal tube, which have sufficient strength but are flexible in bending.
In an automated version, the handle end of the cutting apparatus has steps, attachments, latch components, linkages or other features so that the motion of the cutter assembly extension, the cutting element, and the suture extension are actuated from the delivery system handle. The cutter can be advanced during plug compression, and the cutting element retracted to cut the suture, in a coordinated and automated manner during the device deployment sequence, using manual forces and displacements, latch release spring deployments, motor driven displacements, or other means.
The suture can be a continuous length of suture from the anchor, through the plug and cinch disk, all the way to the handle. A predetermined amount of suture extension can be accommodated, such as that obtained by a force-actuated triggering of the suture cutting. Alternatively, a shorter length of suture can be coupled to a suture extension such as a more rigid filament, wire or tube structure such as by swaging, fastening using a tubing fastener, or other bonding means. The suture extension can reduce the total displacement due to stretching of the suture during deployment of the vascular closure device, enhancing the positional control and improving the reliability of the device deployment. The shearing block can be a static structure with a hole through which the suture passes, or it can have a shape or orientation change, such as from straight to angled, to reduce friction between the suture and the shearing block during cinching, yet obtain an angled hole orientation for effective cutting. Multiple components can be used to achieve a shape change, or the shearing block can rotate to reorient the hole, or the shearing block can deform to better capture and control the suture and facilitate cutting by the cutting element. A feature incorporated with the cutting element can push or actuate an orientation change for the shearing block hole, so that the reorientation happens automatically when the cutting element is pulled back.
The cutting surface portion of the cutting element can slide with respect to the shearing block; in one relative orientation the shearing block holds the suture away from the cutting element to prevent damage to the suture. In another relative orientation the cutting element passes across the hole in the shearing block to cut the suture. For example, by pulling on the proximal end of the cutting element, which is accomplished either automatically or by actuation of the delivery device handle, the cutting element is retracted a short distance to trim the suture at the location of the shearing block. The cutting element, shearing block, and excess suture are removed with the device sheath at the conclusion of the procedure.
The shearing block can have a sharp edge rather than the cutting element, or both can have a sharp edge.
The cutting element is typically withdrawn to trim the suture to length. However, most motions of the cutting element can be reversed in orientation, so that the cutting element can be advanced a short distance to trim the suture to length. The cutting or shearing edge(s) can be oriented for close contact on advancing or on retracting of one or more elements.
The suture can take a straight path through cutter components, or the suture can be displaced to take a curved or angled path through cutter components to facilitate the cutting.
The shearing block can be advanced or withdrawn a short distance against a stationary cutting element to trim the suture to length.
A manual actuation feature such as a grasping ring can be incorporated to provide additional movement or control in case the automatic actuation fails to completely trim the suture.
The suture cutting apparatus can be modified to provide for minimally-invasive or automated cutting of sutures, even if the sutures are not associated with an anchor plug cinch type of vascular closure device.
If any mechanical advantage for compressing and deploying the plug is desired, a pulley system, or gear system, or hydraulic system, or other mechanical system can be incorporated into the handle.
Various overall configurations of the handle can be used. For example, the apparatus can be shaped like a syringe, or have an angled handle like a gun, or have concentric sliding cylinders with flanges, or have a squeeze mechanism where two portions of the handle are squeezed together to actuate the cinching mechanism, or have other configuration as is convenient for the principle actuations of components: attachment of handle to insertion sheath, and proximal movement to snug anchor against the insertion sheath and the artery and retract sheath and deploy and cinch the plug. Other actuations can still happen automatically, such as suture tensioning, controlled travel for cinching and deployment, and releasing of the suture, in keeping with the present invention. Mechanical advantage can be incorporated if desired.
An alternate embodiment utilizes sliding finger hooks, where the finger hooks slide in channels in the handle, where the sliding action automatically actuates a short distance retraction to provide the gap for plug deployment.
For plug materials which are more compressible, an automatic pre-compression action can be provided to pre-compress the plug prior to retraction of the sheaths.
Alternative cinch mechanisms other than the cinch disk include a cinch knot, a friction disk, a crimp, a friction tube, thermal forming, and elastic “spring” actuation, and combinations.
The plug can enhance hemostasis by swelling and physically filling space. Alternatively, the plug can expand from a crumpled, folded or other compressed state to a less-crumpled, folded, or otherwise compressed state to fill space for improved hemostasis. Thrombosis-promoting surfaces, morphology, chemistry, or medication can be incorporated to promote clotting for improved hemostasis. Combinations of hemostasis enhancement means can be utilized.
Indicators can be added to the device to inform the user of certain successful operations, or steps not performed, such as alignment markings, windows, flags, tabs, sounds, colors, snaps and stops felt by the hand, and so forth. These indicators could indicate locking of the hub, seating of the anchor, advancement of the push rod, and so forth.
Various combinations of the cited elements, features, and methods can be utilized, together with other enhancements and features as are known in the art.
It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed. | Methods of installing a vascular closure device, the vascular closure device adapted for sealing an opening in biological tissue and comprising an anchor, a compressible plug, a cinch and a suture, the method comprising the steps of providing an insertion sheath, inserting the insertion sheath into the opening in the biological tissue, providing a device sheath having the vascular closure device preloaded therein with a proximal portion of the suture attached to the device sheath, subsequent to the step of inserting the insertion sheath, inserting the device sheath into the insertion sheath, and retracting the insertion sheath and device sheath simultaneously, wherein during the retraction, the insertion sheath and the device sheath are fixed to one another and devices adapted to the methods. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a starting clutch for a continuously variable transmission that also provides for the selection of the power mode for a vehicle or other mobile equipment. Numerous versions of continuously variable transmissions utilizing variable pulleys and a continuous belt are presently known in the prior art, and the generally accepted arrangement for an automotive vehicle utilizes a clutch for a forward-neutral-reverse selector mechanism between the engine or prime mover and the variable pulleys. However, the rate at which the belt can be shifted diminishes as the pulley speed decreases. Also, the vehicle and pulleys must be brought to a complete halt in order to shift from forward to reverse with reversal of the direction of rotation of the pulleys.
To overcome these problems, the clutch and the selector mechanism have been transferred from a location between the engine and the pulleys to a position between the pulleys and the axle ratio and differential to the vehicle wheels, as shown in the Smirl U.S. Pat. No. 4,241,618. In this arrangement, the pulleys are continuously rotated, even at idle rpm, while the engine is running. Initiation of vehicle movement is accomplished by a speed-responsive friction starting device and the power mode, either forward or reverse, attained through a mechanical selector.
Also known in the prior art is the use of a dual clutch arrangement acting in a vehicle transmission. A dual clutch is utilized with each clutch plate being separately hydraulically actuated to provide for the forward speed ratios, reverse and neutral. However, the clutches are used to conjunction with friction brake bands engaging brake drums which operate in conjunction with one or more planetary gear sets. One major problem in this type of arrangement is the amount of drag losses that occur due to incomplete disengagement of the clutches and/or brake bands.
The present invention provides a non-mechanical power mode selector arrangement for a continuously variable transmission without the drag losses previously found in dual clutch transmissions.
SUMMARY OF THE INVENTION
The present invention relates to the provision of a novel dual starting clutch for a continuously variable transmission wherein the dual clutches independently provide for the forward and reverse power modes of the transmission to the vehicle wheels without halting or reversing the transmission to shift pulleys. The dual clutch arrangement provides one clutch disc operatively connected to the forward gear train for the vehicle wheels while the other clutch disc is operatively connected to the reverse gear train for the wheels. The clutch discs are separated by an intermediate pressure plate, and a hydraulically-actuated pressure plate is positioned on the side of each clutch disc opposite to the intermediate plate. Selective hydraulic actuation of either pressure plate will cause engagement with its respective clutch disc to initiate movement in the forward or reverse direction.
The present invention also comprehends the provision of a novel dual starting clutch for a continuously variable transmission wherein the independent clutch plates drive the forward gear set and the reverse gear set, and a reverse gear deactivation means is incorporated in the gear sets to deactivate the reverse clutch when in the forward drive mode to eliminate any drag loss of the reverse clutch. The deactivation means may take the form of shifting out of mesh either the idler gear or the reverse gear on the driven shaft or to provide a single jaw clutch on the driven shaft for the reverse gear. Also, a reverse clutch plate brake is disclosed to ease the re-engagement of gears in the reverse gear train.
Further objects of the present invention are to provide a construction of maximum simplicity, efficiency, economy and ease of assembly and operation, and such further objects, advantages and capabilities as will later more fully appear and are inherently possessed thereby.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross sectional view of the dual clutch and gear set assembly as utilized for a continuously variable transmission.
FIG. 2 is a schematic end view showing the reverse gear set with the idler gear.
FIG. 3 is a partial cross sectional view of the idler gear on its idler shaft with means for its disengagement from the gear set.
FIG. 4 is a longitudinal cross sectional view of a dual clutch assembly with a second embodiment of reverse gear deactivation means and a reverse clutch plate brake.
FIG. 5 is a longitudinal cross sectional view of a dual clutch assembly with a third embodiment of reverse gear deactivation means and a reverse clutch plate brake.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring more particularly to the disclosure in the drawings wherein are shown illustrative embodiments of the present invention, FIGS. 1 through 3 disclose a continuously variable transmission and clutch assembly 10 for an automotive vehicle wherein a first variable pulley 11 on the driving shaft from the vehicle engine (not shown) drives a second variable pulley 12 through an endless belt (not shown) to constantly rotate a second shaft 13 on which the pulley 12 is mounted. A dual clutch assembly 15 is mounted on the stepped end 14 of shaft 13 to alternately drive a first sleeve shaft 16 and a second sleeve shaft 17, both encompassing the shaft 13. The first sleeve shaft at its rear end terminates in a forward gear 18 meshing with a similar gear 19 connected to a third or driven shaft 21 leading to the axle ratio and differential for rotation of the vehicle wheels. A reverse gear set includes a gear 22 at the rear end of the outer or second sleeve shaft 17, a gear 23 splined on the third shaft 21 and an idler gear 25 on an idler shaft 26 (FIG. 3) and meshing with both gears 22 and 23.
The dual clutch assembly 15 includes an intermediate annular pressure plate 27 mounted in an annular plate or support 28 having an axial outer flange 29 suitably secured onto the outer edge of pressure plate 27 and an inner flange 31 secured, as by welding, to the outer flange 33 of an annular pressure fluid distributing plate 32, which in turn has its inner diameter 34 secured to the shaft 13. A forward clutch plate 35 is secured to a hub 36 splined to first sleeve shaft 16 and positioned on one side of pressure plate 27, while a reverse clutch plate 37 is secured to a hub 38 splined to the second sleeve shaft 17 and positioned on the opposite side of pressure plate 27.
A first axially movable pressure plate 39 is located with respect to intermediate pressure plate 27 to sandwich the forward clutch plate 35 therebetween and is operatively connected to the outer flange 42 of an annular dished piston plate 41 having an inner flange 43 slidably mounted on the shaft 13. The pressure plate 39 has an annular groove 44 receiving the outer flange 33 of plate 32, and a plurality of collars 45, welded to the pressure plate 39, extend through openings 46 in the annular plate 28.
A second or reverse axially movable pressure plate 47 on the opposite side of intermediate pressure plate 27 from forward pressure plate 39 cooperates with pressure plate 27 to sandwich the reverse clutch plate 37 therebetween. This pressure plate 47 is operatively connected to an outer dished plate 48 and retained therein by snap ring 51; the outer plate extending around the annular plate 28 and inner piston 41 and terminating in an inner flange 49 slidably mounted on the stepped end 14 of shaft 13. The outer plate has openings receiving the collars 45 and an annular channel 52 accommodating the inner flange 31. A return spring assembly has a retainer 53 with an outer flange 54 secured between the collars 45 and the heads of bolts 55 threaded into the collars, an intermediate axial portion and an inner conical portion 56 bearing at its inner edge onto the inner edge of a conical spring 57 having an outer edge 58 contacting the channel 52 of the plate 48.
A first pressure chamber 59 is formed between the fluid distributing plate 32 and the piston plate 41 and communicates with an annular passage 61 for pressurized hydraulic fluid in the shaft 13 via one or more lateral passages 62. A center conduit in passage 61 forms a second passage 63 for hydraulic fluid extending through the axis of shaft 13 and passage 61 to terminate in one or more lateral passages 64 leading to a second pressure chamber 65 formed between the plate 32 and the outer plate 48. Appropriate annular resilient seals act to prevent leakage from the pressure chambers, and cooling fluid is admitted to the clutch plates 35 and 37 to cool the friction surfaces during engagement or disengagement.
The forward gear 19 on the driven shaft 21 is integral with hub 66 splined onto shaft 21, and the reverse gear 23 is integral with a hub 67 also splined on the shaft 21. As seen in FIG. 3, the idler gear 25 has an integral hub 68 with an axial extension 69 provided with an annular groove 71 receiving a shifter fork 72 or similar actuating member. An elongated bushing 73 encompasses the shaft 26 and extends between a pair of stop members 74 and 75, mounting the shaft 26 with the gear 25 rotatably mounted on the shaft by the bearing.
In the clutching arrangement as shown in FIG. 1, the dual clutch 15 provides problems of drag losses due to low clearance between the clutch plates and pressure plates upon disengagement thereof and viscous drag losses caused by the presence of the cooling fluid on and between the friction surfaces. Thus, when the forward clutch plate 35 is engaged between the pressure plates 27 and 39, the reverse clutch plate may be providing undesirable spin drag losses due to incomplete disengagement which reduce the efficiency of the total drive assembly. Also, when the reverse clutch plate 37 is engaged, there will be drag losses occasioned because of incomplete disengagement of the forward clutch plate, however, the drag losses in reverse are not of importance because the vehicle will be moving in reverse at relatively low speeds for a short distance. As drag losses are undesirable when the forward clutch is engaged, disengagement of the idler gear 25 is utilized to eliminate the reverse clutch plate drag losses by allowing the reverse clutch plate to rotate at the same speed as the remainder of the clutch assembly.
The vehicle operator controls movement of the vehicle by shifting a selector lever (not shown) which controls the feeding of pressurized hydraulic fluid through either passage 61 or 63. As the pulleys are constantly rotating, the engine also provides constant rotation of a fluid pump providing the hydraulic fluid. When the operator depresses the throttle to increase engine rpm, the pressure of the fluid from the pump is increased and, depending on the position of the control lever, either chamber 59 or 65 has a pressure increase. The movement of the shift fork 72 is suitably tied to the movement of the selector lever controlling fluid pressure to passages 61 and 63. In neutral or reverse mode, the fork moves the idler gear 25 along bearing 73 against the stop 74 so that the gear meshes with reverse gears 22 and 23; the selector lever when in the reverse mode directing fluid to the pressure chamber 65 to cause engagement of the reverse clutch plate 37 to rotate gears 22, 25 and 23 and the driven shaft 21 in one direction of rotation.
When the selector lever is shifted to the forward mode, the shifter fork 72 moves the idler gear 25 axially on the shaft 26 to a position adjacent stop member 75 and disengages idler gear 25 from the reverse gears 22 and 23. Also, fluid pressure is discontinued to chamber 65 and fluid is directed to pressure chamber 59, and the forward clutch plate 35 is engaged to rotate the gears 18 and 19 and the driven shaft 21 in the opposite direction. With the idler gear 25 disengaged, any drag occurring at the reverse clutch plate 37 will not be transmitted to the shaft 21 for more efficient operation. Disengagement of the idler gear 25 also reduces gear noise because the reverse gear train is not in mesh. The reverse gear teeth are preferably chamfered to permit engagement of the idler gear without blocking.
Although the reverse clutch deactivation means is shown in the form of a shifter fork for movement of the idler gear 25, the idler gear could be activated through the same hydraulic pressure control as for actuation of the forward and reverse clutches. The use of the dual clutch arrangement eliminates the necessity of a forward-neutral-reverse gearing mechanism with a synchronizer and shift fork, which should be less expensive with improved system reliability. A parking brake gear 76 is provided between the gears 18 and 22 to stop the vehicle transmission while in the parked position.
FIG. 4 discloses an alternate embodiment of dual clutch assembly 81 wherein like parts have the same reference numeral with a script a. Rather than shifting the idler gear 25 shown in FIG. 3, this embodiment contemplates the shifting of the reverse gear 23a on the driven shaft 21a. In this embodiment, the driven shaft is longitudinally splined at 82 for a substantial length of the shaft with the forward gear 19a having its internally splined hub 66a located on the splined portion 82 abutting a shoulder 83 and retained in position by a snap ring 84 received in an annular groove formed on the shaft. The internally splined hub 67a on reverse gear 23a allows the hub to reciprocate along the shaft and has an extension 86 with an annular groove 87 to receive a shifter fork 72a to move the reverse gear 23a from the engaged position shown in FIG. 4 axially along the shaft 21a to a position where the gear is completely disengaged from the idler gear (not shown).
To prevent drag from the reverse clutch plate 37a inhibiting idler or reverse gear shift into engagement, a braking arrangement 89 is mounted in the housing 88. This braking arrangement includes an annular portion 91 formed in the housing and having a hydraulic fluid inlet passage 92 leading to an annular distributor chamber 94 in an annular plate 93 secured to the housing by bolts 95; the plate being suitably sealed to the housing. A plurality of circumferentially equally spaced bores 97 are formed in portion 91 with each containing a cup-shaped piston 98 having its closed end abutting an annular pressure plate 99 mounted on the housing through the projections or pins 101 extending through complementary openings in the plate. A Belleville washer 102 is mounted on each pin and the pins are headed at 103 so that the washers urge the plate against the housing. An annular friction plate 104 is mounted on the sleeve shaft 17a abutting and keyed to the reverse gear 22a for rotation therewith.
The operation of this embodiment is similar to that of the assembly of FIG. 1, in that when the operator selects the forward mode, there is no fluid pressure in chamber 65a and pressure is directed to the chamber 59a. Simultaneously, the shift fork 72a moves the reverse gear 23a along the shaft 21a toward the forward gear 19a to disengage the gear 23a from the idler gear and allow the reverse clutch plate 37a, which is not under pressure from pressure plate 47a, to rotate at the same speed as the remainder of the clutch assembly and provide zero drag.
When the operator selects the reverse mode, fluid pressure is discontinued to chamber 59a and, with the reverse clutch plate snugged up, pressure is applied through passage 92 and chamber 94 to cause the pistons 98 to move and urge pressure plate 99 against the friction plate 104 to hold the reverse clutch plate from turning and permit the shift fork to move reverse gear 23a back into mesh with the idler gear. Then, there is a build up of pressure in chamber 65a while pressure in chamber 94 is discontinued to allow engagement of the reverse clutch plate. Upon cessation of pressure in chamber 94, the Belleville washers 102 urge the pressure plate 99 away from the plate 104 to retract pistons 98 and allow rotation of reverse gear 22a. Obviously, the braking assembly 89 of this embodiment could be utilized in the dual clutch assembly 15 shown in FIGS. 1 through 3 with equal effectiveness.
A third embodiment of dual clutch assembly 107 is shown in FIG. 5 with like parts having the same reference numeral with a script b. In this version, the reverse gear 23b is mounted on the driven shaft 21b by bearings 108 to rotate relative thereto, and the reverse gear hub 67b has an axial extension 109 with exterior splines 111 formed thereon. A collar 112 is splined onto the shaft 21b adjacent the forward gear 19b and has exterior splines 113 thereon identical to the splines 111. A single jaw clutch member 114 has interior splines engaging the collar splines 113 and may be moved axially by a shift fork (not shown) engaging a groove 115 on the member 114 to engage the collar with the splines 111 on the reverse gear hub extension 109. Also, the reverse gear braking arrangement 89b is shown and is utilized to retain the reverse gear 22b stationary to prevent rotation of the reverse clutch plate and allow engagement of the clutch member 114 with the reverse gear hub splines 111 when the operator shifts to the reverse mode before rotation of the reverse gears. Operation of the clutch assembly is substantially the same as the previous two embodiments.
Where it is desirable that the reverse idler gear or reverse driven gear remain in mesh should it be necessary to rock a vehicle in snow or mud, a simple control means can be provided to deactivate the reverse clutch brake and leave the gears in mesh. Shifting between forward and reverse would then be accomplished off of the respective clutches. This is possible because the disengagement of a gear in the reverse gear train is only necessary to reduce clutch drag losses and gear noise levels in forward gear. After the rocking action is complete, a reverse gear can be easily disengaged if the transmission is in forward gear. | A dual wet output clutch for a continuously variable transmission which acts as a starting clutch upon a signal from a throttle induced hydraulic fluid supply to connect the transmission with the vehicle wheels and replaces a mechanical forward-neutral-reverse selection by hydraulic actuation of one of the dual clutches to provide forward or reverse power. Also, a secondary mechanism is utilized with the reverse gear to deactivate the reverse clutch in the forward mode and reduce drag loss. | 8 |
This is a division of application Ser. No. 08/309,706, filed Sep. 21, 1994, now abandoned.
FIELD OF THE INVENTION
This invention relates to wool materials of hollow mineral fibers and, more specifically, to insulation products of hollow multi-component glass fibers. The invention also pertains to the manufacturing of hollow fibers from thermoplastic materials, and more particularly to a spinner apparatus for centrifuging multi-component fibers from two streams of molten thermoplastic materials such as glass or other mineral fibers or polymer fibers.
BACKGROUND OF THE INVENTION
Small diameter solid fibers of glass and other thermoplastic materials have been used in a variety of applications including acoustical or thermal insulation materials. When these small diameter glass fibers are properly assembled into a lattice or web, commonly called a wool pack, glass fibers which individually lack strength or stiffness can be formed into a product which is quite strong. The glass fiber insulation which is produced is lightweight, highly compressible and resilient. For purposes of this patent specification, use of the term "glass" is intended to include any of the glassy mineral materials, such as rock, slag and basalt, as well as traditional glasses.
The common prior art methods for producing glass fiber insulation products involve producing solid fibers of glass from a rotary process. A single molten glass composition is forced through the orifices in the outer wall of a centrifuge commonly known as a spinner, producing primarily solid and straight glass fibers. The fibers are drawn downward by a blower. A binder required to bond the fibers into a wool product is sprayed onto the fibers as they are drawn downward. The fibers are then collected and formed into a wool pack.
When forming insulation products of glass fibers, the ideal insulation would have uniform spacing between the fibers and the surface area of the fibers would be maximized. Insulation is basically a lattice for trapping air between the fibers and thus preventing movement of air. The lattice also retards heat transfer by scattering radiation. A more uniform spacing of fibers and an increase in fiber surface area would maximize scattering and, therefore, would have greater insulating capability.
In the production of wool insulating materials of glass fibers, it becomes necessary to use fibers that are relatively short. Long fibers tend to become entangled with each other forming ropes or strings. These ropes create a deviation from the ideal uniform lattice and reduce the insulating abilities of the glass wool. However, short fibers that are straight form only a haphazard lattice, and some of the fibers lie bunched together. It is clear that existing glass wool insulating materials have significant non-uniformities in the distribution of fibers within the product. Thus, the ideal uniform lattice structure cannot be achieved.
Additionally, when using straight fibers it is necessary to add an organic binder material to the fibers. The binder is required to hold the product together by bonding at the fiber to fiber intersections. Not only is the binder itself expensive, but great pains must be taken to process effluent from the production process due to the negative environmental impact of most organic compounds. Further, the binder must be cured with an oven using additional energy and creating additional environmental cleanup costs.
As the number of fibers used in the insulation product is increased, the surface area of the fibers is also increased as well as the insulating capability of the resultant wool product. However, increasing the number of fibers also increases the cost of the product due to the cost of the additional material used. Even small changes in the amount of fiber material used can impact production costs.
In the shipping and packaging of insulation products, high compressibility is preferred. It is desirable to compress the wool for shipping and then have it recover rapidly and reliably to the desired size. Current insulation products are limited in the amount of compression possible while still attaining adequate recovery. When the product is compressed, the binder holds firm while the fibers themselves flex. As the stress upon the fibers increases due to excessive compression, the fibers break.
Attempts have been made in the prior art to produce non-straight solid glass fibers. In a mechanical kink process, glass fibers are pulled from a textile bushing. While still at high temperatures, the fibers are pulled by mechanical means through a series of opposed gears or a crimping device to attenuate and crimp them. The net result is a bundle of kinked glass fibers.
The major disadvantage to mechanical kinking is that the fibers are not conducive to satisfactory glass wool production. Every fiber produced in this manner has a uniform shape, defeating the purpose of the kink, because the glass wool produced does not have a uniform distribution. Further, because the process is non-rotary, it has an unsatisfactory low throughput and the fibers produced are too coarse for wool insulating materials.
Stalego, U.S. Pat. No. 2,998,620, discloses curly (helical) glass fibers of bicomponent glass compositions. Stalego discloses producing staple curly fibers by passing two glass compositions having differing coefficients of thermal expansion through the orifices of a spinner. The glasses are extruded as a solid dual glass stream in aligned integral relationship such that the fibers curl naturally upon cooling due to the differences in their coefficients of thermal expansion. However, Stalego discloses employing the curled fibers in the processing of yarns such as being woven into fabric or included as a reinforcement in fired pottery and clays. Stalego does not disclose the use of curly fibers in insulation products. In addition, Stalego discloses in one embodiment a spinner having vertically aligned compartments separated by vertical baffles around the periphery of the spinner, with alternate compartments containing the different glasses. The patentee teaches that an orifice wider than the baffle is to be drilled where the baffle intersects the spinner peripheral wall. As the orifice is wider than the baffle, the orifice is in communication with both of the vertical compartments on either side of the baffle, and both the A glass and B glass will exit the spinner from the orifice, forming a solid dual glass stream.
Tiede in U.S. Pat. No. 3,073,005 discloses a non-rotary process for making bicomponent curly solid glass fibers. The fibers are made by feeding differing glass compositions to an orifice in side by side contact such that the two glasses are attenuated into a single fiber. Tiede discloses using the glasses in fabric production as well as cushion and floatation materials. Tiede does not disclose insulation products made with curly glass fibers.
Slayter et al. in U.S. Pat. No. 2,927,621 also discloses the production of curly fibers. In Slayter, solid glass fibers of a single glass composition are passed through opposed contoured skirts after the fibers have been softened by hot gases. The fibers then take on the shape of the contour of the skirts. However, the thick, long fibers are unsuitable for insulating materials. Rather, the produced fibers are employed in filtering media, and additionally have a binder applied.
Accordingly, a need exists for an improved wool insulating material with a uniform volume filling nature and a maximized fiber surface area such that the wool insulating material has improved recovery and reduced thermal conductivity, remains cost effective, and can be employed without the use of a binder material. It would also be desirable to produce an improved wool insulating material which has the aforementioned attributes but which can be produced with reduced amounts of fiber material.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention these needs are met by providing insulation products that are produced using hollow fibers made from suitable thermoplastic insulation materials such as glass, and preferably using fibers which are irregular in shape and generally hollow. An insulation product employing hollow fibers can perform generally as effectively or better than the same product made from solid fibers, yet require substantially less insulation material to produce. Up to twice as many or more hollow fibers can be produced from the same amount of fiber insulation material used to form solid fibers. With more fibers being used, the overall surface area of fibers in the insulation product can be increased even though less insulation material is being used. Increasing the fiber surface area increases performance by lowering the thermal conductivity (i.e.,"k") of the insulation product.
A method is provided for making an insulation product of hollow fibers whereby molten insulation material is centrifuged through a plurality of orifices and gas is directed into the molten insulation material through a plurality of gas conduits, wherein each gas conduit directs gas into one of the portions of the molten insulation material being centrifuged through one of the orifices to form a hollow fiber having a hollow bore formed therethrough. The hollow fibers are combined to form the insulation product.
By employing hollow fibers that are irregular, rather than straight, kinked or even curly, a more uniform lattice structure can also be achieved. This is referred to as uniform volume filling. The increased uniformity will allow higher recovery ratios after being compressed. More importantly, uniform volume filling results in even greater reductions in thermal conductivity. Also, the greater entanglement of irregularly-shaped fibers could allow sufficient wool pack integrity without the use of an organic binder. By sufficient integrity it is meant that the fibers of the wool batt will remain entangled and not separate when an 8 ft. (2.4 m) wool batt is suspended under its own weight either along its length or along its width. These are referred to as the machine direction and the cross direction, respectively. However, if so desired, a binder material may be added to provide additional strength to the wool insulating material. Also, the irregular shape of the fibers of the invention makes the product less prone to cause irritation, and may make the product less dusty. Ideally, each fiber is different in shape to obtain a more uniform volume filling nature.
In accordance with one aspect of the invention there is provided a plurality of irregularly-shaped hollow glass fibers and an insulation product comprising such fibers. The hollow nature of the fibers may be quantified in terms of their void fraction, which is defined as (D i /D o ) 2 , where D i is the inside diameter and D o is the outside diameter of the fiber. While benefits can be realized with almost any degree of void fraction, in general, the greater the void fraction the greater the benefits obtained. Each of the preferred hollow glass fibers has a void fraction of greater than about 30%, more preferably greater than about 40%, and even more preferably in the range of from about 50% to about 80%.
In accordance with a second aspect of the present invention, each of the irregularly-shaped hollow glass fibers comprises at least two distinct glass compositions with different coefficients of thermal expansion. The difference in the coefficient of thermal expansion between two glass compositions is preferably greater than about 2.0 ppm/°C. (parts per million), more preferably greater than about 4.0 ppm/°C., and most preferably greater than about 5.0 ppm/°C. Further, the fibers are preferably binderless. The term "binderless" is intended to mean that binder materials comprise less than or equal to 1% by weight of the product. Further, the term "binder" is not meant to include materials added for dust suppression or lubrication.
In accordance with a third aspect of the invention there is provided a wool insulating product comprising irregularly-shaped hollow glass fibers with a substantially uniform volume filling nature, wherein each of the fibers consists of at least a first glass composition and a second glass composition. The first glass composition generally varies within the range of from about 15 to about 85% of the total glass content of each hollow fiber. The second glass composition comprises the balance of the glass content of each fiber. A small fraction of the fibers may be single composition. For purposes of this patent specification, in using the terms "glass fibers" and "glass compositions", "glass" is intended to include any of the glassy forms of materials such as rock, slag, and basalt, as well as traditional glasses. Thermoplastic materials and thermoplastic fibers include, in addition to glass and other mineral fibers, fibers from polymer materials such as polyester fibers and polypropylene fibers.
In accordance with a forth aspect of the present invention, an apparatus is provided for making multiple component hollow fibers. The apparatus includes a housing, such as that of a spinner, having a peripheral wall with a plurality of fiber forming nozzles or tips. Each nozzle can be a separate part but is preferably formed as an integral part of the housing wall in order to reduce costs and increase the density of orifices that are possible on the wall. Each nozzle has at least a first and a second passage through which a first and a second molten thermoplastic material respectively flow to a fiber forming orifice located in the peripheral wall. The first and second passages of the nozzle are respectively in fluid communication with a source of the first and second molten thermoplastic materials. Preferably, in the case of a spinner, the housing is divided into a series of compartments by baffles, with each compartment receiving one of the molten thermoplastic materials. Each of the nozzle passages extends from one of the compartments. The passages in adjacent ones of the compartments communicate with one another and with the orifices to merge the first and second molten thermoplastic materials together. A gas conduit is operatively adapted to provide each nozzle with a suitable gas, such as air, nitrogen, argon, combustion gases, etc., for being ingested into the molten thermoplastic materials flowing out of the orifice to thereby form a multiple component hollow fiber. In the case of a spinner, generally vertically-aligned compartments have been found most preferable with the baffles positioned circumferentially around the interior of the peripheral wall.
The first and second molten thermoplastic materials are supplied to the housing by any suitable equipment. For example, with a spinner, if the materials are glasses, the equipment will include melting furnaces and forehearths to supply the molten glasses. A divider is provided in the housing for directing the first molten thermoplastic material into alternate ones of the compartments and for directing the second molten thermoplastic material into the remaining ones of the compartments so that adjacent compartments contain different thermoplastic materials.
In one form, adjacent ones of the passages in adjacent compartments may converge in either a V- or Y-shape, or into a slot shaped orifice. In one embodiment, each gas conduit comprises a tube disposed through one of the baffles and out the orifice, preferably extending beyond the peripheral wall. The tube is sized so as to provide a gap between it and the perimeter of the orifice of sufficient size to permit the multiple molten thermoplastic materials to be extruded therethrough. Preferably, those passages in adjacent compartments converge at an angle of from about 14° to about 45° from normal to the spinner peripheral wall (i.e., a relative angle between them of about 28° to 90°). The passages are sized to provide a build up of molten thermoplastic materials in the compartments and preferably so that substantially equal proportions of the two molten thermoplastic materials are provided to the orifices. The ratio of the thermoplastic materials present in the fibers may be adjusted by changing the flow rate of each molten material. However, it should be appreciated that the size of the passages may need to be varied to control the flow rates.
The divider in the preferred spinner includes a generally horizontal flange positioned intermediate the spinner peripheral wall. The divider preferably further includes a generally vertical interior wall, with the interior wall including a series of orifices therein spaced to provide access for the first molten thermoplastic material into alternate ones of the compartments and to provide access for the second molten thermoplastic material into the remaining ones of the compartments.
In a preferred embodiment of the invention, the thermoplastic materials are glasses, and the spinner is adapted to receive two separate molten glass streams for fiberization into dual glass hollow fibers.
Accordingly, it is a feature of the present invention to provide a series of orifices positioned in a spinner peripheral wall which are fed with different molten thermoplastic materials by passages from adjacent compartments, with the molten material being ingested with a suitable gas to form multiple component hollow fibers. This, and other features and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view in elevation of apparatus for making dual component hollow fibers in accordance with the present invention;
FIG. 2 is a schematic view in perspective of an embodiment of the insulation product of the present invention;
FIG. 3 is a cross-sectional view in elevation of the fiberizer/spinner used in the practice of the invention;
FIG. 4 is a plan view, partly in section, of a portion of the spinner taken along line 4--4 of FIG. 3 with the annular blower excluded;
FIG. 5 is a schematic partial view, in elevation, of the spinner taken along line 5--5 of FIG. 4;
FIG. 5A is an enlarged view of the encircled area 5A of FIG. 5;
FIG. 6 is a partial cross-sectional view of a V-hole embodiment of the orifices in the spinner;
FIG. 7 is a partial cross-sectional view of a Y-hole embodiment of the orifices in the spinner;
FIG. 8 is a partial cross-sectional view of a slotted embodiment of the orifices in the spinner;
FIG. 8A is a view of the spinner taken along line 8A--8A of FIG. 8;
FIG. 9 is a perspective view taken from the interior of the spinner showing the divider and compartments for the A and B components;
FIG. 10 is a schematic view in perspective of a helical solid glass fiber of the prior art;
FIG. 11 is a schematic view in perspective of a irregularly-shaped hollow glass fiber of the present invention in a natural, unconstrained state;
FIG. 12 is a schematic view in perspective of the fiber of FIG. 11 in a stretched state; and
FIG. 13 is an artistically enhanced schematic view in perspective of the irregularly-shaped hollow glass fiber of FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be described in terms of insulation products made from irregularly-shaped dual glass hollow fibers and apparatus for making same. It is to be understood that the invention encompasses insulation products made from and apparatus for making not only dual component glass hollow fibers but also single component glass hollow fibers and single or multiple component hollow fibers made from other thermoplastic materials such as polyester or polypropylene. In addition, the present invention also applies to single or multiple component hollow fibers having other than irregular shapes, for example curly (helical) fibers.
The insulation products made of irregularly-shaped hollow glass fibers of the present invention may be produced from a rotary fiber forming and pack heat setting process as shown in FIG. 1. Two distinct molten glass compositions (A glass and B glass) are supplied from any suitable source of glass such as furnaces 10 and forehearths 12 to rotary fiberizers 14. As discussed more explicitly below, the fiberizers form hollow, dual component fibers. Preferably, the glasses have different mechanical attributes so that upon cooling, they will assume an irregular (as opposed to straight) configuration. Such different mechanical attributes may be, for example, differing coefficients of thermal expansion, differing melting points, differing viscosities, or differing mechanical strengths. Veils 18 of hollow dual glass fibers, such as irregularly-shaped hollow glass fibers produced by the fiberizers 14, are collected on conveyor 16 as wool pack 20 by means of a vacuum positioned beneath the conveyor (not shown). As the fibers are blown downwardly by air or gases to conveyor 16 by means of blowers 22 adjacent the fiberizers 14, they attenuate, cool, and attain their irregular shape.
The wool pack 20 may then optionally be passed through oven 24 at heat setting temperatures of from about 700° to 1100° F. (371° to 593° C.). The heat setting temperature may be achieved either by retarding the fiber cooling process after fiber forming to retain some of the heat from the fiber forming process, or by reheating the fibers in heat setting oven 24. While passing through the oven, wool pack 20 is shaped by top conveyor 26 and bottom conveyor 28, and by edge guides (not shown). While in oven 24, the glass fibers may be subjected to flows of hot gases to facilitate uniform heating. When the fibers are constrained by conveyors 26 and 28, the fibers are stressed in the manner of a compressed spring. When subjected to heat setting temperatures, the fibers relax, reducing stress, so that when the constraints are removed, the wool pack does not expand but holds its desired shape. After a period of up to 10 minutes, the wool pack then exits oven 24 as insulation product 30. The fibers bend as they cool and become more entangled, enhancing the insulation product's structural integrity.
It is to be understood that heat setting is an optional aspect of the present invention. Alternatively, the wool pack may be encapsulated with an exterior plastic layer as taught by Schelhorn et al, U.S. Pat. No. 5,277,955, the disclosure of which is hereby incorporated by reference in its entirety. FIG. 2 illustrates a section 56 of a wool pack encapsulated within an exterior polymeric layer 58. Further, the wool pack may be subjected to other fabrication techniques including stitching, needling, or hydro-entanglement.
As shown in FIG. 3, spinner 60 includes a housing having a spinner peripheral wall 64 and a spinner bottom wall 62. The spinner 60 is rotated on spindle 66, as is known in the art. The rotation of the spinner 60 centrifuges molten glass through orifices in the spinner peripheral wall 64 to form primary hollow fibers 68, in a manner described in greater detail later on. The primary hollow fibers 68 are maintained in a soft, attenuable condition by the heat of annular burner 70. An internal burner 71 (shown schematically) is preferably used to heat the interior of spinner 60 to help maintain the glasses in a suitably molten state and, as will be discussed later in detail, to provide combustion gases used in making the primary fibers 68 hollow. Annular blower 72 is positioned to pull primary fibers 68 and further attenuate them into secondary dual-glass hollow fibers 76, suitable for use in wool insulating materials. The irregularly-shaped dual-glass hollow fibers 76 are then collected on a conveyor (as shown in FIG. 1) for formation into a wool pack.
The interior of spinner 60 is supplied with two separate streams of molten glass, a first stream containing glass A and a second stream containing glass B. The glass in the first stream drops from a first delivery tube 78 directly onto spinner bottom wall 62 and flows outwardly due to the centrifugal force toward spinner peripheral wall 64 to form a head of glass A as shown. Glass B, delivered via a second delivery tube 80, is positioned closer to spinner peripheral wall 64 than the first stream, and the B glass in the second stream is intercepted by horizontal annular flange 82 before it can reach the spinner bottom wall 62. Thus, a build-up or head of glass B is formed above horizontal flange 82 as shown.
As best shown in FIGS. 4 and 9, the spinner 60 is adapted with a vertical interior wall 84 which is generally circumferential and positioned radially inwardly from the spinner peripheral wall 64. A series of vertical baffles 86, positioned between spinner peripheral wall 64 and vertical interior wall 84, divide that space into a series of generally vertically-aligned compartments 88 which run substantially the entire height of spinner peripheral wall 64. Alternate compartments contain glass A and glass B which flow, respectively, into the compartments 88 through slots 89 in interior wall 84. It can be seen that horizontal flange 82, vertical interior wall 84, and baffles 86 together comprise a divider for directing glasses A and B into alternating adjacent compartments 88 so that every other compartment contains glass A while the remaining compartments contain glass B.
Spinner peripheral wall 64 has orifices 90 located thereon. Orifices 90 are positioned adjacent to, and in general alignment with, the radial outward edges of the vertical baffles 86. As can been seen in FIGS. 5 and 9, a series of ports or passages 92 and 93 are located in each of the compartments 88 through which molten thermoplastic material will flow. Preferably, these passages 92 and 93 are located adjacent either side of baffles 86, with each pair of passages being operatively adapted to communicate with one another and one of the orifices 90 in the peripheral wall 64. In this way, each set of passages 92 and 93 and orifice 90 forms a nozzle enabling a flow of both glass A and glass B to emerge from the orifice 90 to permit a single dual-glass primary fiber 68 to be formed. Preferably, each slot 89 is sized so that a sufficient amount of molten glass accumulates in its corresponding compartment 88 to ensure that the molten glass flows out of each orifice uniformly.
A gas conduit 94, a tube in the illustrated embodiment, is used to provide each nozzle with a suitable gas, such as air, nitrogen, argon, combustion gases, etc., for being ingested into the molten A and B glass components flowing out of the orifice 90 to form a hollow bore in the emerging dual-glass primary fiber 68. The gas conduits 94 extend through bore holes provided in the interior wall 84, the baffles 86 and the spinner peripheral wall 64, see FIGS. 4 and 9. Each tube 94 may be secured in place by any suitable method, such as by welding or brazing. Each tube 94 has a leading end 95 extending beyond the spinner peripheral wall 64 and a trailing end 96 extending radially inward of interior wall 84 into the interior of spinner 60.
In the illustrated embodiment, one or more burners 71 burn natural gas, mostly methane, producing a combustion gas that fills the interior of spinner 60. A bottom center casing plate 97 (see FIG. 3) is used in combination with the burners 71 to sufficiently seal the spinner 60 so that the combustion gases buildup a back pressure P 1 in the interior of spinner 60 as they exit from the burners 71. In this way, the interior of spinner 60 functions as a manifold supplying pressurized combustion gases to the trailing end 96 of each tube 94. The combustion gases then exit the leading end 95 of each tube 94 at a pressure P 2 sufficient to form a bore in the primary fibers 68. Each tube 94 is operatively adapted and positioned so that no molten glass enters its trailing end 96 during the fiber forming process.
The gas flow rate through each tube 94 can be calculated according to the following equation:
Q=λD.sup.4 /128μ (P.sub.1 -P.sub.2 /L+pw.sup.2 R),
where
Q=the gas flow rate,
μ=the gas viscosity,
L=the tube 94 length,
D=the tube 94 inside diameter,
P 1 =the gas pressure inside spinner 60 (governed by fiberizer 14),
P 2 =the gas pressure at the tube's exit 95 (generally atmospheric pressure or less),
p=the gas density,
w=the spinner RPM (revolutions per minute), and
R=the mean radial location of tube 94.
The leading end 95 of each tube 94 is coaxially positioned within its orifice 90 and sized so as to provide a gap of sufficient dimension between the tube 94 and the perimeter of the orifice 90 to permit a sufficient amount of the molten A and B glasses to be extruded therethrough to form a hollow primary glass fiber 68. The primary fibers 68 preferably have an outside diameter in the range of about four (4) to about six (6) microns.
Each tube 94 preferably has an overall length in the range of about 0.75" (1.9 cm) to about 1.50" (3.81 cm), an outside diameter in the range of about 0.016" (0.406 mm) to about 0.100" (2.54 mm), and a wall thickness in the range of about 0.004" (0.102 mm) to about 0.020" (0.508 mm). The leading end 95 of each tube 94 is preferably positioned somewhere in the region ranging from within the outer surface of the wall 64 a distance equal to about twice the outside diameter of the tube 94 to beyond the outer surface of the wall 64 a distance equal to about twice the outside diameter of the tube 94. While the leading ends 95 may not need to extend beyond wall 64, the leading ends 95 are more preferably either about flush with the outer surface of wall 64 or extending therefrom up to and including a distance equal to about the outside diameter of the tube 94.
As shown, the passages 92 and 93 are generally vertically aligned and are preferably of like size (i.e., the same length and diameter) and supplied with glass at the same flow rate to provide equal flow lengths for the A and B glass components. This ensures that when the A and B components exit orifices 90 in side-by-side relation, there will be approximately equal amounts of A and B glasses for each fiber. It will be recognized that if unequal proportions of the A and B glasses in the dual component fibers is desired, the rate at which each glass is supplied to the spinner 60 or the dimensions that passages 92 and 93 are sized may be varied. Having unequal proportions of glass in the dual component fibers may be desirable in certain instances. Additionally, the passages in each compartment may vary in size to provide a variation in the ratios of A and B glasses in the dual component fibers formed.
The number of passages 92 and 93 formed depends on the height of the spinner peripheral wall. The number and size of the passages 92 and 93 and the slots 89 as well as the flow rate of the molten glasses into compartments 88 are chosen to build up a "head" of molten material covering the passages in each compartment. While each set of passages 92 and 93 and orifice 90 can be in the form of a separate nozzle mountable in and removable from peripheral wall 64, each nozzle is preferably an integrally formed part of spinner wall 64 because a greater number of orifices 90 can be provided, increasing fiber production.
Orifices 90, and passages 92 and 93 may be drilled into the spinner wall by any of several known drilling techniques such as laser drilling, electrical discharge milling (EDM), or electron beam drilling. As best shown in FIGS. 6 and 7, passages 92 and 93 are preferably drilled at an angle of from about 14° to about 45° (i.e., a relative angle between them of about 28° to 90°) from normal to the spinner peripheral wall 64. Depending upon the angle chosen, passages 92 and 93 may form a V-shape as shown in FIGS. 5, 5A and 6, or along with orifice 90 a Y-shape as shown in FIG. 7. The optimum drilling angle from normal for the V-shape passages 92 and 93 is about 25° and for the Y-shape is between about 22.5° and about 45°. Other configurations can be used to converge the dual streams of glass together. For example, each passage 92 and 93 could communicate with a slotted orifice 90 that extends substantially completely through the wall 64, such as that shown in FIGS. 8 and 8A, or into any other operatively shaped slotted orifice 90. For the slotted orifice 90 of FIGS. 8 and 8A, orifice 90 preferably has a length L in the range of about 0.1 to about 0.13 inches (0.254 to 0.330 cm) and a width W in the range of about 0.006 to about 0.015 inches (0.152 to 0.381 mm).
The preferred diameter of the orifice 90 used with either the V- or Y-shape is in the range of about 0.0287 to about 0.113 inches (about 0.0729 to about 0.287 cm) depending upon the outside diameter of the tube 94 being used. Typically, passages 92 and 93 will have diameters in the range of from about 0.023 to about 0.121 inches (about 0.058 to about 0.307 cm), and preferably from about 0.0287 to about 0.1093 inches (about 0.0729 to about 0.2776 cm). For example, when a tube 94 having an outside diameter of about 0.016" is used, the orifice 90 may have a diameter in the range of about 0.0287 to about 0.047 inches and the passages 92 and 93 may have diameters in the range of about 0.023 to about 0.059 inches. When the tube 94 has an outside diameter of about 0.040", the diameter of the orifice 90 may be in the range of about 0.0476 to about 0.063 inches and the passage diameters in the range of about 0.0437 to about 0.075 inches. And, when the tube 94 has an outside diameter of about 0.100", the orifice diameter may be in the range of about 0.1035 to about 0.113 inches and the passage diameters in the range of about 0.1016 to about 0.121 inches.
Exemplary nozzles, with the Y-shaped form of passages 92 and 93 (see FIG. 7), and tubes were successfully tested. The passages 92 and 93 in each test nozzle had the same length of about 0.124" (0.315 cm) and diameter of about 0.030" (0.076 cm), with the passages being pitched at an angle of about 35.4° from normal to the spinner peripheral wall 64. Each orifice 90 had a diameter of either about 0.055" (0.140 cm) or about 0.058" (0.147 cm). Each tube 94 had an overall length of about 2.0" (5.08 cm), an outside diameter of about 0.040" (0.102 cm), and a wall thickness of about 0.010" (0.254 mm). The leading end 95 of each tube 94 extended beyond wall 64 a distance D of about 0.020" (0.508 mm).
The irregularly-shaped hollow fibers of the present invention are dual-glass fibers, i.e., each fiber is composed of two different glass compositions, glass A and glass B. If one were to make a cross-section of an ideal irregularly-shaped hollow glass fiber of the present invention, one half of the fiber would be glass A, with the other half glass B. In reality, a wide range of proportions of the amounts of glass A and glass B may exist in the various irregularly-shaped hollow glass fibers in the wool insulating material (or perhaps even over the length of an individual fiber). The percentage of glass A may vary within the range of from about 15 to about 85% of the total glass in each of the irregularly-shaped hollow glass fibers with the balance of total glass being glass B. In general, insulation products of the present fibers will consist of hollow fibers of all different combinations of the percentages of glass A and glass B, including a small fraction of hollow fibers that are single component. The proportion of glass A to glass B present in the hollow fibers can be determined by cross-sectioning a representative sample of fibers and examining each cross section by scanning electron microscopy (SEM) or any other suitable method.
The present dual-glass hollow fibers have a curvilinear nature due to the difference in thermal expansion coefficients of the two glasses. Thus, as the dual-glass hollow fiber cools, one glass composition contracts at a faster rate than the other glass composition. The result is stress upon the fiber. To relieve this stress the fiber must bend. If no rotation of the fiber is introduced, a flat coil having a generally constant radius of curvature will be produced, the coil being in one plane such as in a typical clock spring. Rotation of dual-glass fibers can be measured by reference to the interface along the hollow fiber between the two glass components. In order to get out of a single plane relation, some rotation must be introduced. Constant rotation of the fibers will produce a helix having a constant pitch. The hollow fiber making up the helix has a constant direction of rotation--either clockwise or counter-clockwise. The helix also has a generally constant radius of curvature. FIG. 10 shows a 3-dimensional schematic projection of a helically shaped single glass solid fiber 112 of the prior art. As an aid to visualization, the shadow 114 of the fiber 112 cast by an overhead light onto a flat surface has been added.
An irregularly-shaped hollow fiber of the invention differs from a helically shaped single glass solid fiber in that the rotation of the inventive fiber is not constant, but rather varies irregularly both in direction (clockwise and counter-clockwise) and in magnitude. The magnitude of rotation of a fiber is how sharply the fiber twists and turns per unit length of the fiber. The curvature is generally constant as dictated by the difference in thermal expansion coefficients and the A/B proportion. FIG. 11 shows a 3-dimensional projection of an irregular hollow fiber 122 of the invention. As an aid to visualization, the shadow 124 of the fiber 122 cast by an overhead light onto a flat surface has been added. When fiber 122 is put under tension, the tensioned fiber 122A and corresponding shadow 124A illustrate that the irregularity of the fiber is maintained, as shown in FIG. 12. Irregular hollow fiber 122B, shown in FIG. 13, is fiber 122 of FIG. 11 artistically enhanced by exaggerating the thickness and by adding segmentation lines to show better perspective.
Due to a continuously changing attenuation environment, each irregularly-shaped hollow fiber is twisted in a unique way. No two fibers are exactly alike. The hollow fiber's final shape is one with a baseline curvature due to the dual-glass nature, which is modified by the twisting, irregular rotation of the plane of curvature caused by the continuously changing or stochastic attenuation environment. The fiber has a baseline curvature that is twisted through three dimensions. It is generally not helical. The fiber's irregular nature allows the fibers to stand apart from one another and achieve a uniform volume filling nature. Additionally, wool insulation material made of irregularly-shaped hollow glass fibers is less irritating (not as itchy) to the skin as wool insulating materials made with primarily straight fibers, and may not be as dusty.
The nature of the irregularly shaped hollow fibers may be analyzed using a direction vector analysis. The set of coordinates describing the path of an irregularly shaped hollow fiber in 3-D space may be generated using photographs taken from two different angles, 90° apart. The coordinates may be adjusted to give equal three dimensional distances between the data points along the length of the fiber, in order to produce adjusted coordinate data points (ACD). Three vectors may be computed for each of the ACD's as follows:
V i =Fiber direction vector (a unit vector directed from one ACD to the next)
F i =First derivative vector of V i with respect to the distance interval between ACD's
S i =Second derivative vector of V i with respect to the distance between ACD's.
The magnitude of rotation R i for any given ACD is as follows: ##EQU1##
U i is a unit vector perpendicular to the plane containing V i and V i-1 .
The magnitude of rotation R can be plotted in graph form as a function of distance along the length of the hollow fiber. The data used in such a graph may be smoothed with a 5 point weighted moving average to reduce noise accentuated by the derivatizing process. Based on such data compiled for solid dual glass fibers, the rotation of an unconstrained irregularly shaped hollow fiber of the invention should vary irregularly in magnitude and sign along the length of the fiber. It is believed that the crossover points (i.e., where the rotation changes sign) will occur at a frequency of about one per centimeter for a five (5) micron outside diameter hollow fiber. In contrast, a helically shaped single glass solid fiber has zero crossover points along the same length. It is expected that the number of crossover points per centimeter of the irregular hollow fibers of the invention for a 5 micron outside diameter fiber will be at least 0.3 and most likely within the range of from about 0.5 to about 5.0.
Another way to quantify the irregularity of the fibers is to calculate the average rotation magnitude and the standard deviation of the rotation magnitudes along the length of the fibers. The average value for the magnitude of rotation for a helically shaped single glass solid fiber is well above zero (or well below zero for opposite rotation). The standard deviation of the magnitude of rotation for the helix is smaller than the average value of the magnitude of rotation. The ratio of standard deviation to the average magnitude of rotation is 0.25 for a typical helically shaped single glass solid fiber.
In contrast, for an irregularly shaped hollow fiber of the invention, the average magnitude of rotation is expected to be very small, generally close to zero. The standard deviation of the magnitude of rotation is also expected to be at least comparable to the average magnitude of rotation, if not significantly larger than the average magnitude of rotation. Preferably, the ratio of the standard deviation to the average magnitude of rotation will be greater than about 0.75. More preferably, it will be greater than 1.0 and most preferably it will be greater than 5.0. It is expected that the ratio for the inventive hollow fibers will be 8.3 or even higher.
The irregular shape of the fibers gives the wool insulating material a more uniform volume filling nature. The primarily straight fibers of the prior art are arranged haphazardly in the wool pack. They are not uniform in volume filling. By uniform volume filling it is meant the fibers have a desire to spread out and fill the entire volume available to them in a uniform manner. A more uniform volume filling nature allows a more efficient use of glass fibers to resist the flow of heat.
In addition to the benefits from an irregular shape, by employing fibers that are hollow, more fibers can be used to form the wool batt without increasing the total amount of insulating material used. With more fibers being used, the overall surface area of the fibers in the wool increases. Increasing the fiber surface area in the wool lowers the thermal conductivity of the insulation product. Thus, with hollow fibers, less insulation material is needed to produce a product with the same or better insulating capabilities. With or without a substantial improvement in performance, such a product can be more competitively priced because with less insulation material being used the material costs and in turn the cost of the product can be reduced.
The hollow nature of the present fibers may be quantified in terms of their void fraction, which is defined as (D i /D o ) 2 , where D i is the inside diameter and D o . is the outside diameter of the fiber. Each of the preferred irregularly shaped hollow glass fibers has a void fraction of greater than about 30%, more preferably greater than about 40%, and even more preferably in the range of from about 50% up to and including about 80%. As the void fraction increases, the number of hollow fibers that can be produced from the same amount of glass also increases, somewhat exponentially. For example, about twice as many hollow fibers having a void fraction of 50% can be produced from an amount of glass compared to the number of solid fibers of the same size that can be produced. The number of hollow fibers increases to about ten times as many as solid fibers as their void fractions approach 90%. It is believed that the amount of protrusion or retraction of the tube end 95 relative to the outer surface of the spinner wall 64 will affect the void fraction of the glass fibers produced therefrom. The void fraction of the hollow fibers should increase, up to a point, as the leading ends 95 extend further beyond the outer surface of wall 64.
Thermal conductivity or k value is a measure of a material's ability to conduct heat. Thus, the lower a material's k value the better that material is as an insulator. Also, in general, the more uniform the lattice of the material and the more fiber surface area there is, the greater that material's insulation ability. Thus, thermal conductivity can be a measure of the uniform volume filling nature of the insulation material as well as the total fiber surface area. Building insulation products are quantified by their ability to retard heat flow. Resistance to heat flow or R value is the most common measure of an insulation product's ability to retard heat flow from a structure. R-value is defined by the equation: R value=t/k, where R-value is resistance to heat flow in hrft 2 ° F./Btu (m 2 ° C./Watt); t is recovered thickness in inches; and k is thermal conductivity in Btu in/hrft 2 ° F. (Watt/m° C.).
Insulation products of the present invention are expected to exhibit a substantial reduction in k values from that of the prior art using less glass material and using fibers with the same outside diameter. The wool insulating material of the present invention is expected to require approximately 5 to 81/2% less glass than the solid fiber prior art material, to reflect the same k values and generate an equivalent R value, as a result of only its irregular shape. Significant reductions, of as much as half or more, in the amount of glass needed to generate an equivalent R value is expected as a result of the present fibers being hollow. Comparable weight savings is expected to be seen in light, medium and high density insulating materials. In comparing prior art insulation products of the same weight (i.e., same glass content), such products of the present invention are expected to have a greater fiber content, by up to twice or more, and in turn an overall larger fiber surface area than that of a prior art product made with solid fibers. Having more fiber surface area, the present insulation products are expected to exhibit a directly related decrease in thermal conductivity (i.e., increase in R value). Thus, the present invention is expected to enable insulation products to be produced with greater insulating capabilities for the same cost as well as less expensive insulation products that perform the same, compared with similar prior art products.
By making the fibers hollow according to the principles of the present invention, reductions in k values, for a set density and effective fiber outside diameter, are believed possible. By way of example only, it is anticipated that insulation products of the present invention having a density of 0.5 pcf and made with irregularly shaped hollow fiber having an outside diameter of 5 microns and a void fraction of 30% will exhibit a k value of about 0.287 Btu in/hrft 2 ° F. or better. It is further anticipated that with everything else remaining the same, the k value will drop to about 0.281 Btu in/hrft 2 ° F. when the fibers have a void fraction of 40%, to about 0.273 Btu in/hrft 2 ° F. when the fibers have a void fraction of 50%, to about 0.248 Btu in/hrft 2 ° F. when the fibers have a void fraction of 80%, and to about 0.233 Btu in/hrft 2 ° F. when the fibers have a void fraction of 90%.
Insulation products are packaged in high compression in order to ship more insulation in a defined volume, such as a truck. At the point of installation the insulation product is unpackaged and the product expands or recovers. The thickness to which the insulation product recovers is referred to as the recovered thickness. A specific thickness of insulating material is required to perform to a specified R value.
The ability of an insulation product to recover depends upon both the uncompressed product density and the density to which the product is compressed. Wool insulating material can be generally classified into three broad categories: light, medium and heavy density. Light density insulation products are those with a product density within the range of 0.15 to 0.6 pcf (2.4 to 9.6 Kg/m 3 ). Medium density insulating materials are those with a product density of from 0.6 to 0.9 pcf (9.6 to 14.4 Kg/m 3 ). Heavy density wool insulating materials are those higher than 1.0 pcf (16 Kg/m 3 ).
The compressed density is the density to which the wool batt can be compressed for shipping while still maintaining a satisfactory recovery. If a product is compressed to too high a density, a substantial portion of the glass fibers may break. As a result, the product will not recover to a satisfactory thickness. For prior art light density insulation products of straight solid fibers, the maximum practical compressed density is from about 3 to about 6 pcf (48 Kg/M 3 to 96 Kg/M 3 ), depending on the product density.
Light density wool insulating materials of the present invention are expected to produce dramatically improved recovery properties due to the unique shape and properties of the irregularly-shaped fibers. Being binderless, one would expect irregularly-shaped glass fibers to slide upon compression as do the binderless straight fibers of the prior art. However, the irregularly-shaped fibers cannot slide very far because the irregular shape catches on neighboring fibers, thereby preventing significant movement. Further, there is no binder placing stress on the fibers near the intersections. Rather, the irregularly-shaped fibers twist and bend in order to relieve stress. Thus, the fibers' positions are maintained and any available energy for recovery is stored in the fiber. This stored energy is released when the compression is removed and the fibers return to their recovered position.
A wool insulation product can contain up to twice as many or more hollow fibers, compared to another product made from an equal amount of glass and containing the same size, i.e., same length and outside diameter, but solid fibers. However, even if the number of hollow fibers used in the wool product is increased by up to twice as many or more, it is believed that such an increase will not significantly diminish the wool's compressibility or its ability to recover. For one reason, no binder is used, and for another, the irregularly shaped fibers are able to store recovery energy. In addition, even if fully compressed, the wool would not come close to the 100% theoretical density of the glass (i.e., about 160 pcf). However, even if at some point the increase in hollow fibers did significantly diminish the compressibility and recoverability of the wool product, there will likely be enough of an increase in the fiber content of the wool to still improve its insulating capabilities.
The term recovery ratio in the present invention is defined as the ratio of recovered density to compressed density, after an insulation product is compressed to the compressed density, unpackaged, and allowed to recover to the recovered density, according to ASTM C167-90. For example, an insulation product compressed to a density of 6 pcf (96 Kg/m 3 ) which recovers to 0.5 pcf (8 Kg/m 3 ) has a recovery ratio of 12:1. In general, the overall appearance (i.e., irregular shape) of a dual-glass hollow fiber is about the same as that of a dual-glass solid fiber. Light density wool batts made of irregularly-shaped solid, rather than hollow, fibers in accordance with U.S. patent application Ser. No. 08/148,098, filed Nov. 5, 1993, now U.S. Pat. No. 5,431,992 and entitled DUAL-GLASS FIBERS AND INSULATION PRODUCTS THEREFROM, the disclosure of which is hereby incorporated by reference, may be compressed to a compressed density within the range of about 6 to about 18 pcf (96 to 288 Kg/M 3 ) and recover to a recovered density of within the range of about 0.3 to about 0.6 pcf (4.8 to 9.6 Kg/M 3 ). This is a recovery ratio within the range of from 12:1 to about 50:1. Light density wool batts made with the present hollow fibers are expected to perform comparably. Preferably, insulation products of the invention will be compressed to a compressed density within the range of from about 9 to about 18 pcf (144 to 288 Kg/M 3 ) and are expected to recover to a recovered density within the range of from about 0.3 to about 0.6 pcf (4.8 to 9.6 Kg/M 3 ). Most preferably, the light density insulation products will be compressed to a density of within the range of from about 9 to about 15 pcf (144 to 240 Kg/m 3 ) and expected to recover to a recovered density of within the range of from about 0.3 to about 0.5 pcf (4.8 to 8 Kg/M 3 ).
Such a dramatic increase in the amount of compression that can be applied to light density insulation products of the present invention while still maintaining a satisfactory recovered density will have a significant effect. For standard R19 insulation products, it is expected that compressed density can be increased from around 4 pcf (64 Kg/M 3 ) to about 12 pcf (192 Kg/M 3 ) by employing irregularly-shaped glass fibers of the present invention. This translates to around 3 times as much insulating material which can be shipped in the same volume shipping container of a truck, rail car, etc. The potential savings in shipping cost is enormous. Furthermore, because shipping costs usually increase as shipping weight increases, products made with the present lighter weight hollow fibers can be shipped less expensively. In addition, being more compressible and light weight, the present insulation products provide benefits in storage and handling for warehousing, retailing and installing the product.
To achieve the unique irregularly-shaped hollow glass fibers of the present invention, specific compositions satisfying a number of constraints are required. The first constraint involves the coefficient of thermal expansion. There is no direct constraint on the values for the coefficient of thermal expansion of either glass A or glass B. Preferably, however, the coefficients of thermal expansion of glass A and glass B, as measured on the individual glasses by standard rod techniques, differ by at least 2.0 ppm/°C.
The dual-glass compositions of the present invention comprise one high-borate, low-soda lime-aluminosilicate composition as glass A and one high-soda, low-borate lime-aluminosilicate composition as glass B satisfy all constraints necessary for a successful irregularly-shaped hollow glass fiber. By high-borate, low-soda lime-aluminosilicate composition, it is intended that the glass composition have a borate content of within the range of about 14% to about 24% by weight of the total components. By a high-soda, low-borate lime-aluminosilicate composition, it is intended that the glass composition have a soda content within the range of from about 14% to about 25% by weight of the total components.
Preferably, the first glass composition comprises by weight percent from about 50 to about 61% silica or SiO 2 , from about 0 to about 7% alumina or Al 2 O 3 , from about 9 to about 13% lime or CaO, from about 0 to about 5% magnesia or MgO, from about 14-24% borate or B 2 O 3 , from about 0 to about 10% soda or Na 2 O, and from about 0 to about 2% potassium oxide or K 2 O.
The second glass composition is preferably one which comprises by weight percent from about 52 to about 60% silica or SiO 2 , from about 0 to about 8% alumina or Al 2 O 3 , from about 6 to about 10% lime or CaO, from about 0 to about 7% magnesia or MgO, from about 0 to about 6% borate or B 2 O 3 , from about 14 to about 25% soda or Na 2 O, and from about 0 to about 2% potassium oxide or K 2 O. It is understood that in each composition there will typically be less than about 1% total of various other constituents such as, for example Fe 2 O 3 , TiO 2 and SrO, not intentionally added to the glass, but resulting from the raw materials used in the batch formulation.
More preferably, the dual-glass composition of the present invention comprises a first glass composition containing approximately 52-57% silica, 4-6% alumina, 10-11% lime, 1-3% magnesia, 19-22% borate, 4-6% soda, 0-2% potassium oxide, and a second glass composition containing approximately 57-65% silica, 2-6% alumina, 8-9% lime, 4-6% magnesia, 0-6% borate, 15-21% soda, and 0-2% potassium oxide. While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the methods and apparatus disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims. | A method of making an insulation product of hollow fibers whereby molten insulation material is centrifuged through a plurality of orifices and gas is directed into the molten insulation material through a plurality of gas conduits, wherein each gas conduit directs gas into one of the portions of the molten insulation material being centrifuged through one of the orifices to form a hollow fiber having a hollow bore formed therethrough. The hollow fibers are combined to form the insulation product. | 3 |
STATEMENT OF GOVERNMENT INTEREST
The following description was made in the performance of official duties by employees of the Department of the Navy, and, thus the claimed invention may be manufactured, used, licensed by or for the United States Government for governmental purposes without the payment of any royalties thereon.
TECHNICAL FIELD
The following description relates generally to an apparatus for enabling the use of one electrical servicing cable for supplying aircrafts having a three-phase 115V/400 Hz AC power system, or aircrafts having a 270 VDC electrical power system, to enable proper pre-flight and maintenance operations.
BACKGROUND
Aircrafts require pre-flight and maintenance electrical servicing. When an aircraft is parked on the ground or on an aircraft carrier or the like, power is typically supplied via an electrical cable assembly. The cable assembly typically includes a power source attached at one cable end, and the other end is free to be attached to a power receptacle on the body of the aircraft. Different aircrafts employ different types of electrical power systems, and therefore there is a compatibility requirement for the electrical cable assemblies and the aircraft power receptacles.
Traditionally, most of the aircrafts deployed on US Navy ships have a 115 VAC/400 Hz AC, electrical power system. In order to perform maintenance and pre-flight operations, aircrafts are outfitted with an external power receptacle, typically a six pole NATO standard per MS90362. The existing Aircraft Electrical Servicing System (AESS) aboard US Navy ships provide electrical power to embarked aircraft by way of a portable servicing cable assembly with a plug that fits the MS90362 receptacle. Next generation aircrafts like the F-35 Joint Strike Fighter (JSF) have a 270 VDC electrical power system and have a 270 VDC external power receptacle. As a result, any ship or airport that will receive the JSF will need to provide 270 VDC electrical power for maintenance and pre-flight operations.
The introduction of JSFs in addition to the traditional aircraft will have a significant cost, infrastructure, size and weight impacts to the carrier ships, if a plurality of power systems are to be provided on each carrier ship. Thus, it is desired to provide a single power system that is compatible with both the 115 VAC/400 Hz AC and the 270V DC systems. It is also desired to have a power supply system that is relatively inexpensive and that does not require a significant change in infrastructure.
SUMMARY
In one aspect, the invention is an aircraft electrical servicing adapter for use with a power supply system and an aircraft. According to the invention, the power supply system includes a controller, a 28 VDC power source, a 270 VDC power source, and a 115V/400 Hz AC power source, a 115V/400 Hz cablehead plug, and a first power recognition circuit segment. The aircraft is equipped to receive power from a 270 VDC power source and a 28 VDC power source, the aircraft having a 270 VDC receptacle. In this aspect, the aircraft electrical servicing adapter comprises an adapter body, a power end attached to the adapter body, an aircraft end attached to the adapter body, and a second power recognition circuit segment having a diode. In this aspect, the second power recognition circuit segment is provided for completing a single power recognition circuit with the first power recognition circuit segment. The aircraft electrical servicing adapter further includes a socket arrangement having six socket openings located in the aircraft end of the adaptor, for receiving 270 VDC receptacle pins of an aircraft. The adapter also has a receptacle arrangement having six pins, the receptacle arrangement located on the power end of the adaptor for mating with the 115V/400 Hz AC cablehead plug of the power supply arrangement. In this aspect, the receptacle arrangement comprises a two part pin having a first contact portion and a second contact portion, with the first and second contact portions forming at least a portion of the first power recognition circuit segment with the diode connected across the contacts. In this aspect, when the receptacle arrangement is inserted into the 115V/400 Hz AC cablehead plug the single power recognition circuit is completed and communicates to the controller that the adapter is attached to the cablehead. This results in the controller supplying power from the 28 VDC power source and the 270 VDC power source to the cablehead.
In another aspect, the invention is a system for supplying power to different types of aircraft. In this aspect, the system includes one or more aircrafts. Each of the one or more aircrafts is equipped to receive power from a 115V/400 Hz AC power source, a 270 VDC power source and a 28 VDC power source. In this aspect, the invention includes a power supply system, the power supply system comprising a controller, a 28 VDC power source, a 270 VDC power source, and a 115V/400 Hz AC power source. The power supply system also includes a 115V/400 Hz AC cablehead plug, and a first power recognition circuit segment for forming a single power recognition circuit with either a second power recognition circuit segment or a third power recognition segment. In this aspect, the invention includes an aircraft electrical servicing adapter. The aircraft electrical servicing adapter comprises an adapter body, a power end attached to the adapter body, and an aircraft end attached to the adapter body. The aircraft electrical servicing adapter further includes a second power recognition circuit segment having a diode, and a socket arrangement having six socket openings located in the aircraft end of the adaptor for receiving 270 VDC receptacle pins of an aircraft. Additionally, the adapter further includes a receptacle arrangement having six pins, with the receptacle arrangement located on the power end of the adaptor for mating with the 115V/400 Hz AC cablehead plug of the power supply arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features will be apparent from the description, the drawings, and the claims.
FIG. 1 is an exemplary illustration of a system for powering a plurality of aircraft types, according to an embodiment of the invention;
FIG. 2 is a schematic illustration of a system for powering a plurality of aircraft types, according to an embodiment of the invention;
FIG. 3A is an exemplary illustration of an aircraft electrical servicing adapter, according to an embodiment of the invention;
FIG. 3B is a perspective illustration of a socket arrangement as viewed from arrow A in FIG. 3A ;
FIG. 3C is a perspective illustration of a receptacle arrangement as viewed from arrow B in FIG. 3A ;
FIG. 3D is an exemplary illustration of a two-part pin according to an embodiment of the invention; and
FIG. 3E is an exemplary illustration of an aircraft electrical servicing adapter having an elongated cable, according to an embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1 is an exemplary illustration of a system 100 for powering a plurality of aircraft types, according to an embodiment of the invention. The system 100 may be located on an aircraft carrier, or alternatively be located on a land-based airport or hanger, for providing pre-flight and/or general electrical servicing. As shown, the system 100 includes an aircraft electrical servicing adapter 150 , a cablehead 160 , and a cable 165 , which is wound on a cable storage device 166 , such as a spool. The cable 165 is attached to a power supply 175 .
FIG. 1 shows aircrafts 101 and 110 . Aircraft 101 includes a standard six pole 115 VAC/400 Hz AC external power receptacle 120 . Aircraft 110 has a 270 VDC power receptacle. The cablehead 160 includes a socket that is structured to mate with the standard six pole external power receptacle 120 , allowing power from power source 175 to be supplied to an aircraft such as 101 , which includes the standard receptacle 120 . However the structure of cablehead 160 does not allow direct mating with 270 VDC power receptacles 130 as included on aircrafts such as 110 . According to the present invention, the cablehead 160 may be connected to the 270 VDC power receptacle via the aircraft electrical servicing adaptor 150 , which is compatible with both the cablehead and the 270 VDC power receptacle. Although FIG. 1 shows two aircrafts, the illustrated aircrafts 101 and 110 merely represent the types of aircrafts for which the system is applicable. Thus, the system 100 may include more aircrafts or less aircrafts than depicted in FIG. 1 . As will be outlined below, the system provides a safe and reliable means of ensuring that the correct type of power is applied to each type of aircraft.
FIG. 2 is a schematic illustration of a system 200 for powering a plurality of aircraft types, according to an embodiment of the invention. FIG. 2 shows a system 200 having a power supply system 202 . The power supply system 202 includes power sources 205 , 210 , and 215 . Power source 205 provides a 28 VDC power supply, power source 210 provides a 270 VDC power supply, and power source 215 provides a 115 VAC/400 Hz AC power supply. The power supply system 202 also includes a power supply controller 220 for controlling the operation of the supply system 202 , as well as the operation of the overall system 200 . FIG. 2 also shows cablehead 230 .
FIG. 2 further illustrates an aircraft electrical servicing adapter 250 and an aircraft 260 having an external power receptacle 262 , a 270 VDC receptacle which is situated on an aircraft such as 110 shown in FIG. 1 . As shown in FIG. 2 , and as outlined above, the physical structure of the cablehead 230 is incompatible with the external power receptacle 262 . However, as shown, connection between the abovementioned elements may be achieved via the adapter 250 .
FIGS. 3A-3D are exemplary illustrations of the aircraft electrical servicing adapter 250 , according to an embodiment of the invention. As shown in FIG. 3A , the adapter 250 includes an adapter body 310 , which primarily includes the adapter circuitry (shown in FIG. 2 ) including ON and OFF buttons 311 and 312 respectively. The adapter 250 may also include an adapter controller for controlling the operation of the adapter. As shown, the adapter body 310 may be rectangular. However the body 310 may be of any desired shape. FIG. 3A shows the adapter body 310 having a back face 315 and a front face 320 , with an aircraft end 330 of the adapter attached to the back face 315 and a power end 340 of the adapter attached to the front face 320 .
The aircraft end 330 of the adapter comprises a cable 332 which may comprise an elastomeric material. As shown in FIGS. 3A and 3B , the aircraft end 330 includes a socket arrangement 335 having six socket openings ( 336 , 338 ). The socket openings are arranged in two rows, a first row having two socket openings 336 and a second row having four socket openings 338 . As shown, the two socket openings 336 of the first row are larger than the four socket openings 338 of the second row. The socket arrangement 335 represents a mating arrangement for physically mating with a 270 VDC receptacle of an aircraft.
As shown in FIGS. 3A and 3C , the power end 340 of the adapter comprises a six-pin receptacle arrangement 345 surrounded by a protective shield 350 . The six-pin arrangement includes a first row having three pins 355 , and a second row having three pins. The second row includes a two-part F pin 360 having two separate contacts or conducting portions. FIG. 3D shows the structure of the two-part F pin 360 . The pin 360 includes a lower portion 365 comprising a conducting material. The pin 360 also includes an upper portion comprising two separate regions, a first region comprising insulating material shown at 366 and a second region comprising conducting material shown at 367 . As shown, the region comprising the insulating material is sandwiched between the conducting material of the lower portion and the conducting material of the upper portion. Additionally, the lower portion 365 has a larger diameter than the upper portion ( 366 , 367 ). This structure allows the two-part F pin 360 to have two separate contact points when the cablehead is inserted thereon, thereby forming and closing a power recognition circuit, as outlined below.
FIG. 3A shows a length in the z-direction, L 3 , measuring the length of the adapter 250 from the aircraft end to the power end. In order to have a compact apparatus, L 3 is about 8 inches to about 14 inches, preferably from about 9 inches to about 12 inches in length. According to an embodiment of the invention, the adapter body may have a length in the z-direction of about 3 inches to about 5 inches. The shield at the power end may be about 1 inch to about 2 inches in the z-direction, and the cable at the aircraft end may be about 3 inches to about 6 inches in the z-direction. Additionally, the adapter may also have a thickness (x-direction) of about 3 inches to about 6 inches, and a height (y-direction) of about 3 inches to about 5 inches. In another embodiment shown in FIG. 3E , the cable at the airplane end may have a length L 4 of about 10 ft to about 40 ft to facilitate the attachment of the adapter to an airplane via the airplane receptacle.
In operation, if an aircraft having a 270 VDC receptacle is to be connected to the power supply system 202 , the aircraft electrical servicing adapter 250 must be an intermediary between the components. According to this embodiment, with reference to FIGS. 2 , 3 A, 3 B, 3 C, and 3 D, the adapter 250 is connected at the adapter's power end 340 to the cablehead 230 of the power supply system 202 . As shown in FIG. 3C , the power end 340 includes a receptacle arrangement having six pins including the two-part pin 360 . See also FIG. 3D . When the cablehead 230 and the adapter 250 make a proper electrical connection, a power recognition circuit is completed. As shown in FIG. 2 , the power recognition circuit comprises a first power recognition circuit segment 233 located within the power supply system 202 , and a second power recognition circuit segment 253 in the adapter 250 . The first power recognition circuit segment may include a power supply independent of supplies 205 , 210 , and 215 . The second power recognition circuit segment, illustrated in FIG. 2 , includes contacts F 1 and F 2 of the two-part contact, and a diode connected across the contacts. When the single power recognition is completed between the first and second segments, the diode allows current to flow in only one direction. This unidirectional current flow communicates to the controller 220 that the adapter 250 is connected to the power supply system 202 . In response to this information, the controller 220 closes the coils in the 28 VDC power source 205 and the 270 VDC power source 210 , allowing the supply of power from the aforementioned sources to the adapter 250 , and preventing the supply of potentially damaging power from the 115 VAC/400 Hz AC power source 215 .
As shown in FIG. 2 , the adapter 250 includes a first relay 251 and a second relay, contactor 252 , as well as an electrical switch for switching ON and OFF the current flow through the second relay 252 . When the power from sources 205 and 210 are supplied to the adapter 250 , the current from the 28 VDC supply 205 is allowed to flow through the adapter via the first relay 251 . As a safety measure, the 270 VDC current is prevented from automatically flowing through the adapter 250 . The 270 VDC current is only allowed through the adapter 250 if the electrical switch is turned ON.
After the current from the 28 VDC supply 205 is allowed to flow through the adapter 250 , the current flows through to the aircraft 260 via the receptacle 262 , if the aircraft is electrically connected to the adapter 250 . If the aircraft is electrically connected to the adapter 250 , the 28 VDC current flows through to the aircraft and back towards the adapter. FIG. 2 shows the current flowing from pin I and jumping back to the adapter via pin 2 . When this current flows back to the adapter, it flows towards the ON/OFF switch, thereby energizing the switch and allowing a user to close the switch (into the ON position). In the ON position, current from the 270 VDC source is allowed to flow through the second relay through the adapter to the aircraft, thereby fully powering the aircraft. This arrangement where the switch 253 can only be turned ON if the 28 VDC current first flows to an electrically connected aircraft, protects a user from the hazardous effects of a 270 VDC power surge when the adapter is not connected to an aircraft. In other words, according to this arrangement, the 270 VDC power is only supplied through the adapter if an aircraft is properly attached to the adapter. It should be noted that if there is some sort of system error, and the 115 VAC/400 Hz supply is applied to the adapter 250 , the relays 251 and 252 would not allow the alternating current to flow through the adapter 250 , thereby preventing potential hazard to a user or to a connected 270 VDC aircraft. FIG. 2 also shows a thermal switch within the second power recognition circuit segment, which protects against overheating in the adapter.
It should be noted that an aircraft 275 having a 115 VAC/400 Hz six pin receptacle 277 , as shown in FIG. 2 , may be connected directly to the power supply system 202 via the complementarily mating cablehead 230 and aircraft receptacle 277 . In this arrangement, as opposed to a two-part F-pin 260 , the aircraft receptacle includes a solid F-pin, similar to pin 355 shown in FIG. 3C . The solid F-pin showed schematically in FIG. 2 , at least partially forms a third power recognition circuit segment. Together with the first power recognition circuit segment 233 , the third segment forms a single power recognition circuit. When the solid F pin is inserted into the socket arrangement of the cablehead, the single power recognition circuit between the aircraft receptacle and the power supply system is completed. Because this arrangement does not include a diode, the current flow in the completed recognition circuit is not limited to one direction. The resulting bidirectional current flow signals to the power supply system controller 220 that a 400 Hz receptacle is attached to the cablehead 230 , and that the 115 VAC/400 Hz AC power source is required. In response to this information, the controller 220 closes the coils in the 115 VAC/400 Hz power source 215 , allowing only the supply of power from source 215 to the aircraft 275 , and preventing the supply of potentially damaging power from the 28 VDC and 270 VDC power sources.
What has been described and illustrated herein are preferred embodiments of the invention along with some variations. The terms, descriptions and figures used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the invention, which is intended to be defined by the following claims and their equivalents, in which all terms are meant in their broadest reasonable sense unless otherwise indicated. | A system for enabling the use of one electrical servicing cable having a 115V/400 Hz AC cablehead, to supply aircrafts having either a three-phase 115V/400 Hz AC electrical power system, or a 270 VDC/28 VDC electrical power system, for aircraft pre-flight and maintenance operations. The system includes a controller for determining and controlling the supply of appropriate power to an aircraft. The system includes an aircraft electrical servicing adapter that facilitates the safe supply of power to a 270 VDC aircraft via the 115V/400 Hz AC cablehead. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to laundry detergent compositions, and, more particularly, to such compositions containing a polymer which is a water soluble poly(vinylpyridine) betaine containing a quaternary nitrogen and a carboxylic acid group, which polymers have effective dye complexing properties therein.
2. Description of the Prior Art
Dye complexing polymers have been used in laundry detergent and fabric softener compositions. In such application, during washing a mixture of colored and white fabrics, some of the dyes may bleed out of a colored fabric under washing conditions. The degree of bleeding is influenced by the structure of the dye, the type of cloth and the pH, temperature and mechanical efficiency of the agitation process. The bled dye in the wash liquor can be totally innocuous and get washed off in the wash liquor. However, in reality, this fugitive dye has a tendency to redeposit either onto the same fabric or onto another fabric leading to patches and an ugly appearance of the washed material. This redeposition of the bled dye can be inhibited in several ways. One method is to introduce compounds which can complex with the fugitive dye and get washed off thus preventing redeposition.
Polyvinylpyrrolidone (PVP), by virtue of its dye complexation ability, has been used to inhibit dye deposition during washing of colored fabrics under laundry conditions. The performance of PVP as a DTI, however, is adversely affected by the presence of anionic surfactants in the washing process.
Other polymers which have been used as DTIs in laundry detergent compositions include polyvinylpyridine N-oxide (PVPNO); polyvinylimidazole (PVI) and copolymers of polyvinylpyridine and polyvinylimidazole (PVP-PVI).
U.S. Pat. Nos. 5,776,879; 5,929,175; 5,869,442; 5,863,880, assigned to the same assignee as herein are related to this invention.
The other prior art in this field is represented by the following patents and publications:
Patent
Subject Matter
(1)
JP 53-50732
Formulas Nos. 3, 6 and (1) are water
insoluble compounds and polymers used
in printing ink compositions;
(2)
PCT/US94/06849
Dye inhibiting composition polymers of
WO 95/03390
PVP, polyamine N-oxide,
vinylimidazole are used in laundry
detergent compositions;
(3)
U.S. Pat. No.
Polyamine N-oxide polymers described
5,460,752
for use in laundry detergent
compositions;
(4)
EPA 664335 A1
Polysulfoxide polymers;
(5)
PCT/US93/10542
Laundry compositions include
WO 94/11473
polyamine-N-oxide and brighteners
and surfactants;
(6)
PCT/EP93/02851
PVP and PVI are present in laundry
WO 94/10281
compositions;
(7)
PCT/US94/11509
Poly(4-vinylpyridine-N-oxide) (PVNO)
WO 95/13354
and copolymers of VP and VI are
described;
(8)
EP 754748 A1
Vinylpyridine copolymers and formic
acid;
(9)
066433 A1
Polyamine oxide polymers;
(10)
U.S. Pat. No. 5,604,197
PVPNO + clay softening;
(11)
U.S. Pat. No. 5,458,809
PVPNO;
(12)
U.S. Pat. No. 5,466,802
PVPNO and PVP-VI;
(13)
U.S. Pat. No. 5,627,151
Copolymers of VP or VI; vinylpyridine
or dimethylaminoethyl methacrylate or
dimethylaminopropylmethacrylamide,
including up to 20% vinylacetate;
(14)
PCT/US95/04019
PVPNO, PVP, PVP-PI and copolymers
WO 95/27038
of VP and VI;
(15)
EPA 628624 A1
PVPNO with protease;
(16)
DE 4224762 A1
VP polymers;
(17)
J. Polymer
Water-insoluble poly(4-vinylpyridine)
Sci. 26,
compounds and polymers
No. 113, p.
25-254 (1957)
Accordingly, it is an object of this invention to provide new and improved laundry detergent compositions containing effective water soluble dye complexing polymers.
A feature of the invention is the provision of a water soluble poly(vinylpyridine) betaine containing a quaternary nitrogen and a carboxylic acid group as the dye transfer complexing polymer in laundry detergent compositions.
Another feature of the invention is the provision of laundry detergent compositions containing such new and improved water soluble poly(vinylpyridine) polymers, which exhibit color stability during storage, and particularly effective dye complexing properties during the washing process even in the presence of anionic surfactants.
SUMMARY OF THE INVENTION
What is described herein is a laundry detergent composition containing a water soluble poly(vinylpyridine betaine) polymer which contains a quaternary nitrogen and a carboxylic acid group. The polymer has the formula:
where m is indicative of the degree of polymerization,
X is an anion,
R 1 , R 2 , R 3 and R 4 are independently hydrogen, alkyl or aryl, and
n is 1-6,
and quats and copolymers thereof.
Preferred embodiments of the invention are polymers in which X is hydroxyl; R 1 , R 2 , R 3 and R 4 are hydrogen; n is 1 or 2; and the polymer is 25-100% quaternized; most preferably 75-100%.
A suitable polymer has a weight average molecular weight of about 5,000 to 1,000,000; preferably 20,000 to 200,000, where m is about 30-5000, preferably 100-1000.
Water soluble copolymers of the defined polymer above with polymerizable comonomers, such as vinyl pyrrolidone, vinyl imidazole, acrylamide and vinyl caprolactam also are useful herein.
The polymers of the invention have effective dye complexing properties for use in laundry detergent compositions which include at least 1% by weight of an anionic, cationic or non-ionic surfactant or mixtures thereof.
DETAILED DESCRIPTION OF THE INVENTION
The dye transfer inhibition polymers of the invention wherein n=2-6 and X is OH are made by reacting a poly(vinylpyridine) with an α,β-unsaturated carboxylic acid by Michael addition. Suitable α,β-unsaturated acids in this reaction include crotonic acid, itaconic acid, maleic acid, fumaric acid, acrylic acid, methacrylic acid and the like. Crotonic acid is preferred. In aqueous medium the betaine anion is hydroxyl.
A preferred polymer herein is poly(4-vinylpyridine) carboxyethyl betaine hydroxide having the formula:
which is made by reacting poly(4-vinylpyridine) with crotonic acid to form the betaine carboxylate followed by addition of water to form the desired betaine carboxylic acid.
Polymers of the invention wherein n=1-6 and X is a halide are made by reacting poly(4-vinylpyridine) with a halocarboxylic acid such as 2-chloroacetic acid, 2 or 3-chloropropionic acid, and the like.
The invention will now be described in more detail with reference to the following examples.
EXAMPLE 1
Poly(4-Vinylpyridine)
(Solution Polymerization)
Into a 1-l, 4-necked resin kettle, fitted with a stainless steel anchor agitator, a nitrogen purge adapter and a reflux condenser, a mixture of 160 g of 4-vinylpyridine monomer and 440 g of isopropanol were charged. The nitrogen purge is begun and continued throughout the run. The above mixture at ambient temperature was then gradually heated to 75° C. and held for 30 minutes. 2.0 grams of initiator t-butylperoxy pivalate was charged while operating the anchor agitator at 350 rpm. The mixture was kept at 75° C. throughout the run. The resulting mixture was agitated for one hour. Then 0.5 g of Lupersol® 11 was added every hour until the residual 4-vinylpyridine level was less than 0.5%.
EXAMPLE 2
Poly(4-Vinylpyridine)
(Suspension Polymerization)
Into a 1-l, 4-necked resin kettle, fitted with a stainless steel anchor agitator, a nitrogen purge adapter and a reflux condenser, a mixture of 60 g of 4-vinylpyridine monomer, 3.0 g of K-30 poly(4-vinylpyrrolidone) and 240 g of water were charged. The nitrogen purge is begun and continued throughout the run. The above mixture at ambient temperature was then gradually heated and held at 85° C. for 30 minutes with the anchor agitator set at 350 rpm. An initial charge of 1.0 g. of t-butyl peroxypivalate (Lupersol® 11) was added to the mixture and agitation was continued for one hour. Then 0.5 g of Lupersol® 11 was added every hour over an 8-hour period until the residual 4-vinylpyridine level was less than 0.5%. The resulting poly(4-vinylpyridine) is recovered by filtering and drying in an 80% yield.
EXAMPLE 3
Poly(4-Vinylpyridine) and Crotonic Acid
Into a 1-l, 4-necked resin kettle fitted with a nitrogen gas adapter, reflux condenser, thermometer, and glass agitator with Teflon blade 90 g of isopropyl alcohol and 60 g of 4-vinylpyridine were charged. Agitation was started and kept at 200 rpm. Nitrogen was introduced into the kettle and continue throughout the polymerization reactions. The resulting mixture was gradually heated up from ambient temperature to 80° C. and held for about a half-hour. Then an initial charge of 0.6 g of t-butyl peroxypivalate (Lupersol® 11) was added to the mixture. After 2 hours, an additional dose of 0.3 g of initiator was also added every 2 hours until the residual 4-vinylpyridine monomer level was less than 0.5%. Meanwhile 24.6 g of crotonic acid (a 1:0.5 molar ratio of 4-vinylpyridine to crotonic acid) was completely dissolved in 127 g distilled water and the mixture was added to the kettle held at 80° C. After mixing for 10 minutes the isopropyl alcohol solvent was stripped completely from the batch by gradually applying vacuum. The batch was then held for 15 hours at 80° C. The reaction product is present in a 50% solids solution.
EXAMPLE 4
Poly(4-Vinylpyridine) and Crotonic Acid
Into a 1-l, 4-necked resin kettle fitted with a nitrogen gas adapter, reflux condenser, thermometer, and glass agitator with Teflon blade, 90 g of isopropyl alcohol and 60 g of 4-vinylpyridine are charged. Agitation was started and was held at 200 rpm. Nitrogen was introduced into the kettle and continue throughout the polymerization reactions. The above mixture was gradually heated up from ambient temperature to 80° C. and held for about a half-hour. An initial charge of 0.6 g of t-butyl peroxypivalate (Lupersol 11) was added to the mixture and was held for 2 hours. Then an additional dose of initiator 0.3 g Lupersol 11 was also added every 2 hours until the 4-vinylpyridine monomer level is less than 0.5%. Meanwhile 39 g of crotonic acid was completely dissolved in 127 g distilled water and the mixture was added to the kettle held at 80° C. After 10 minutes of mixing, the isopropyl alcohol solvent was stripped completely from the batch by gradually applying vacuum. The batch was then held for 15 hours at 80° C. The reaction product is recovered in an 80% solids solution.
EXAMPLE 5
Poly(4-Vinylpyridine) and Crotonic Acid
Into a 4-necked, 1-l reaction kettle, equipped with a thermometer, reflux condenser, and a half-moon Teflon blade agitator, was charged 60 g of poly(4-vinylpyridine) (Example 2) and 200 g of water. The mixture was heated to 80° C. with agitation; then 34 g of crotonic acid and 100 g of water was added to the kettle and the resulting mixture was heated at reflux temperature for 15 hours. The reaction product contains 70% crotonic acid.
EXAMPLE 6
Poly(4-Vinylpyridine) and Acrylic Acid
(Solution Polymerization)
In the apparatus of Example 5, 160 g of poly(4-vinylpyridine) (Example 1) was charged as a 40% aqueous isopropyl alcohol solution. Agitate and heat the batch to 80° C. Then 23 g of acrylic acid was introduced and the resulting mixture was heated at reflux temperature for 8 hours. Then 200 g water was added, agitated and vacuum applied to strip off isopropyl alcohol. The reaction product was cooled and water added to a 40% solids level.
EXAMPLE 7
Poly(4-Vinylpyridine) and Crotonic Acid
(Solution Polymerization) (Isopropyl Alcohol)
Into a 1-l, 4-necked resin kettle fitted with a nitrogen gas adapter, reflux condenser, thermometer, and glass agitator with Teflon blade, 90 g of isopropyl alcohol, 40 g of 4-vinylpyridine and 20 g of vinylpyrrolidone were charged. Agitation was started and was held at 200 rpm. Nitrogen was introduced into the kettle and continued throughout the polymerization reaction. The above mixture was gradually heated up from ambient temperature to 80° C. and held for about half-hour. An initial charge of 0.6 g (1% based on total monomer weight) of t-butyl peroxypivalate (Lupersol® 11) was added to the mixture which was then held for 2 hours. An additional dose of 0.3 g of initiator was added every 2 hours for 12 hours or until the residual 4-vinylpyridine monomer level was less than 0.5%. Meanwhile 24.6 g of crotonic acid was completely dissolved in 127 g distilled water and the mixture was added to the kettle held at 80° C. After 10 minutes of mixing, isopropyl alcohol was stripped completely from the batch by applying vacuum gradually. The batch was then held for 9 hours at 80° C. or until the residual crotonic acid level was less than 1.0%. The product is semi-viscous, has a dark brownish color and is soluble in water.
EXAMPLE 8
Poly(4-Vinylpyridine) and Itaconic Acid
(Solution Polymerization) (Isopropyl Alcohol)
Into a 4-necked, 1-l reaction kettle, equipped with a thermometer, reflux condenser, and a half-moon Teflon blade agitator, charge 160 g of poly(4-vinylpyridine) (Example 1) 40% aqueous solution. Agitate and heat the batch to 80° C. Add 40 g of itaconic acid into the kettle and keep the mixture at reflux temperature for 15 hours. Add 200 g water and let it mix properly then apply vacuum to strip isopropyl alcohol. Cool down and readjust solid to 40%.
EXAMPLE 9
Poly(4-Vinylpyridine and Chloroacetic Acid
(Solution Polymerization)
A 1-liter, 4-necked resin kettle was fitted with an anchor agitator, a nitrogen purge adaptor, a thermometer, two subsurface feeding tubes connected with two feeding pumps, and a reflux condenser. The kettle was charged with 150 g of 4-vinylpyridine and 150 g of isopropanol. Nitrogen purging was started and continued throughout the process as was agitation at 200 rpm. Then the reactants were heated to 80° C. in 20 minutes and held at that for 30 minutes. Then 390 microliter of t-butyl peroxypivalate (Lupersol® 11) was charged. The solution polymerization reaction was carried out at 80° C. for 2 hours. Then a 195 microliter portion of Lupersol® 11 was added and reaction continued at 80° C. for another two hours. The latter step was repeated another 6 times. Then 150 g water and 135 g of chloroacetic acid was charged and the contents were rinsed with 100 g of water. The resultant mixture was heated to remove 100 g of distillate then 100 g of water was added to the mixture; the step was repeated and yet another 50 g of distillate was removed. Then the mixture was cooled to room temperature. The product was obtained as a solution whose solids level was adjusted to about 48%.
EXAMPLE 10
The process of Example 9 was repeated using 155 g of 3-chloropropionic acid. A related product was obtained.
While the invention has been described with particular reference to certain embodiments thereof, it will be understood that changes and modifications may be made which are within the skill of the art. Accordingly, it is intended to be bound only by the following claims, in which: | This invention relates to laundry detergent compositions, and, more particularly, to such compositions containing water soluble poly(vinylpyridine) betaine polymers containing a quaternary nitrogen and a carboxylic acid group, which polymers have effective dye complexing properties therein. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation application of U.S. patent application Ser. No. 12/431,961 filed Apr. 29, 2009, which is a divisional of U.S. patent application Ser. No. 12/156,335 filed May 30, 2008, which is a continuation of U.S. patent application Ser. No. 10/571,709 filed Mar. 2, 2007, which is an application under 37 USC 371 of International Application Serial No. PCT/GB2004/003890 filed Sep. 13, 2004, which in turn claims priority of British Patent Application Serial No. 0321337.8 filed Sep. 11, 2003.
FIELD OF THE INVENTION
The present invention relates to a method and a system for distributing mobile applications and is suitable particularly, but not exclusively for receiving, processing and displaying advertisements on mobile terminals.
BACKGROUND OF THE INVENTION
Currently the Short Message Service (SMS) is the medium of choice for personal messaging. In addition to personal messaging, several companies have designed systems that are intended to include advertisement information in SMS messages. For example, International patent application WO 03/015430 describes a service whereby advertisement data (including length of advertisement (number of characters), a preview of the advertisement and an identifier associated with the advertisement provided by external sources) are stored on mobile terminal in a “local” store, and the user selects an advert, from the store, to accompany an outgoing message. The terminal then calculates a length available for text, and the sender is allowed to enter a message having a length up to the calculated length. An outgoing message is then created, comprising the advertisement ID associated with the selected advertisement and the user's message text, and having a header indicating that the message has advertising content. The outgoing message is then sent from the terminal and received by the SMSC, which checks the header of the message; any message having an identifier corresponding to the advertisement type is passed to an “ad server”. The ad server processes the message, effectively selecting an advertisement from a store, creating one or more messages that comprise the selected advertisement and creating an SMS message that can be read by the recipient's mobile phone terminal.
Despite the popularity of SMS messaging, wireless has not yet made its mark as an advertising medium. This is partly because each SMS message is limited to 160 characters, and these characters can only be selected from the ASCII set, which makes it difficult to include meaningful and catchy product information in the messages. As a result the ad server quite often creates a plurality of messages, which means that either the receiving terminal has to be equipped with some software that concatenates the messages together in some elegant manner (since presentation is very important with advertising), or the receiving terminal simply displays the messages separately, as is the case with non-modified SMS messages exceeding 160 characters in length. Since the success of the advertising industry is heavily reliant on the impression created by advertisements, and since SMS messages can only provide an extremely restricted visual impact, this means that, as an advertising medium, the SMS communication service is rather limited.
International patent application PCT/AU00/01296, published as WO0131497 describes delivering advertisement data wirelessly as video data. In one arrangement video data streams are unicast or multicast to individual subscribers, the subscribers having a corresponding player or decoder on their terminal for decoding and displaying the received streams. These video streams are described as e.g. live news, video-on-demand (VOD) provider etc., and the video advertising can include multiple video objects, which can be sourced separately. In one arrangement, a video advertisement object can be dynamically inserted into a video stream being delivered to the decoder, the nature of this insertion being controlled by control data embedded in the advert object. Alternatively an interactive video file can be downloaded, rather than streamed, to a device so that it can be viewed offline or online at any time. A downloaded video file has all of the interaction and dynamic media composition capabilities that are provided by the online streaming process and includes menus, advertising objects, and forms that register user selections and feedback. Whilst this is creates a significantly improved impression, from the point of view of perception of a product or service, video files (object or streamed data) require a significant amount of bandwidth and often taken an unacceptable amount of time to download to a mobile device.
An object of the present invention is to provide a convenient method of presenting information to a user of a mobile terminal.
SUMMARY OF THE INVENTION
Aspects of the present invention are set out in the appended claims.
Features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example, only, which is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a mobile network arranged in accordance with an embodiment of the invention;
FIG. 2 is a block diagram showing components of, and arranged to execute on, the terminal T 1 shown in FIG. 1 ;
FIG. 3 is a schematic illustration of a message presentation setting specified by one of the components shown in FIG. 2 ;
FIG. 4 a is a flow diagram showing steps involved in an aspect of the invention concerning embedding advertisement data into applications running on the terminal shown in FIG. 1 ;
FIG. 4 b is a flow diagram showing further steps involved in an aspect of the invention concerning applications running on the terminal shown in FIG. 1 ;
FIG. 5 is a flow diagram showing steps involved in an aspect of the invention concerned with displaying advertisements distributed to a mobile terminal via the mobile network shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention are concerned with distribution of advertisement data to mobile devices and interactive features of the distributed advertisement data. The invention has several aspects, including the way in which advertisement data is formatted; interactive content of advertisement data; embedding of advertisement data in applications such as games and the like; peer-to-peer distribution of advertisements and of applications arranged to display and run such advertisement data; and selection of message settings utilizing advertisement data. Details of these aspects will be described in detail later in the description, but first a description of the infrastructure needed to support the aspects will be presented.
FIG. 1 shows an example of a data system 1 within which embodiments of the invention operate. In FIG. 1 , the blocks indicate components of the data system 1 . In the arrangement shown in FIG. 1 , a terminal T 1 communicates with various network devices within the data system 1 . The terminal T 1 may be a wireless terminal such as a mobile phone, a PDA or a Laptop computer that is configured to run an advertisement application 10 according to the invention, as will be described in more detail below.
The data system 1 comprises: a WAP gateway G 1 , which is typically a network operator's WAP gateway configured to send and receive signals over BLUETOOTH or GPRS; an advertisement services server S 1 , with which the advertisement application 10 communicates via the WAP gateway G 1 ; an MMSC store and forward network node 11 , which is managed by the network operator and arranged to control transmission of MMS messages between senders and recipients; Public Land Mobile Network (PLMN) radio and switching network infrastructure components identified as Base Station BSS 13 and MSC 15 , together with an SMS store and forward network node 17 and gateway G 2 which enables SMS messages to be transmitted from the mobile network PLMN to the server S 1 ; and a database DB 1 , arranged to receive and store, from the advertisement services server S 1 , content data together with data in respect of subscribers and in respect of terminals such as T 1 . The data system 1 can also include network devices required to support communication via the GPRS communication service; for example, the data system 1 may include a Gateway GPRS Support Node (not shown), which is adapted to provide an interface between a GPRS network and external data networks (such as the Internet or private networks) receiving data packets from mobile devices, and forwarding them, in a known manner, through external networks.
The advertisement services server S 1 is arranged to store and download content data such as news, sport and images, which have been sourced from third party content providers shown as S 2 , S 3 , S 4 via Network N 1 , and application data such as object files, executable files and script files. The content and application data may be, or include, advertisement data, as will be described in more detail below, and is typically sent to the server S 1 over a TCP/IP link. In addition to receiving IP packets from servers S 2 , S 3 and S 4 , the server S 1 is configured to deploy data and WAP applications to mobile terminals such as T 1 over a BLUETOOTH link. Accordingly the WAP services server S 1 can be accessed by the terminal T 1 , either directly by the advertisement application 10 or in response to input from the user of terminal T 1 . In addition, the server S 1 is arranged to receive and store (in database DB 1 ) demographic information relating to subscribers of the data service, which can be used in selection of appropriate content and application data.
Aspects of the advertisement application 10 will now be described in more detail. FIG. 2 is a schematic diagram showing an embodiment of an advertisement application 10 according to the invention. The application 10 can be distributed to terminal T 1 using peer-to-peer methods (i.e. from other terminals) or downloaded from the server S 1 , via BLUETOOTH or GPRS communication services, or stored on a memory card associated with the terminal T 1 or on the SIM card associated with the terminal T 1 . The advertisement application 10 is preferably a native application, i.e. written in a low level computer language that is compiled to run directly by the CPU of terminal T 1 (e.g. C or C++), or a Java™ application, in which case the terminal T 1 also includes a Java virtual machine (NM)/Java runtime arrangement capable of running the advertisement application 10 as an application level software environment.
In one embodiment, the advertisement application 10 includes an initialization process, which, when the advertisement application 10 is invoked for the first time, requests certain demographic information from the subscriber. For example, the initialization process can display a form having several fields therein such as identity, age, sex, interests etc., which the subscriber has to complete for the application to become fully operational. Once the user has entered data into these fields, the initialization process inserts the data into one or more messages. The messages can be embodied as SMS messages, in which case they are transported to the server S 1 via BSS 13 , MSC 15 , SMSC 17 and G 2 , or as WAP packets and transported to the server S 1 via G 1 using WAP over BLUETOOTH (or GPRS). In response, and provided the data sent comprises sufficient information, the server S 1 transmits an unlocking code, which automatically unlocks the application 10 , making it fully operational.
The advertisement application 10 comprises an update engine 201 and a processing engine 203 , the update engine 201 being arranged to send data indicative of subscriber settings and advertisement selection to the server S 1 . Preferably the update engine 201 communicates with the server S 1 periodically (e.g. daily), uploading the subscriber's settings and advertisement selections for the forthcoming period. The processing engine 203 is arranged to process application data such as games, and content data such as images, news and sports, which have been received from the server S 1 (or from other remote services). In addition, the processing engine 203 is arranged to process advertisement data, which, in one embodiment are sent as SMS or MMS messages, but could alternatively be sent as data packets via GPRS or BLUETOOTH.
The update engine 201 is arranged to display various message presentation settings to the subscriber, which can be modified to enable the user to select his preferred settings. Presentation settings that can be modified include a frame around messages, font of messages, and orientation and positioning of text and graphics and the like within and around the message, and an example is shown in FIG. 3 . Once the subscriber has entered his preferred settings, the update engine 201 transmits a file including the settings information to the server S 1 , which stores the settings in the database DB 1 , for use in modifying messages subsequently sent by the user (as will be described in more detail below).
The processing engine 203 is configured to request and receive content data, advertisement data, executable files and/or object files from the server S 1 (or other remote servers), and to process the received data and files. In the case of content data (e.g. news and sports), the processing engine 203 is arranged to display the content, embedding advertisement data therein. The advertisement data could, for example, be inserted between news stories, whenever certain keywords appear, in accordance with predetermined settings that accompany the content data, or at random. The advertisement data are preferably sent with the content data, and include an identifier (herein referred to as advertisement ID) which identifies the subject matter of the advert. Advertisements, and hence the subject matter thereof, are preferably selected by the server S 1 in accordance with the type of content data and the subscriber's settings.
In the case of executable files and/or object files, these are downloaded to the terminal T 1 and invoked by the processing engine 203 . The files can be downloaded on demand, or in accordance with previously specified conditions, in which case the advertisement application 10 may include a socket connection arranged to listen for data and, in response to receipt thereof, to pass the received data onto the processing engine 203 . The executable files can include games, more specifically trial games, which include real-time calls for visualization of data; in one arrangement and in use, the games include real-time calls between levels of the game.
Aspects of the invention that relate to processing and serving visualization requests will now be described with reference to FIG. 4 a . The processing engine 203 receives a visualization request from the executable process, the request having been invoked either in response to a command issued by the processing engine 203 or autonomously generated by the executable process itself (step 400 ). Having sent the visualization request, operation of at least part of the executable process is paused, and control is handed over to the processing engine 203 . In response to receipt of the visualization request, the processing engine 203 identifies (step 401 ) whether the call specifies that data should be retrieved from a remote source. If the request specifies a remote source, the processing system 203 sends (step 403 ) a request to server S 1 , preferably via the WAP gateway G 1 , for advertisement data. The request may include certain parameters, such as type of process etc., and the server S 1 responds by selecting (step 405 ) an advertisement in accordance with the settings of the subscriber (retrievable from the database DB 1 ) and those parameters (if any) included in the request. The selected advertisement is then transmitted (step 407 ) to the terminal T 1 , and upon receipt thereof the processing engine 203 displays the advertisement (step 409 ). Having displayed the advertisement the processing engine 203 sends an instruction to the executable process (step 411 ), causing it to resume whichever processing step was paused at step 400 . Resuming processing, when the executable process is a game might, for example, involve moving onto the next level in the game.
Alternatively the processing engine 203 could select one of the advertisements that has previously been transmitted to, and hence stored on, the terminal T 1 ; for example, if the subscriber has recently received news data (and advertisement data with the news data), the processing system 203 could review (step 411 ), by means of advertisement ID associated with advertisement data, those advertisements already stored on the terminal T 1 , with a view to identifying (step 413 ) an advertisement that matches the subscriber preferences and/or indeed the type of executable process. Of course, in the event that none of the local advertisements is relevant to the preferences, the processing engine 203 can retrieve advertisements from the remote store, following steps 403 , 405 , 407 . As a further alternative, and when the executable process is a game, when the processing engine 203 first invokes the trial game, it can, firstly, identify types of advertisements that are to be displayed between levels. The processing engine 203 then sends a request to the server S 1 , as per step 403 , but in this variant the request is for all of the advertisements that could be displayed at any point in the game (e.g. various levels). The server selects (as per step 405 ) relevant advertisements and transmits them (as per step 407 ) to the terminal T 1 . Then, when the trial game makes a call for an advertisement to be displayed, the processing engine 203 can select one of the adverts that was transmitted at step 407 on the basis of the subject matter and level of the game and the subject matter of an advertisement (as identifiable from the associated advertisement ID) in addition, or as an alternative, to the user's preferences. An advantage of this variant is that selection of relevant advertisement data will incur minimum time delay; for cases where the executable process is a game this embodiment will present a minimal interruption to operation of the trial game.
For the case where the executable process is a game, and referring to FIG. 4 b , the game can include a “select game” function, which, if invoked (step 421 ), causes the processing engine 203 to halt the trial game (step 423 ) and retrieve (step 425 ) the standard version of the game (i.e. without adverts). Alternatively, the game could comprise an executable portion that, during execution of the trial game, is locked. In this variant step 425 could involve retrieving an unlocking code. Once the unlocking code has been received the processing engine 203 could apply the received unlocking code to the game, thereby allowing the user full access thereto.
Step 425 may additionally include performing certain transaction-related steps, such as requesting payment details from the subscriber, which, if entered, are preferably encapsulated within SMS messages and forwarded to the advertiser, via server BSS 13 , MSC 15 , SMSC 17 , G 2 and advertisement services server S 1 . In the event that the advertisement data selected at step 405 (or 413 ) are related to the game, they could include data which, when visualized, comprise selectable items that are configured to enable the user to select different versions of the game.
In some cases the advertisement data include an image file and a script file, the script file including control instructions for controlling how an image is to be displayed. In one arrangement the control instructions include movement instructions, specifically panning instructions controlling how an image moves across or around the display, and the rate at which the image is to be moved across the display. An example of a script file that controls movement of a football bouncing across the screen is set out below (image files here are “whitescreen.jpg”, “anim_nike_logo.jpg”, “anim_nike_football.jpg”):
NAME NIKE // 4 letter ID
#include “m1anim.rh”
RESOURCE ANIMATION {
ad_duration_milliseconds = 4000;
campaign_name = “Nike”;
advertisement_name = “Nike Football”;
image_files = { “whitescreen.jpg”, “anim_nike_logo.jpg”,
“anim_nike_football.jpg” };
effects = {
IMAGE_EFFECT {
image_file_no = 2;
on_off_points = { 200, 2500 };
top_left = {
CP_2_LONG {type = 2; time = 200; x = −55; y = 0; },
CP_2_LONG {type = 2; time = 800; x = 121; y = 0; },
CP_2_LONG {type = 2; time = 1400; x = 0; y = 154; },
CP_2_LONG {type = 2; time = 1800; x = 121; y = 154; },
CP_2_LONG { type = 2; time = 2200; x = 60; y = 77; }
};
size = {
CP_2_LONG { x = 55; y = 54; }
};
source_pos = {
CP_2_LONG { x = 0; y = 0; }
};
},
IMAGE_EFFECT {
image_file_no = 1;
on_off_points = { 2000 };
top_left = {
CP_2_LONG { time = 2200; x = 11; y = 208; },
CP_2_LONG { time = 2700; x = 11; y = 170; }
};
size = {
CP_2_LONG { x = 153; y = 28; }
};
source_pos = {
CP_2_LONG { x = 0; y = 0; }
};
},
IMAGE_EFFECT {
image_file_no = 0;
on_off_points = { 0, 4000 };
top_left = {
CP_2_LONG { type = 0; time = 0; x = 0; y = 0; },
CP_2_LONG { type = 0; time = 200; x = 176; y = 0; },
CP_2_LONG { type = 0; time = 3500; x = 0; y = 0;}
};
size = {
CP_2_LONG { x = 176; y = 212; }
};
source_pos = {
CP_2_LONG { x = 0; y = 0; }
};
},
FADE_EFFECT {
fade_no = 0;
on_off_points = { 0, 200 };
fade_data = {
CP_2_LONG { time = 0; x = 255; y = 0; },
CP_2_LONG { time = 200; x = 0; y = 0; },
CP_2_LONG { time = 201; x = 255; y = 0; }
};
},
FADE_EFFECT {
fade_no = 1;
on_off_points = { 3000, 4000 };
fade_data = {
CP_2_LONG { time = 3000; x = 255; y = 0; },
CP_2_LONG { time = 3500; x = 0; y = 0; },
CP_2_LONG { time = 4000; x = 255; y = 0; }
};
},
};
}
Known systems, such as that described in international patent publication number WO01031497, include means for sending advertisements that move dynamically across the screen; however, these moving images are embodied as compressed video files, which occupy a considerable amount of bandwidth. An advantage of this aspect of the invention is that, since the moving images are embodied as a combination of an image, file and a script file, they occupy far less bandwidth.
Preferably the advertisement image file includes a selectable portion (such as a drop down menu or a button), which, when selected, displays one or more options, These options can include “forwarding” the advertisement to another subscriber, which causes the processing engine 403 to create an MMS message comprising the advertisement data; displaying another page with more information based on the already downloaded script and image file contents; accessing the web site of the company associated with the advertisement; and/or sending a request for further information to the company associated with the advertisement, If the latter option is selected, the request is sent to the advertiser (via server S 1 ), which selects data in accordance with the request and inserts the selected data into a standard mobile phone form, transmitting the form to the terminal T 1 as an encoded SMS message or as a WAP data packet (via BLUETOOTH or GPRS).
Referring now to FIG. 5 , in a further aspect, the processing engine 203 could be arranged to invoke advertisement data whenever a user performs certain actions. Such actions include creating a new message, receiving and reading a message, accessing a web site, requesting data etc. This aspect will now be described for the example of creating a message; at step 501 , in response to the subscriber creating a new message using a messaging application running on the mobile terminal, the processing engine 203 interrupts the messaging application and selects advertisement data, e.g. based on the time of day and/or the location of the subscriber, and displays the selected advertisement on the terminal (step 503 ). To facilitate this aspect of the invention the advertisement application 10 ensures that a minimum amount of advertisement data is stored on the terminal T 1 at all times and refreshes the data periodically (typically every day, but the timescales could be either shorter or longer depending on the type of advertisement).
In some arrangements the advertisement application 10 can be configured so that the subscriber can only continue with his intended action if he interacts with the terminal T 1 within a particular time period. This time period overlaps with the time during which advertisement data are displayed. When the advertisement data relate to a moving image, this aspect of the invention is particularly useful, since, in the event that the subscriber fails to interact with the terminal within the time period the application 10 can simply play the advertisement again. The visualization step 503 is repeated until the subscriber successfully interacts with the terminal within the time period (steps 505 , 507 ), following which the messaging application running on the mobile terminal is enabled, by the processing engine 203 , to resume processing once again.
From the point of view of advertising, an advantage of this aspect of the invention is that subscribers are forced to pay attention to the advertisement data if they wish to interact with their terminal T 1 . However, in order to minimize inconvenience to the user the time period within which user input is monitored should be reasonably short; for example, if the advertisement data are displayed once every 5 seconds, the time period could last for 3 seconds and occur within the middle of the advertisement.
As described above, the update engine 201 is arranged to send message presentation settings to the server S 1 . These presentation settings are subsequently used by the server S 1 during a message modification process, whereby SMS, MMS or email messages, which are sent from one subscriber to another subscriber, are modified to include advertisement data. In addition to appending advertisement data to messages, the message modification process involves using the presentation settings to modify the way in which messages are presented on a screen, effectively customizing both the content and the presentation of messages. For outgoing MMS messages to be modified in this manner, outgoing messages have to be routed to the server S 1 in the first instance. Once received by the server S 1 , the server S 1 modifies messages—e.g. by selecting and appending an advertisement to the message in accordance with subscriber data stored in the database DB 1 , and/or by modifying the presentation of the message in accordance with the settings data transmitted by update engine 201 . In the event that the settings data include data specifying preferred types of advertisements, selection of an advertisement is additionally dependent on these preferences. A notable feature of this aspect of the invention is that message settings and advertisement preferences are not transmitted together with the message, but are transmitted separately; by the update engine 201 , as described above. An advantage of this aspect of the invention is that, for a given time period, advertisement preferences only have to be sent once rather than each time a message is created. It should be noted that those MMS messages that themselves comprise advertisement data—e.g. having been forwarded from terminal T 1 in response to selection of an option presented to the user of terminal T 1 as described above—are preferably not modified by the server S 1 . Those MMS messages that comprise such forwarded advertisements can have data in their header portion identifying the MMS message as an advertisement-type message. Accordingly, to differentiate between MMS messages that should be modified and messages that should not be modified the server S 1 is arranged to initially review the headers of the received MMS message. In the event that one or more headers of the MMS message are identified to relate to advertisement data the message is not modified, but is instead transmitted directly to the network operator's MMSC 11 .
If a message has been modified by the server S 1 to include advertisement data, the server S 1 transmits the message to the network operator's MMSC 11 for transmission to the recipient of the message (in accordance with conventional methods). In an alternative implementation, the data system 1 can include a proxy MMSC (not shown), in which case the terminal settings could be modified such that all messages are sent to the proxy MMSC in the first instance. The update engine 201 would then transmit the message settings (presentation and advertisement) to the proxy MMSC instead of to the server S 1 . In this variant the proxy MMSC would include the selecting and modifying functionality described above, and be arranged to forward the modified messages to the operator's MMSC 11 as described above.
A particularly convenient use for embodiments of the invention is in public venues such as festivals, shows and the like, since embodiments can be used to distribute venue specific information transparently to mobile terminals associated with attendees of the festival. Several application servers such as server S 1 could be located at various points within the venue and the server S 1 be arranged to transmit application, advertisement and content data wirelessly to the terminals. Preferably the data are transmitted using BLUETOOTH, since this provides a convenient and location dependent means of controlling content delivery. Each such server S 1 could be arranged to access a database DB 1 , the content of which has preferably already been updated to store advertisement data relating to the sponsors of the event; in addition third party servers, such as S 2 , S 3 , S 4 could upload data to the database DB 1 and server S 1 by sponsors of, and during, the event. Mobile terminals entering the vicinity of server(s) S 1 could receive application 10 , wirelessly, together with data to be invoked and displayed by the application 10 and alert the user of the mobile terminal as to various products, services and demonstrations on offer within the venue. Other possible uses of embodiments of the invention include airports, retail stores (in particular supermarkets), libraries and the like.
The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. | Embodiments of the invention are concerned with a method and a system for distributing mobile applications, in particular to aspects of receiving, processing and displaying advertisements on mobile terminals. In one aspect, embodiments provide a software component for controlling movement for an advertisement image on a mobile terminal, the mobile terminal comprising a display area and a processor, the software component comprising processable instructions defining movement of the advertisement image relative to the display area, wherein the instructions are wirelessly transmissible to the mobile terminal and the processor is arranged to process said instructions in order to more the advertisement image. | 7 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/143,407 filed Jan. 8, 2009 entitled “Probe Apparatus for Recognizing Abnormal Tissue”, the entire contents of which is incorporated by reference herein.
[0002] This application is related to co-pending U.S. patent application Ser. No. 11/604,653 filed Nov. 27, 2006, entitled “Method of Recognizing Abnormal Tissue Using the Detection of Early Increase in Microvascular Blood Content”, the disclosure of which is incorporated in its entirety by reference, which application claims priority to U.S. Application No. 60/801,947 entitled “Guide-To-Colonoscopy By Optical Detection Of Colonic Micro-Circulation And Applications Of Same”, which was filed on May 19, 2006, the contents of which are expressly incorporated by reference herein.
[0003] This application is also related to co-pending U.S. patent application Ser. No. 11/604,659 filed Nov. 27, 2006 and entitled “Apparatus For Recognizing Abnormal Tissue Using The Detection Of Early Increase In Microvascular Blood Content,” the contents of which are expressly incorporated by reference herein.
[0004] This application is also related to co-pending U.S. patent application Ser. No. 11/261,452 entitled “Multi-Dimensional Elastic Light Scattering”, filed Oct. 27, 2005, the contents of which are expressly incorporated herein by reference.
[0005] Some references, which may include patents, patent applications and various publications, are cited and discussed in the description of this invention. The citation and/or discussion of such references is provided merely to clarify the description of the present invention and is not an admission that any such reference is “prior art” to the invention described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference.
FIELD OF THE INVENTIONS
[0006] The present invention relates generally to light scattering and absorption, and in particular to probe apparatuses and component combinations thereof that are used to screen for possibly abnormal living tissue
BACKGROUND
[0007] Optical probes are known that detect optical signals. Simple optical probes will transmit broadband or a laser light to a target with one optical fiber, and receive the light such as light that is elastically scattered from a specimen, fluorescent light, Raman scattered light, etc., with another optical fiber. The received backscattered light can be channeled to a receiver, such as a CCD array, and the spectrum of the signal is recorded therein.
[0008] While such probes work sufficiently for their intended purposes, new observations in terms of the type of measurements that are required for diagnostic purposes have required further enhancements and improvements.
SUMMARY
[0009] The present inventions relates generally to light scattering and absorption, and in particular to probe apparatuses and component combinations thereof that are used to recognize possibly abnormal living tissue.
[0010] In one aspect, the embodiments described herein are directed toward an apparatus that emits broadband light obtained from a light source onto microvasculature of tissue, particularly in a mucosal tissue layer disposed within a human body, and receives interacted light that is obtained from interaction of the broadband light with the microvasculature for transmission to a receiver.
[0011] In another aspect, the embodiments described herein are directed toward a apparatus that emits broadband light obtained from a light source onto tissue disposed within a human body, particularly in a mucosal tissue layer disposed within a human body, and receives interacted light that is obtained from interaction of the broadband light with the microarchitecture tissue for transmission to a receiver.
[0012] In a particular aspect, a disposable, finger mounted optical probe is described.
[0013] In a further embodiment, an optical probe that contains a disposable tip with a retractable integral probe is disclosed.
[0014] Different further embodiments of both the disposable, finger mounted optical probe and the optical probe that contains the disposable tip with the retractable integral probe are described which include various combinations of optical fibers, polarizers and lenses that assist in the selection of a predetermined depth profile of interacted light for a variety of different wavelength ranges of light, and for different applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures, wherein:
[0016] FIGS. 1 and 2 illustrate a housing of a disposable, finger mounted optical probe according to one embodiment.
[0017] FIG. 3 illustrates a disposable tip and re-usable trunk usable in one embodiment of the disposable, finger mounted optical probe.
[0018] FIGS. 4( a )-( b ) illustrate another embodiment of the disposable, finger mounted optical probe containing a pre-loaded optical assembly.
[0019] FIGS. 5 a - 5 c are illustrations of the method of use of the disposable, finger mounted optical probe.
[0020] FIGS. 6A , B( 1 )-( 2 ) and C show usage of an embodiment of an optical probe that contains a permanent housing and disposable tip with retractable integral optical fibers.
[0021] FIG. 7 illustrates a partial illustration of a particular embodiment of an optical probe that contains a permanent housing and a disposable tip assembly with a retractable integral optical fiber assembly.
[0022] FIG. 8 illustrates a partial illustration of another particular embodiment of an optical probe that contains a permanent housing and disposable tip assembly with a retractable integral optical fiber assembly.
[0023] FIG. 9 illustrates a particular embodiment of a disposable tip that includes a protective sheath that is used with the optical probe that contains a permanent housing and disposable tip assembly with a retractable integral optical fiber assembly.
[0024] FIG. 10 illustrates a partial illustration of a further particular embodiment of an optical probe that contains a permanent housing and disposable tip assembly with a retractable integral optical fiber assembly and an integral CCD module.
[0025] FIG. 11 illustrates a particular optical probe assembly configuration used for EIBS.
[0026] FIG. 12 illustrates another particular optical probe assembly configuration used for EIBS.
[0027] FIG. 13 illustrates a further particular optical probe assembly configuration used for EIBS.
[0028] FIG. 14 illustrates in cross section an embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 .
[0029] FIG. 15 illustrates in cross section a further embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 .
[0030] FIG. 16 illustrates a particular optical probe assembly configuration used for LEBS.
[0031] FIG. 17 illustrates another particular optical probe assembly configuration used for LEBS.
[0032] FIG. 18 illustrates a further particular optical probe assembly configuration used for LEBS.
[0033] FIG. 19 illustrates a further particular optical probe assembly configuration used for LEBS.
[0034] FIG. 20 illustrates a further particular optical probe assembly configuration used for LEBS.
[0035] FIGS. 21( a ) and ( b ) illustrate in cross section an embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 .
[0036] FIG. 22 illustrates in cross section a further embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] The present inventions are more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Various embodiments are now described in detail. Referring to the drawings, like numbers indicate like components throughout the views. As used in the description herein, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. Moreover, titles or subtitles may be used in the specification for the convenience of a reader, which shall have no influence on the scope of the present invention. Additionally, some terms used in this specification are more specifically defined below.
[0038] The terms used in this specification generally have their ordinary meanings in the art, within the context of the invention, and in the specific context where each term is used. Certain terms that are used to describe the invention are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the invention, For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, not is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification.
[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In the case of conflict, the present document, including definitions will control.
[0040] As used herein, “around”, “about” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around”, “about” or “approximately” can be inferred if not expressly stated.
[0041] The present invention, in one aspect, relates to a probe apparatus that is used for optically screening a target for tumors or lesions. Various targets and corresponding optical probe types are disclosed, as well as various different probe housing designs are disclosed, and combination of them can be used interchangeably. Certain of the optical probe designs are for use in detecting what is referred to as “Early Increase in microvascular Blood Supply” (EIBS) that exists in tissues that are close to, but are not themselves, the lesion or tumor. Other of the LEBS (Low-coherence Enhanced Backscattering) optical probe designs are for use in detecting backscattered light that results from the interaction of low-coherent light with abnormal scattering structures in the microarchitecture of the tissue that exist in tissues that are close to, but are not themselves, the lesion or tumor. Both of these optical probe types, which have been described in applications previously filed and which are, as a result, known. As will be described herein, whether detection is made using the techniques associated with EIBS or LEBS probes and microarchitecture of the tissue, the probes as described herein, while normally made for usage with one of these techniques, will have aspects that are common between them.
[0042] One difference between a probe that detects EIBS and an LEBS probe that detects tissue microarchitecture is that with an probe that detects EIBS, data from a plurality of depths can be obtained in one measurement by looking at co-pol and cross-pol and co-pol minus cross-pol received signals, whereas for an LEBS probe, only one depth is obtained for a specific configuration.
[0043] A particular application described herein is for detection of such lesions in colonic mucosa in early colorectal cancer (“CRC”), but other applications such as pancreatic cancer screening are described as well.
[0044] The target is a sample related to a living subject, particularly a human being. The sample is a part of the living subject, such that the sample is a biological sample, wherein the biological sample may have tissue developing a cancerous disease.
[0045] The neoplastic disease is a process that leads to a tumor or lesion, wherein the tumor or lesion is an abnormal living tissue (either premalignant or cancerous), which for the probes described herein is typically a colon cancer, an adenomatous polyp of the colon, or other cancers.
[0046] The measuring step is performed in vivo using the probes described herein and may further comprise the step of acquiring an image of the target. The image, obtained at the time of detection, can be used to later analyze the extent of the tumor, as well as its location.
[0047] In the various embodiments, the probe projects a beam of light to a target that has tissues and/or blood circulation associated therewith, depending upon the target type. Light scattered from the target is then measured, and target information is obtained from the measured scattered light. The obtained target information can be information for the targets as described in the patent applications incorporated by reference above, as well as the data related to blood vessel size and oxygenated hemoglobin as described in U.S. patent application Ser. No. 12/350,955 filed Jan. 8, 2009 entitled “Method Of Screening For Cancer Using Parameters Obtained By The Detection Of Early Increase In Microvascular Blood Content” filed on this same day, bearing Attorney Docket Number 042652-0376943.
[0048] The beam of light projected is obtained from a light source that may comprise an incoherent light source (such as a xenon lamp, light emitting diode, etc).
[0049] In all of the embodiments described herein, there is at least one first type fiber comprises an illumination fiber, wherein the illumination fiber is optically coupled to the light source.
[0050] There is also at least one second type fiber formed with one or more collection fibers, wherein the one or more collection fibers are optically coupled to a detector, such as an imaging spectrograph and a CCD at the distal end portion, which imaging spectrograph is used to obtain an image of the target and obtain detected data therefrom.
[0051] The following further details of the preferred embodiments that will further describe the invention. Without intent to limit the scope of the invention, exemplary instruments, apparatus, methods and their related results according to the embodiments of the present invention are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the invention. Moreover, certain theories are proposed and disclosed herein; however, in no way they, whether they are right or wrong, should limit the scope of the invention so long as the invention is practiced according to the invention without regard for any particular theory or scheme of action.
[0052] The optical probes described herein can be used in-vivo to take optical measurements of tissue, such as just inside the rectum to assess a patient's risk of colon cancer. If rectal, the rectally inserted probe for analysis of rectal mucosa provides a means of assessing a patient's risk of developing colon cancer without the need for colonoscopy or colon purging.
[0053] In order to facilitate the acquisition of such a measurement, the probes described herein are necessarily introduced into a patient's colorectal vault via an insertion device such as a colonoscope, an upper GI therapeutic scope (a device which is generally known), a disposable, finger mounted device, or an optical probe that contains a permanent housing and disposable tip with retractable integral optical fibers, the latter of which are further described herein.
[0054] For clinical evaluation of a colon, the probe is inserted into the rectum to establish contact with the colorectal mucosal wall, perform optical measurements as needed, and is then removed. The probes described further herein provide an insertion device for guiding the probe on a pathway through the rectum to reach the colo-rectal mucosal wall, while shielding the probe tip from possible blockage caused by loose stool that the probe may encounter. While contacting the colorectal mucosal wall, the insertion device then allows the optical portion of probe to extend some distance out of the tip of the insertion device and perform optical measurements as needed.
[0055] The optical probes with insertion devices as described further herein contain components that are partially or entirely disposable, since for health reasons certain components are not readily used in multiple different patients.
[0056] FIGS. 1-3 illustrate a housing 110 of a disposable, finger mounted optical probe 100 according to one embodiment, which is a semi-flexible component that includes a finger loop 116 worn over the physicians finger. As shown in FIG. 3 , incorporated within the housing 110 is a complete optical probe 120 , including a re-usable trunk 140 and disposable tip 130 , described further herein, which are connected together by some type of engagement mechanism, such as threads on both the tip assembly 130 and the trunk assembly 140 . This finger mounted optical probe 100 is inserted into the patient's rectum mounted on the finger of the physician, allowing for passage of the optical probe 120 to the mucosal wall for measurement acquisition while shielding from potential loose stool both the optical probe, and particularly the optical components of the optical probe 120 that are disposed within the disposable tip 130 .
[0057] The housing 110 of the disposable, finger mounted optical probe 100 is sufficiently lubricious to provide for easy passage of optical fibers through internal lumen 112 , and on its outer surface for non-lubricated device insertion into a patient's rectum. The housing may be made of liquid injection molded silicone rubber or similar material. Further, a parylene-N coating may be added to some or all surfaces of the housing 110 to increase overall lubricity for ease of feeding of probe through inner lumen, and insertion into the patient.
[0058] The outer front surface of the housing 110 preferably includes a perforated membrane 114 that shields the probe tips from loose stool that may be encountered within the patient, through which the probe tip can pass through just prior to acquisition of optical measurement on the mucosal wall, as described herein, though such a perforated membrane 114 is not necessarily needed.
[0059] Further, the disposable, finger mounted optical probe 100 will preferably either have: 1) a pre-formed geometry/curvature such that it can be guided to the proper location in the colo-rectal mucosal anatomy, 2) sufficient flexibility such that the physician can bend and/or manipulate it to the same area for optical measurement, or 3) some combination of both aforementioned attributes. If preformed, the probe 100 preferably has flexibility such that it could be inserted in a straight fashion, and shape memory such that it would retake its original shape once fully inserted into patient's colorectal vault.
[0060] The probe 100 as illustrated in FIG. 1-3 allows for pass through of a fully assembled optical probe. This embodiment require the disposable tip 130 to be attached to the reusable trunk 140 prior to insertion. The disposable tip 130 is clean or sterile when initially used prior to insertion, and also includes attached thereto a hygienic sheath 150 that acts as a hygienic shield to cover the reusable trunk 140 , which need not be sterile or sterilized when used. The hygienic sheath 150 may be made of a sterile thin polyethylene film or similar material.
[0061] FIGS. 4( a )-( b ) illustrate another embodiment of the disposable, finger mounted optical probe 100 A containing a pre-loaded optical assembly. In this embodiment, the housing 110 and the lumen 112 therein provides for pre-loading of an optical assembly 160 , such that the re-usable trunk (as described with reference to FIG. 3) will connect to the optical assembly 160 (essentially the same as the disposable tip 130 ) within the lumen 112 , and the entire assembly, once connected, can then continue to be positioned by moving through the lumen 112 , and eventually out through any perforated membrane 114 . As shown in FIG. 4( b ), the optical assembly, in one embodiment, may include a lens mount 162 , a rolling diaphragm 164 that provides fixturing of the optical assembly and a hygienic seal This hygienic seal can be simply a narrowing of the lumen such that the lens mount 162 fits tightly around the optical assembly to prevent fluid from flowing backward but is not so tight as to prevent the optical assembly from sliding forward and back, and a lens 166 , though other components, such as polarizers and spacers, can also be used within optical assembly 160 .
[0062] In the embodiment of FIG. 4 , the hygienic sheath is preferably attached to the disposable housing 110 at the entry end 118 of the housing, though the sheath is not shown in the Figure, though it could also be attached within the lumen 112 and be part of the optical assembly 160 to address the possibility of cross-contamination. This sheath would extend back to cover all non-disposable surfaces of the probe assembly which may be manipulated by the physician. The finger-mounted insertion device 100 A is preferably entirely disposable, and intended for single-use. An advancement assist ring 116 may be permanently attached to the optical probe to facilitate single handed probe insertion.
[0063] Measurement acquisition may be initiated by a foot pedal connected to an instrumentation unit, a button built into the reusable portion of the probe assembly, or some other mechanism. If blind measurement acquisition and/or insertion is not deemed acceptable, a forward viewing CCD or CMOS camera module may be designed into the device, with camera residing in the reusable probe trunk, and window built into the disposable insertion device, as shown in FIG. 10 .
[0064] FIGS. 5 a - 5 c are illustrations of the method of use of the disposable, finger mounted optical probe 100 . In use, the probe assembly 120 , formed of the re-usable trunk 140 and the disposable tip 130 , is inserted into the housing 110 as shown, and an advancement assist ring 180 , permanently attached to the re-usable trunk 140 , will attach to the end 118 of the housing 110 . As shown in FIGS. 5A and 5B , the sheath 150 is pulled back so that it extends sufficiently below the sterile gloved hand of the physician to provide a sterile environment for the patient. As shown in FIG. 5C , the disposable tip 130 of the probe assembly 120 is pushed through the perforated membrane 114 at the time the measurement is taken.
[0065] FIGS. 6 A( 1 )-( 2 ), B and C show usage of an embodiment of an optical probe 200 that contains a permanent housing 210 and a disposable tip assembly 220 with retractable integral optical fiber assembly 220 (essentially the same as the optical assembly 120 that is formed of the disposable tip 130 and the re-usable trunk 140 as described in the FIG. 3 embodiment above), as well as an overall view of this embodiment. In all of the embodiments there exist the permanent housing 210 , which preferably includes thereon a trigger activation button 212 , a grip 214 for holding in the physician hand, and a roller wheel 216 or similar element integrated into the housing 210 to facilitate single-handed probe advancement, as shown in FIG. 6A . FIGS. 6 B 1 and 6 B 2 show at a high level both the connection of the disposable tip assembly 230 to the re-usable trunk assembly 240 , as well as the unwrapping of the protective sheath 250 over the exterior of the housing 210 . It is noted that in FIG. 6A the sheath 250 is only shown unrolled on the insertion portion 260 , but preferably the sheath 250 will extend below the entire housing 210 . FIG. 6C provides close up views of the disposable tip assembly 230 , and shows both a CCD forward viewing window 270 for a CCD array disposed therebehind (not shown here, though components illustrated in FIG. 10 can work herein), as well as the perforated membrane 280 through which the disposable tip 220 assembly will be moved when the measurement is taken. In use, the insertion portion 260 is inserted into the patient's rectum, with the grip 214 of the housing 210 held by the physician, allowing for internal optical assembly to be positioned on the mucosal wall while shielded from potential loose stool. This allows for advancement of the internal optical probe assembly, including the lens as described hereinafter, out of the protective cap associated with the disposable tip assembly 220 , and onto the patient's colo-mucosal wall for measurement acquisition.
[0066] In a preferred implementation, the housing 210 a two-piece, rigid injection molded handle comprised of ABS (Acrylonitrile butadiene styrene) or similar material. Further, an overmolded soft-touch material such as Pebax or Hytrel may comprise the insertion portion 260 . The disposable tip assembly 230 in this configuration may be comprised of a similar soft-touch material overmolded soft-touch material such as Pebax or Hytrel. The hygienic sheath 250 attached to the lens mount 238 within disposable tip assembly 230 may be made of a thin polyethylene film or similar material.
[0067] It is noted that it may be that a sheath 250 isn't used, and the insertion portion 260 is sterilized after each use. In such a use, the insertion portion 260 is preferably lubricious enough on its outer surfaces for non-lubricated device insertion into a patient's rectum.
[0068] Further, this probe 200 also preferably has 1) a pre-formed geometry/curvature such that it locates the internal optical assembly, and particularly the optical tip, onto proper location in the colo-rectal mucosal anatomy, and 2) sufficient flexibility such that the physician could bend and/or manipulate the device to the same area for optical measurement. The probe 200 is sufficiently flexible such that it can be inserted in a straight fashion, and has shape memory such that it retakes its original shape once fully inserted into patient's colorectal vault.
[0069] FIG. 7 illustrates a partial illustration of a particular embodiment of an optical probe 200 A, with only the optical components shown, not the sheath 250 and lower part of the housing 210 . The shown semi-flexible insertion portion 260 contains therein the retractable integral optical fiber assembly 220 , formed of the disposable tip assembly 230 and the trunk assembly 240 . As shown the trunk assembly 240 will contain an outer sheath 248 , which preferably includes at the distal end a protrusion ring 242 , which abuts a similar protrusion ring 262 associated with the insertion portion of the housing 210 . Also associated with the re-usable trunk assembly 240 is a springing engaging mechanism 244 for the optical components of the disposable tip assembly 230 to connect in an aligned manner, as well as, in certain configurations, other optical components 246 , such as a polarizer or protective cover. Other engagement mechanism, such as threads on both the tip assembly 230 and the trunk assembly 240 can be used.
[0070] The disposable tip assembly 230 contains a protective cap 231 that has an alignment element 233 and perforated membrane 236 , described further herein, that maintains the lens mount 238 in place prior to connection to the optical fiber trunk assembly 240 . As shown in FIG. 9 , the disposable tip assembly also preferably has attached thereto the sheath 250
[0071] The lens mount 238 will contain a lens 232 , such as a GRIN lens, a ball lens, an achromatic doublet lens, etc can be used, disposed therein or as part of a one-piece assembly, as well as an alignment member 234 that engages with the alignment element 233 . The alignment member 234 in one embodiment is a channel into which a protrusion that is the alignment element 233 fits. Once the disposable tip assembly 230 , and specifically the lens mount 238 , is connected to the trunk assembly 240 , and the engaging mechanism 244 , the entire optical assembly 220 is moved through the rectum to the measurement point. At that time, the optical fiber assembly 220 can be slightly rotated and moved forward, so that the lens mount 238 , via the alignment member 234 , is guided by the alignment element 233 , so that the lens 232 can protrude through the perforated membrane 236 .
[0072] FIG. 8 illustrates a partial illustration of a particular embodiment of an optical probe 200 B, with only the optical components shown, not the sheath 250 and lower part of the housing 210 . In this embodiment, as shown the disposable tip assembly 230 does not contain a front face to the protective cover 231 or a perforated member, and as such the lens 232 , mounted in the lens mount 238 , is exposed. Otherwise, the elements shown in FIG. 8 are the same as those described previously with respect to FIG. 7 . Since the lens 232 is pre-exposed, the probe 200 B does not required advancement of retractable integral optical fiber assembly 220 to break through any protective cap membrane. Thus, once inserted and put into contact with the patient's colo-mucosal wall, the probe 200 B is immediately ready for measurement acquisition.
[0073] If blind insertion is not deemed acceptable, a forward viewing CCD camera may be designed into the device, with camera residing in the tip of reusable portion of the wand, and window built into the disposable wand tip, as shown in FIG. 10 . As shown, the disposable tip assembly 230 is modified by including the glass viewing cover 237 as part of the protective cap 231 , and the probe 200 further includes a CCD or CMOS module, as will as an image return wiring 292 as needed. Depending on the configuration, the CCD or CMOS module may include battery power, may be powered via wires for the power, and/or the power and/or image signals may be transmitted wirelessly using various conventional data and short range power transmission schemes.
[0074] Different penetration depths are implemented with these probes in a variety of ways. Different fibers and/or disposable tips can be used (in some instances with different probes, in other instances all within the same probe) in order to achieve the desired results. For probes that detect EIBS in particular, the choice of the spacing between the fiber termination and lens (e.g. nominally 1 focal length but could be more or less) and selection of the lens type and focal length adjustment depth can be used to achieve different penetration depth. For LEBS probes that detect tissue microarchitecture, the selection of the lens and the distance from the termination of the fibers to the lens or the length of the glass spacer determine the special coherence length of light, which will vary the penetration depth.
[0075] In use, depending upon the target and the application, each probe may take multiple measurements, and the detected data from each measurement stored for subsequent usage. Typically a number of different measurement locations, such as 3-6, but not typically greater than 10 will be made. Depending on the probe or the manner in which the probe is used, various different penetration depths may then be sensed at each measurement location.
[0076] FIG. 11 illustrates a particular optical probe assembly configuration used for EIBS. FIG. 12 illustrates another particular optical probe assembly configuration used for EIBS. It is noted that the lens mount and polarizer mount may be combined to form a single component. FIG. 13 illustrates a further particular optical probe assembly configuration used for EIBS. It is noted that the lens mount and polarizer mount may be combined to form a single component. In each of FIGS. 11 , 12 and 13 , the components are identified, and they together show that various combinations of components can be used: certain embodiments may or may not have polarizers, spacers and different numbers of optical fibers can also be used. In this regard, reference is made to the previously filed U.S. patent application Ser. No. 11/604,659 filed Nov. 27, 2006 and entitled “Apparatus For Recognizing Abnormal Tissue Using The Detection Of Early Increase In Microvascular Blood Content.”
[0077] FIG. 14 illustrates in cross section an embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 .
[0078] FIG. 15 illustrates in cross section a further embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 , and shows a decentering or making the fibers slightly asymmetric with respect to the probe center to minimize reflections. This could be used on any probe designs that detect EIBS described herein.
[0079] FIG. 16 illustrates a particular optical probe assembly configuration used for LEBS. FIG. 17 illustrates another particular optical probe assembly configuration used for LEBS. FIG. 18 illustrates a further particular optical probe assembly configuration used for LEBS. FIG. 19 illustrates a further particular optical probe assembly configuration used for LEBS. FIG. 20 illustrates a further particular optical probe assembly configuration used for LEBS. In both of the FIG. 19 and FIG. 20 probe designs, no lens is used but the solid glass spacer ( FIG. 20 ) or air gap with coverglass ( FIG. 19 ) between the fiber terminations and the tissue selects a specific (and predetermined) spatial coherence length that corresponds to a desired depth. This lensless concept that uses a fix-distance spacer (air or glass) can be used to establish a spatial coherence length. In the other embodiments, the components are identified, and they together show that various combinations of components can be used: certain embodiments may or may not have polarizers, spacers and different numbers of optical fibers can also be used.
[0080] FIGS. 21( a ) and ( b ) illustrate in cross section an embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 .
[0081] FIG. 22 illustrates in cross section a further embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 . FIG. 22 shows a decentering or making the fibers slightly asymmetric with respect to the probe center to minimize reflections. This could be used on any LEBS probe designs described herein. This gives a potential advantage in that internal reflections off surfaces (e.g. the lens/tissue interface, air/lens interface, etc) will be reflected elsewhere away from the fibers.
[0082] The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. | The present invention relates to probe apparatuses and component combinations thereof that are used to recognize possibly abnormal living tissue using a detected early increase in microvascular blood supply and corresponding applications. In one embodiment there is disclosed an apparatus that emits broadband light obtained from a light source onto microvasculature of tissue disposed within a human body and receives interacted light that is obtained from interaction of the broadband light with the microvasculature for transmission to a receiver. Different further embodiments include combinations of optical fibers, polarizers and lenses that assist in the selection of a predetermined depth profile of interacted light. In another embodiment, a kit apparatus is described that has various probe tips and/or light transmission elements that provide for various combinations of predetermined depth profiles of interacted light. In a further embodiment, a method of making a spectral data probe for depth range detection selectivity for detection of blood within microvasculature of tissue is described. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention relates to an improved portable wall system incorporating one or more portable panels having support means along the bottom edge for movable supporting engagement with a floor surface to facilitate movement of the panel and extendible and retractable floor surface engaging means at the lower edge of the panel and spring biased extendible and retractable ceiling surface engaging means at the upper edge thereof to provide for easy installation of the panels in a desired location and to facilitate movement of the panels along a floor surface.
2. Description of the Prior Art
Movable partitions, panels, room dividers and the like for dividing an enclosed space into smaller spaces or enclosing a space or otherwise providing a partition are generally well known and usually include a panel having requisite physical characteristics required by the particular installation and structures for releasably securing the panels between a floor surface and a ceiling. Such panels are frequently constructed of standard size modules which are relatively heavy and awkward to handle. Also, in some instances, the vertical height of the panels is increased or decreased to secure them in position with the increase in vertical height sometimes resulting in damage to or displacement of the ceiling surface, particularly if the ceiling surface is formed by acoustical tile or the like or if the ceiling surface is in the form of a drop ceiling. Prior U.S. patents illustrative of the development in this field of endeavor are as follows:
U.S. Pat. Nos. 2,742,675 filed on 4/24/56; 2,886,147 filed on 5/12/59; 2,945,568 filed on 7/19/60; 2,962,132 filed on 11/29/60; 3,174,593 filed on 3/23/65; 3,335,532 filed on 8/15/67; 3,400,504 filed on 9/10/68; 3,453,790 filed on 7/8/69; 3,753,328 filed on 8/21/73; 3,967,420 filed on 7/6/76.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a portable wall system in the form of a plurality of portable wall panels with each panel including supporting means along the lower edge thereof to enable moving supporting engagement with a floor surface and a structure to increase or decrease the effective vertical height of the panel to facilitate installation of the panels between a floor and a ceiling and removal of the panel from a position between a ceiling and floor as well as movement of the panel along a supporting surface to a desired location.
Another object of the invention is to provide a wall panel in accordance with the preceding object in which the lower edge of the wall panel is provided with a vertically extending and retracting seal member of generally channel shaped configuration telescoped in relation to the lower edge of the panel with mechanical devices inter-connecting the lower edge of the panel and the channel shaped member for extending and retracting the channel shaped member in relation to the lower edge of the panel for changing the effective vertical heighth of the panel.
Still another object of the invention is to provide a wall panel in accordance with the preceding objects in which the upper edge of the panel is provided with a spring biased ceiling engaging member generally of U-shaped configuration telescopic in relation to the upper edge of the panel and spring biased in relation thereto with the spring bias being a relatively small force so that the force exerted on the ceiling will not damage the ceiling surface or displace ceiling components retained in position by gravity or the like.
Yet another object of the invention is to provide wall panels in accordance with the preceding objects in which the structure supporting the lower edge of the panel for movement along a floor surface is in the form of a rotatable ball member, caster wheel, caster device or fixed axis wheel arrangements.
Still another important feature of the invention is to provide a portable wall system including wall panels in which the side edges of the panels and the walls of an enclosure or the like are provided with inter-engaging means for retaining the panels in alignment with each other with each of the panels including a peripheral seal for providing isolation of one surface of the panel from the other and thus preventing transfer of heat, light and sound from one side of the panel or portable wall to the other.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the portable wall system of the present invention installed in an enclosed space.
FIG. 2 is a vertical sectional view, on an enlarged scale, taken substantially upon a plane passing along section line 2--2 of FIG. 1 illustrating the structural details of a portable wall panel employed in the wall system.
FIG. 3 is a transverse, plan sectional view, on an enlarged scale, taken substantially upon a plane passing along section line 3--3 of FIG. 1.
FIG. 4 is a sectional view, similar to FIG. 3 but taken along section line 4--4 of FIG. 1.
FIG. 5 is an enlarged end elevational view of the upper edge portion of one of the wall panels.
FIG. 6 is an enlarged front elevational view, with portions broken away, of the lower corner portion of a wall panel.
FIG. 7 is a vertical sectional view taken substantially upon a plane passing along section line 7--7 of FIG. 6 illustrating further structural details of the ball caster support and the associated channel shaped member having seals along the bottom edge thereof.
FIG. 8 is a sectional view, similar to the upper portion of FIG. 2 but illustrating a modified form of structure mounted on the ceiling for telescopic engagement with the upper edge of the wall panel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now specifically to the drawings, the portable wall system of the present invention is generally designated by the numeral 10 and includes a plurality of wall panels 12 arranged in vertical orientation and horizontal alignment to form a partition, room divider or portable wall between a floor surface 14 and a ceiling surface 16 with the portable panels 12 extending between vertical side walls 18 and 20 of an enclosed space or the like. The wall panels 12 may be constructed of any desired standard size modules and may be constructed of various sizes to be installed in spaces having different heighth dimensions or width characteristics.
Each wall panel 12 includes a pair of planar panel members 22 and 24 disposed in spaced parallel relation to each other and secured to a peripheral frame 26. The panel members 22 and 24 may be constructed of wood, plastic, metal or any other material used in constructing walls and provided with any external ornamentation or appearance characteristics as desired. For example, various types of wallboards, laminated panels, flake board or the like may be used for this purpose with insulating material therebetween if desired with the overall thickness of the panel 12 being varied as desired so that the physical characteristics of the panels 12 will be compatible with the enclosed space in which the panels are used and be capable of being moved to a desired location and handled by individuals. The peripheral frame 26 is of channel shaped configuration with the bight portion thereof disposed inwardly and the two legs extending to a point adjacent the periphery of the panel members 22 and 24 and being secured thereto in any suitable manner with the peripheral frame 26 being preferably in the form of extruded channel shaped members with the channel shaped frames 26 in the vertical edges of the panels having their webs disposed generally flush with the periphery of the panel members 22 and 24. The specific construction of the panel members and the specific construction of the frame supporting these panel members may be varied and in and of itself does not constitute an essential element of the present invention.
The upper edge of the panel 12 is provided with a spring biased, inverted channel shaped seal assembly generally designated by numeral 28 for engaging the ceiling surface 16. The lower edge of the panel 12 is provided with a similar type of channel shaped seal assembly 30 which is vertically extendible and retractable for sealing engagement with the floor surface 14. Also, the lower edge of the panel 12 is provided with a plurality of supporting assemblies generally designated by numeral 32 for movable supporting engagement with the floor surface 14. The channel shaped floor engaging seal assembly 30 is vertically extended and retracted by an elevating and lowering mechanism generally designated by numeral 34.
The floor engaging supporting assembly includes a balltype caster 36 journalled in a housing 38 fixedly supported on a bracket 40 by a nut and bolt assembly 42. The bracket 40 is fixedly secured to the channel shaped peripheral frame 26 by suitable screw threaded fasteners 44 or the like. A plurality of the ball caster type supporting assemblies are provided on each panel with each panel including at least two of the ball casters 36 for rolling contact with the floor surface 14 to facilitate movement of the panels 12 along the floor surface 14 to enable an individual to roll the panel 12 to a desired location when the panel has a vertical heighth less than the distance between the floor and ceiling.
The floor engaging seal assembly 30 includes a channel shaped member 46 having a bight portion 48 paralleling the floor surface 14 and a pair of parallel legs 50 extending upwardly toward the panel members 22 and 24 as illustrated in FIGS. 2 and 7. The lower surface of the bight portion 48 is provided with a pair of depending sealing members 52 in the form of a multiple blade sweeping or gripping member constructed of vinyl, rubber or the like for engagement with the floor surface 14 at a plurality of parallel lines of engagement. The legs 50 of the U-shaped member 46 are telescoped between a pair of depending strips 54 which form the outer components of an H-shaped member 56 having the web portion 58 thereof extending across the bottom edges of the panel members 22 and 24 and the peripheral frame 26 as illustrated FIGS. 2 and 7. The bottom inner edge of each strip 54 is provided with a vinyl seal 60 and the upper outer surface of each leg 50 is provided with a similar seal 62 thus forming a continuous seal between the panel 12 and the floor surface 14 when the sealing strips 52 are in engagement with the floor 14.
The elevating and lowering mechanism 34 includes an elongated threaded bolt 64 having its lower end swivelly connected to the bight portion 48 of the U-shaped member 46 as indicated by reference numeral 66. The swivel connection may be of any suitable detachable type of connection which rotatably connects the bolt 64 to the bight portion 48 of the U-shaped member 46. The bolt 64 extends up through an aperture 68 in the web 58 and the bolt 64 is threaded through a thread block 70 fixedly secured in the peripheral frame 26 as illustrated in FIGS. 2 and 6. The upper end of the bolt 64 is provided with a polygonal head 72 disposed in a recess 74 formed in the panel 12 in which the recess is defined by a box-like housing 76 extending inwardly from the outer surface of the panel member 24 so that the recess 74 is open to the exterior surface of the panel member 24 thereby providing access to the head 72 of the bolt 64 so that the bolt 64 can be rotated by a suitable powered wrench, manual ratchet wrench or the like. Thus, by rotating the bolt 64, the U-shaped member 46 may be elevated and lowered. When the U-shaped member 46 is lowered, as illustrated in FIG. 2, the bight portion 48 and the seals 52 thereon are positioned below the ball caster 36 and the ball caster 36 is elevated out of contact with the floor surface 14. When the U-shaped member 46 is elevated, as illustrated in FIGS. 6 and 7, the aperture 49 in bight portion 48 enables the bight portion 48 and the sealing strips 52 to be elevated above the lower periphery of the ball caster 36 so that the panel 12 then will be rollingly supported on the floor surface. As illustrated, two of the elevating and lowering mechanisms 34 are provided and they are positioned adjacent the supporting assemblies 32 as illustrated in FIG. 6.
The ceiling engaging seal assembly 28 includes an inverted U-shaped member 78 having a bight portion 80 and a pair of parallel depending legs 82. The legs 82 are telescopically received between two parallel strips 84 forming a portion of an H-shaped member 86 having a web 88 extending transversely of the upper edges of the panel members 22 and 24. The upper inner surfaces of these strips 84 have a sealing strip 90 thereon and the lower outer surfaces of the legs 82 have a sealing strip 92 thereon. The bight portion 80 is provided with sealing strips 94 of the type having multiple sealing edges for engaging the ceiling surface 16 thereby providing a continuous seal for the upper end of the panel 12. A threaded bolt 96 extends down through the bight portion 80 and threads through a thread block 98 secured in the peripheral frame 26. A coil spring 100 encircles the bolt 96 and has its lower end engaged with the web 88 and its upper end engaged with the bight portion 80 of the U-shaped member 78 thus spring biasing the U-shaped member 78 upwardly. The coil spring 100 has widely spaced convolutions and is capable of exerting only a relatively small force against the U-shaped member 78 which is sufficient to retain the channel shaped member and the seals thereon against the ceiling but not sufficient to damage the ceiling. The upper end of the bolt 96 is provided with a polygonal head 102 which enables adjustment of the threaded bolt 96 through the thread block 98 which is capable of floating vertically in the peripheral frame 26 so that the bolt 96 and the U-shaped member 78 will move downwardly in unison when upward pressure is exerted thereon by lowering of the lower seal assembly 30. Since the spring 100 will provide a "light touch" of the seal strips 94 with the ceiling surface 16, downwardly opening U-shaped clips, tracks or guides 104 are secured to the ceiling 16 in the location where the wall 10 is to be installed with the downwardly opening channels 104 receiving the polygonal head 102 of the bolts 96 as illustrated in FIGS. 2 and 5 so that the wall 10 does not rely upon the vertical elongation of the panels 12 jamming the upper and lower edges against the ceiling and floor respectively which could damage the ceiling structure when the ceiling is constructed with acoustical tile or is of the drop ceiling type which includes a plurality of rails supporting panels loosely therein by gravity. Such ceiling structures have been quite widely used in various buildings and are subject to being damaged or displaced if excessive vertical pressure is exerted thereon.
The side edges of the panels 12 include a channel shaped member 106 having a bight portion 108 provided with a longitudinal projection 110 and a longitudinal recess 112 and parallel legs 114 telescoped over the panel members 22 and 24 as illustrated in FIG. 3 with the web or bight portion 108 being secured to the frame 26. When adjacent panels 12 are aligned, the projections 110 and recesses 112 are associated with each other in the manner illustrated in FIG. 4 to provide an inter-engagement and one wall of the recess 112 is provided with a vinyl seal strip 116 to provide a vertical seal between the panels 12. The panel 12 which engages a wall 18 has its vertical side edge received in a channel shaped receptor 118 secured to the wall 18 by any suitable screw threaded means, wood screws or other fastening means 120. The legs of the channel shaped receptor 118 telescopically receive the vertical side edge of the panel 12 and each leg is provided with a seal strip 122 as illustrated in FIG. 4.
FIG. 8 illustrates a slightly modified embodiment of the invention in which the ceiling 16 is provided with an inverted U-shaped guide 124 secured to the ceiling with any suitable fastening devices 126. The inner surfaces of the lower edges of the legs of the U-shaped guide 124 are provided with seal strips 127 which sealingly engage an inverted channel shaped member 128 attached to the upper edge of the panel 12'. In this embodiment of the invention as illustrated in FIG. 8, the spring bias arrangement at the upper edge of the panel 12' may be eliminated. The other components at the lower edge of the panel 12' will remain the same. Also, the internal construction between the panel members 22 and 24 has not been illustrated in detail since this will vary depending upon the installational requirements.
The structural features of the portable wall system result in advantages over existing wall systems. By providing vertical adjustment of the floor engaging assembly 30, the side edges of the panels may be disposed in true vertical orientation even though the floor surface may not be level which is the usual situation encountered in many installations. The adjustable floor engaging assembly combined with the rollers eliminates the use of a separate cart or other conveying device employed to transport panels such as shown in the prior art. This also eliminates the necessity of physically lifting and carrying such panels since the variation in the heighth enabled by the adjustable floor engaging assembly and the adjustable ceiling engaging assembly enables the panel heighth to be reduced to a heighth shorter than the distance from the floor to the ceiling thus enabling the panel to be rolled along a supporting surface while in substantially a vertical position.
Also, the use of the U-shaped configuration of the floor engaging member eliminates the necessity of using separate, slotted skirts for concealing the internal components of the prior art panels. Moreover, the channel shaped construction provides a stable engagement with the floor surface and effectively supports the entire weight of the panel.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A portable wall system utilizing portable wall panels defining a wall or partition extending between a floor surface or other lower surface and a ceiling surface or other overhead surface. The portable wall panels each include lower support means for movably supporting the panels on a floor surface to facilitate movement of the panels to a desired location. The upper edge of each panel is provided with a spring biased ceiling or overhead surface engaging member and the lower edge of each panel includes a vertically extendible and retractable floor surface engaging member so that the wall panels will form a complete partition between the floor surface and ceiling surface and be easily installed, removed or released and relocated. The side edges of the wall panels are constructed for inter-engagement with similar panel modules or wall mounted receptors. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an oscillator circuit and, more particularly, to an oscillator circuit generating an oscillation signal in response to, in a first mode, a resonant element such as a crystal and, in a second mode, an external clock signal.
2. Description of the Related Art
An example of such a conventional oscillator circuit is shown in FIG. 13. This circuit is constituted of an inverter circuit consisting of a P-type MOSFET M1 and an N-type MOSFET M2 and having an input node connected to a terminal V 1 and an output node connected to a terminal V 2 , a transfer circuit consisting of a P-type MOSFET M3 having its drain connected to the terminal V 1 and its source connected to the terminal V 2 and an N-type MOSFET M4 having its drain connected to the terminal V 1 and its source connected to the terminal V 2 , an N-type MOSFET M8 connected between the terminal V 1 and the ground, an inverter circuit 11 having its input connected to the terminal V 2 and its output connected to the output V 0 of the oscillator circuit, and an oscillation control circuit consisting of an inverter circuit 12 and a NOR circuit 13. A crystal X1 is optionally connected between the terminal V 1 and the terminal V 2 . In addition, the oscillator circuit includes a stop input signal V S and a switching input terminal V X from a data processing unit such as a CPU (not shown).
This circuit operates as a crystal oscillator circuit when both of the oscillation stop input signal V S and the oscillation switching input signal V X are at the low level. This is because the N-type MOSFET M8 is turned off and both of the P-type MOSFET M3 and the N-type MOSFET M4 are turned on.
On the other hand, when the signal V S is at the high level, the N-type MOSFET M8 is turned on because of the high level of its gate, and the transfer circuit is turned off by the shift of the gate of the P-type MOSFET M3 to the high level and the gate of the N-type MOSFET M4 to the low level, which brings the terminal V 1 to the low level and the terminal V 2 to the high level, stopping the oscillation.
The frequency-gain characteristic of the inverter circuit consisting of the P-type MOSFET M1 and the N-type MOSFET M2 is as shown in FIG. 14(a), so that oscillation is possible at a frequency lower than frequency f 0 where the gain becomes 0 dB. Since the frequency f 0 varies substantially in proportional to the gate width W of the MOSFET as shown in FIG. 14(b), the frequency f 0 has to be selected somewhat higher than a desired oscillation frequency.
Since, however, at that time the consumed current I of the inverter circuit constituted of the P-type MOSFET M1 and the N-type MOSFET M2 is determined by the gate width W of the MOSFET with substantially proportional relation between the consumed current and the gate width as shown in FIG. 14(c), the gate width W should not be taken so large in order to reduce the power consumption. Therefore, a gate width W which gives rise to a frequency f 0 slightly higher than the desired frequency is adopted.
In this oscillator circuit, the gain of the inverter circuit consisting of the P-type MOSFET M1 and the N-type MOSFET M2 decreases with the increasing load capacity C L as shown by the dependence of the load capacity on the gain as given in FIG. 15. When the oscillator circuit is operated for this reason by an external clock signal rather than by the use of the crystal oscillator, the P-type MOSFET M3 and the N-type MOSFET M4 are turned off by bringing the signal V X of the oscillation control circuit to the high level and an external clock signal V C is applied to the terminal V 1 alone. In that case, the clock signal V C is transmitted to the interior of the oscillator circuit through the inverter circuit constituted of the P-type MOSFET M1 and the N-type MOSFET M2 and the inverter circuit 11.
If in this case a load capacity C L exists at the terminal V 2 due to wiring pattern or the like in the exterior of the LSI, the gain decreases as shown in FIG. 15, and the external clock signal is attenuated by the inverter circuit constituted of the P-type MOSFET M1 and the N-type MOSFET M2, resulting sometimes in a situation where the transmission of the signal to the interior fails.
Moreover, if the external clock signal V C is applied to the terminal V 2 alone, the output voltage of the P-type MOSFET M1 and the N-type MOSFET M2 competes with the external clock signal V C , and results either in non-transmission of the external clock signal V C to the interior or a situation in which the MOSFETs become the sources of the noise due to the flow of a high through current.
For this reason, in operating the oscillator circuit by an external clock signal, it would be necessary to externally install an inverter circuit 15 between the terminal V 1 and the terminal V 2 , as shown in FIG. 16.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide an oscillator circuit generating oscillation signal in response to a resonant element in a first mode and to an external clock signal without an external inverter circuit as well as large noises in a second mode.
An oscillator circuit according to this invention includes a first terminal, a second terminal, a tri-state inverter circuit having an input node connected to the first terminal and an output node connected to the second terminal, a feedback circuit connected between the first and second terminals, and a control circuit operating in a first mode to activate each of the tri-state inverter circuit and the feedback circuit and in a second mode to deactivate each of the tri-state inverter circuit and the feedback circuit. The tri-state circuit presents, when deactivated, a high impedance state at the output node thereof.
In the first mode, the tri-state inverter cooperates with a resonant element connected between the first and second terminals to generate an oscillation signal. In the second mode, an external clock signal is applied to the second terminal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other objects, features and advantages of this invention will become more apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a circuit diagram for a first embodiment of this invention;
FIG. 2 is a circuit diagram for a second embodiment of this invention;
FIG. 3 is a circuit diagram for a third embodiment of this invention;
FIG. 4 is a circuit diagram for a clock detection circuit shown in FIG. 3;
FIG. 5 is a signal waveform diagram for describing the operation of the circuit shown in FIG. 3;
FIG. 6 is another signal waveform diagram for describing the operation of the circuit shown in FIG. 3;
FIG. 7 is a circuit diagram for another example of a clock detection circuit shown in FIG. 3;
FIG. 8 is a circuit diagram of a clock detection circuit for a fourth embodiment of this invention;
FIG. 9 is a circuit diagram of the T-type flip-flop shown in FIG. 8;
FIG. 10 is a circuit diagram of the R-S flip-flop shown in FIG. 8;
FIG. 11 is a signal waveform diagram for describing the operation of the circuit shown in FIG. 8;
FIG. 12 is another signal waveform diagram for describing the operation of the circuit shown in FIG. 8;
FIG. 13 is a circuit diagram for a conventional oscillator circuit;
FIGS. 14(a-c) are diagrams showing the characteristics of the inverter circuit;
FIG. 15 is a diagram showing a characteristic of the inverter circuit; and
FIG. 16 is a circuit diagram for another example of the conventional oscillator circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a circuit diagram of an oscillator circuit according to the first embodiment of this invention. This oscillator circuit 100 is fabricated on a single semiconductor chip 150 and includes a tri-state inverter circuit 50 constituted by a serial connection of a P-type MOSFET M6, a P-type MOSFET M1, an N-type MOSFET M2 and an N-type MOSFET M7 between a power line VDD and a ground line and having an input node connected to a terminal V 1 and an output node connected to a terminal V 2 , a transfer circuit 60 as a feedback circuit consisting of a P-type MOSFET M3 and an N-type MOSFET M4, an N-type MOSFET M5 connected between the terminal V 2 and the ground, an inverter circuit 11 having an input node connected to the terminal V 2 and an output node connected to the output V 0 of the oscillator circuit, and an oscillation control circuit 70 consisting of an inverter circuit 12 and a NOR circuit 13. On the outside of the chip 150, a resonant element 80 such as a crystal is connected between the terminals V1 and V2 or an external clock signal V C is applied to the terminal V2. The oscillation signal derived from the output V 0 of the oscillator circuit is supplied to a data processing unit (not shown) on the chip 150.
Next, the operation of this circuit will be described. In a first mode as a crystal oscillator, the crystal 80 is connected between the terminal V 1 and the terminal V 2 . When the terminals V S and V X of the oscillation control circuit are both at the low level, the P-type MOSFET M6 and the N-type MOSFET M7 are turned on a activate a tri-state inverter circuit 50, and the P-type MOSFET M3 and the N-type MOSFET M4 are also turned on to serve as a feedback resistor. At this time, the N-type MOSFET M5 is turned off. Accordingly, this circuit 100 performs an operation as a crystal oscillator circuit.
In a second mode as a circuit responsive to an external clock signal, on the other hand, the external clock signal V C is input to the terminal V 2 no crystal is connected between the terminals V1 and V2. At this time, the terminal V S of the oscillation control circuit 70 assumes the low level and the terminal V X assumes the high level. Therefore, the P-type MOSFET M6 and the N-type MOSFET M7 are turned off to deactivate the tri-state inverter circuit 50. The output end of the circuit 50 is thereby brought into in the high impedance state. Further, the P-type MOSFET M3 and the N-type MOSFET M4 are both turned off to disconnect the terminal V 1 from the terminal V 2 , and the N-type MOSFET M6 is turned off. As a result, the external clock signal V C applied to the terminal V 2 is transmitted to the interior as the oscillation signal V 0 through the inverter 11.
In either first or second mode, when the terminal V S of the oscillation control circuit assumes the high level, the P-type MOSFET M6 and the N-type MOSFET M7 are turned off to bring the output of the tri-state inverter circuit 50 into the high impedance state, and the P-type MOSFET M3 and the N-type MOSFET M4 are turned off to separate the terminal V 1 and the terminal V 2 from each other, and further the N-type MOSFET M5 is turned on to clamp the terminal V 2 at the low level. As a result, the input to the inverter circuit 11 is clamped at the low level to prevent a through-current flowing therethrough. Further, the oscillation signal V 0 is not derived.
In this circuit, the characteristics of the tri-state inverter circuit constituted of the MOSFETs M1, M2, M6 and M7 are the same as those described in connection with the conventional inverter, and the gate width W is adopted which makes the frequency f 0 to be slightly higher than the desired frequency, analogous to the conventional case. In that case, the consumed current in the tri-state inverter circuit of this invention is the same as in the conventional inverter circuit if the oscillation frequencies are equal.
In this circuit, during the oscillation using the external clock signal V C , the output of the tri-state inverter circuit constituted of the MOSFETs M6, M1, M2 and M7 goes to the high impedance state, so that it is possible to operate the circuit by just applying the external clock signal V C to the terminal V 2 alone. Furthermore, the potential and the parasitic capacity of the terminal V 1 at that time will not affect the characteristics of the oscillator circuit.
Moreover, when using an oscillator circuit operated by an external clock signal, there is also an advantage that the terminal V 1 can be used as an input terminal or an output terminal for a signal unrelated to the oscillator circuit.
As described in the above, by eliminating an externally installed inverter circuit, the oscillator circuit according to this invention makes it possible to reduce the cost, the layout area and the power consumption of the inverter circuit compared with the conventional oscillator circuit.
Turning to FIG. 2, there is shown a circuit diagram of the second embodiment in which the same constituents as those shown in FIG. 1 are denoted by the same reference numerals to omit the further description thereof. This circuit is obtained by deleting the N-type MOSFET M5 and replacing the inverter circuit 11 with a NAND circuit 16. With this circuit, effects similar to those of the embodiment in FIG. 1 can be obtained. In addition, in contrast to the necessity in the first embodiment for the external clock signal to be at the low level in stopping the oscillation, in order to conform with the low level of the terminal V 2 at the time of oscillation stop, the potential of the terminal V 2 at the oscillation stop is not fixed in this embodiment and an arbitrary input potential can be adopted.
In these oscillator circuits of the first and the second embodiments, it is necessary to have determined, immediately after turn-on of the power supply, whether the circuit is to be operated by using the crystal oscillator or by the external clock signal. Therefore, it is necessary to indicate the choice by providing a dedicated terminal on the chip 150. In connection with the provision for the dedicated terminal, there would take place such problems as the cost increase due to increase in the number of package pins and the number of pads on the chip, and the preparation of switching signals.
An oscillation circuit for the purpose of solving these problems are therefore shown in FIG. 3 as the third embodiment of this invention. This oscillator circuit 200 is fabricated on a single semiconductor chip 250 and includes a tri-state inverter circuit 50 formed of a series connection of P-type MOSFETs M1 and M6 and N-type MOSFETs M2 and M7 and having an input node connected to a terminal V 1 and an output node connected to a terminal V 2 , a transfer circuit 60 as a feedback circuit formed by a P-type MOSFET M3 and an N-type MOSFET M4 connected in parallel between the terminal V 1 and the terminal V 2 , a NAND circuit 16 having a first input connected to the terminal V 2 and an output connected to the output V 0 of the oscillator circuit, a clock detection circuit 20 having first and second inputs connected to the terminals V 2 and V R , and an oscillation control circuit 70 consisting of inverter circuits 12 and 17 and NOR circuits 13 and 18.
FIG. 4 is a circuit diagram for an example of the clock detection circuit in FIG. 3. This clock detection circuit is constituted of a P-type MOSFET M11 connected between the terminal V 2 and a power supply V DD , a P-type MOSFET M12 having its drain connected to a junction N1, its gate connected to the terminal V 2 and its source connected to the power supply V DD , an N-type MOSFET M13 having its drain connected to the junction N1, its gate connected to the terminal V R and its source connected to the ground potential, a capacitance element C11 connected between the junction N1 and the ground potential, a latch circuit 30 constituted of a tri-state inverter circuit consisting of P-type MOSFETs M14 and M15 and N-type MOSFETs M16 and M17, and a tri-state inverter circuit consisting of P-type MOSFETs M18 and M19 and N-type MOSFETs M20 and M21, having its input at the junction N1 and its output at a terminal V 3 , and an inverter circuit 22.
The operation of this circuit will be described. First, in the case of oscillation using a crystal oscillator in which a crystal 80 as a resonant element is connected between the terminals V 1 and V 2 , the operation of the circuit is shown by the waveforms given in FIG. 5. In starting an LSI, it is general to use a reset signal V R to initialize the internal circuit. In that case, when the reset signal V R goes to the high level in the oscillator circuit, the output of the tri-state inverter circuit constituted of the MOSFETs M1, M2, M6 and M7 goes to the high impedance state, the transfer circuit constituted of the MOSFETs M3 and M4 is turned off, the tri-state inverter circuit constituted of the MOSFETs M14 to M17 operates as an inverter, the output of the tri-state inverter circuit constituted of the MOSFETs M18 to M21 goes to the high impedance state, and the MOSFETs M11 and M13 are turned on.
Since the terminal V 2 is connected only to the crystal oscillator and has no dc current path, the terminal V 2 is sent to the high level by the MOSFET M11, which turns off the MOSFET M12 and brings the junction N1 to the low level, and the terminal V 3 is brought to the low level.
As the reset signal V R returns to the low level later, the low level of the terminal V 3 is latched and the tri-state inverter circuit consisting of the MOSFETs M1, M2, M6 and M7 operates as an ac amplifier, the transfer circuit consisting of the MOSFETs M3 and M4 is turned on to a start the crystal oscillation operation, and the signal at the terminal V 2 is output to the terminal V 0 through the NAND circuit 16.
Next, the operation by receiving an external clock signal V C at the terminal V 2 is shown by the waveform diagram in FIG. 6. As the reset signal V R goes to the high level the output of the tri-state inverter circuit consisting of the MOSFETs M1, M2, M6 and M7 goes to the high impedance state, the transfer circuit consisting of the MOSFETs M3 and M4 is turned off, the tri-state inverter circuit consisting of the MOSFETs M14 to M17 operates as an inverter, the output of the tri-state inverter circuit consisting of the MOSFETs M18 to M21 goes to the high impedance state, and the MOSFETs M11 and M13 are turned on.
Here, the on-resistance of the MOSFET M11 is set to be sufficiently high compared with the internal resistance of the source (not shown) of the external clock signal V C , so that the voltage of the terminal V 2 oscillates in the same way as the external clock signal does, by which the MOSFET M12 repeats the on-and-off operation and charges up the capacitance element C11.
By setting the mutual conductance of the MOSFET M13 to be sufficiently small compared with the mutual conductance of the MOSFET M12, and restricting the charge discharged by M13 to be small compared with the charge accumulated in C11, the junction N1 goes substantially to the high level and the terminal V 3 goes to the high level when a clock signal is input to the terminal V 2 from the outside.
When the reset signal V R returns to the low level later, the high level of the terminal V 3 is latched, and the signal at the terminal V 2 is transmitted to the output VO of the oscillator circuit via the NAND circuit 16, while keeping the output of the tri-state inverter circuit consisting of the MOSFETs M1, M2, M6 and M7 in the high impedance state, and while keeping the transfer circuit consisting of the MOSFETs M3 and M4 turned off.
As in the above, this embodiment obviates the signal for switching between the oscillation by means of an external clock signal and the oscillation by means of a crystal oscillator, and as a result of that it is possible to reduce the number of the signal pins and the bonding pads.
It should be mentioned that the NAND circuit 16 employed in this embodiment is frequently that of the Schmitt type in order to eliminate malfunctions of the oscillator circuit output caused by the noise generated at the terminal V 2 .
Another example of the clock detection circuit 20 is shown in FIG. 7. This circuit is obtained from the circuit in FIG. 4 by replacing the P-type MOSFET M12 by an N-type MOSFET M12a and the P-type MOSFET M11 by an N-type MOSFET M11a and connecting them between the terminal V 2 and the ground potential.
FIG. 8 is a circuit diagram for the fourth embodiment of this invention, which is another block diagram for the clock detection circuit in FIG. 3. An example of the circuit diagram for the T-type flip-flops Q1 to Q3 of this embodiment is shown in FIG. 9, an example of the circuit diagram for the RS flip-flop Q4 is shown in FIG. 10, and as an example of a latch circuit Q5 use is made of the latch circuit 30 shown in FIG. 4.
This circuit counts signals input to the terminal V 2 with a binary counter constituted of three T-type flip-flop circuits Q1 to Q3, and when the output end Q of Q3 goes to the high level, the signal is latched by the RS flip-flop Q4 and the latch circuit Q5 in the next stage.
In the case of oscillation by means of a crystal oscillator, the crystal oscillator is connected between the terminal V 1 and the terminal V 2 . The operation in that case is shown in FIG. 11. As the reset signal goes to the high level, the output of the tri-state inverter circuit consisting of the MOSFETs M1, M2, M6 and M7 goes to the high impedance state, and the transfer circuit consisting of the MOSFETs M3 and M4 is turned off.
Since the terminal V 2 is connected to the crystal oscillator alone and the potential of V 2 undergoes no variation, the counter is not actuated, with the flip-flop Q3 remaining at the low level, and the terminal V 3 goes to the low level. When the reset signal V R returns to the low level later, the low level of the terminal V 3 is latched, the tri-state inverter circuit operates as an ac amplifier, the transfer circuit consisting of the MOSFETs M3 and M4 is turned on, the crystal oscillator starts operation, and the signal at the terminal V 2 is output to the terminal V 0 through the NAND circuit 16.
Next, in the case of oscillation by means of an external clock signal, a clock signal is applied from the outside to the terminal V 2 . The operation for this case is shown in FIG. 12. As the reset signal V R goes to the high level the output of the tri-state inverter circuit including the MOSFETs M1 and M2 goes to the high impedance state, and the transfer circuit consisting of the MOSFETs M3 and M4 is turned off. Then, the counter circuit consisting of Q1, Q2 and Q3 starts counting, and when the flip-flop Q3 goes to the high level, the terminal V 3 goes to the high level. When the reset signal V R returns to the low level later, the high level of Q3 is latched, and the signal at the terminal V 2 is transmitted to the output VO of the oscillator circuit through the NAND circuit 16 while keeping the output of the tri-state inverter circuit including the MOSFETs M1 and M2 in the high impedance state, and while keeping the transfer circuit consisting of the MOSFETs M3 and M4 turned off.
As described in the above, effects similar to the cases of other embodiments can be obtained by this embodiment. Moreover, signals are processed in the logic circuit so that it is possible to carry out clock detection without being affected by the duty cycle of the external clock signal input from the terminal V 2 .
As in the above, this invention utilizes the inverter circuit which is an ac amplifier as a tri-state inverter circuit, and devised a scheme to convert its output to the high impedance state. Therefore, when using an external clock signal, the necessity for inputting inverted signals to the two input terminals can be obviated, so that there is an effect that an inverter circuit for preparing the inverted signals can be eliminated and that noise generation can be suppressed.
Moreover, when a clock detection circuit is provided, it is possible to automatically switch between the external clock operation mode and the crystal oscillation mode by means of the output signal of the detection circuit. Therefore, there is an additional effect that the number of pins and bonding pads for the preparation of the switching signal can be reduced, and makes the switching signal from the outside unnecessary.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as other embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover any modifications or embodiments as fall within the true scope of the invention. | Disclosed herein is an oscillator circuit generating an oscillation signal in response to a resonant element in a first mode and to an external clock signal in a second mode. This oscillator circuit comprises a tri-state inverter circuit and a transfer circuit between the input and output nodes of the tri-state inverter circuit, and the output node of the tri-state inverter circuit is brought into a high impedance condition when an external clock signal is used and into an active state when the resonant element is employed. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a high performance-permanent magnet used for various electrical appliances, particularly a rapidly cooled magnet of the rare earth-containing alloy system, as well as to a method for producing the same. The present invention provides a magnet exhibiting improved magnetic properties by rapidly cooling an alloy melt of the Fe-R-B system (R is a rare earth element(s) including Y, ditto hereinafter) or Fe-Co-R-B system. The present invention proposes to anneal, under specified conditions, the rapidly cooled and then solidified magnet, to homogenize and stabilize the magnetic properties.
2. Description of the Related Arts
High performance rare earth magnets are Sm-Co magnets which are mass produced by powder metallurgy. Although such Sm-Co magnets can exhibit a maximum energy product of 32 MGOe, they are disadvantageous in that the Sm and Co raw materials are very costly. Such elements as cerium, praseodymium, and neodymium, among the rare earth elements, have a smaller atomic mass than samarium and are inexpensive. In addition, iron is inexpensive. Accordingly, Nd-Fe-B magnets have been recently developed. Regarding these magnets, Japanese Unexamined Patent Publication No. 59-46008 describes sintered magnets, and Japanese Unexamined Patent Publication No. 60-9852 describes rapidly cooled magnets. Although the conventional powder metallurgy process of the Sm and Co powder can be applied to the sintered magnets, they do not utilize the advantage of inexpensive raw materials in one aspect; that is, an alloy ingot of the easily oxidizable Nd-Fe must be finely pulverized to a size of from approximately 2 to 10 μm, and thus the treatment process thereof is difficult to carry out. In another aspect, the powder metallurgy process includes a number of processes, such as melting, casting, rough crushing of ingot, fine crushing, pressing, sintering, and shaping as a magnet.
On the other hand, the rapidly cooled magnet is advantageous in that it is produced by a simplified process wherein the fine pulverizing process is omitted. Nevertheless, an enhancement of the coercive force and energy product, and cost-reductios as well as an improvement in the magnetizing property must be realized to make the rapidly cooled material industrially usable.
In the properties of the rare earth-iron-boron magnet, the coercive force has a temperature sensitive characteristic. The temperature coefficient of coercive force (iHc) is 0.15%/°C. for the rare earth cobalt magnet, but the temperature coefficient of coercive force (iHc) is from 0.6 to 0.7%/°C. for the rare earth-iron-boron magnet; thus being four or more times higher than that of the rare earth cobalt magnet. In the rare earth-iron-boron magnet, there is a serious danger of demagnetization upon a rise in temperature, with the result that the design of a magnetic circuit is limited. In addition, this type of magnet is unusable, for example, for parts in an engine room of automobiles used in tropical regions.
Japanese Unexamined Patent Publication No. 60-9852 claims a composition of 10% or more of rare earth element(s) of Nd or Pr, from 5 to 10% of B, and a balance of Fe, in which composition a high coercive force (iHc) is allegedly provided to the R-Fe-B alloy by a rapid cooling. Heretofore, the outstanding magnetic properties of the R-Fe-B alloy were thought to be attributable to the Nd 2 Fe 14 B compound-phase. Accordingly, with regard to both the sintering method and rapid cooling method, a number of proposals for improving the magnetic properties (Japanese Unexamined Patent Publications Nos. 59-89401, 60-144906, 61-79749, 57-141901, and 61-73861) were based on the experiments of the composition in the vicinity of the above compound, i.e., R=12˜17%, and B=5˜8%.
Since the rare earth elements are expensive, preferably the content thereof is low. There is a problem, however, in that the coercive force (iHc) is greatly reduced at a rare earth element content of less than 12%. Note, the coercive force (iHc) is reduced to 6 kOe or less at a rare earth element content of 10% or less, as described in Japanese Unexamined Patent Publication No. 60-9852. In the R-Fe-B alloy, therefore, the coercive force (iHc) is reduced at a rare earth element content of less than 12%. A method of preventing the decrease in the coercive force (iHc) in the composition range as described above, by changing the composition and structure, is not known.
Although the Nd 2 Fe 14 B compound is the basic compound used in both the sintering method and the rapid cooling method, the magnets produced by these methods not only are different in the production methods but also belong to fundamentally different types of magnets, in view of the alloy structure and coercive force-generating mechanism, as described in Oyobuturi (Applied Physics) No. 55, Vol. 2 (1986), page 121. Namely, in the sintered magnet, the grain size is approximately 10 μm. A magnet with such a grain size is, compared with the conventional Sm-Co magnet, a nucleation type, in which the nucleation of inverse magnetic domains determine the coercive force. On the other hand, the rapidly cooled magnet is a pinning type, in which the coercive force is determined by the pinning of the magnetic domain-wallls due to the extremely fine structure of fine particles from 0.01 to 1 μm in size surrounded by amorphous phases. Accordingly, any approach to an improvement the properties of the magnets must first fully consider the differences in the generation mechanisms of the coercive force.
SUMMARY OF THE INVENTION
The present invention is based on the rapid cooling method, in which non-equilibrium phases can be used in addition to the equilibrium phases, and the effects of various elements on the Fe-Re(Co)-B alloy have been investigated. As a result, it was found that the addition of any one of the specific elements, i.e., Zr, Nb, Mo, Hf, Ta, W, Ti, and V, will provide a high performance magnet exhibiting a high coercive force and energy product, notwithstanding a small rare earth element content of less than 12%, and the isotropic property of the magnet. The effectiveness of the additional elements according to the present invention are peculiar to the rapidly cooled magnet and cannot be realized in sintered magnets.
It was further found that the above additional elements improve the magnetizing characteristics and corrosion resistance of the rapidly cooled R-Fe(Co)-B alloy.
In accordance with the objects of the present invention, there is provided a permanent magnet consisting of:
R.sub.a (Ce.sub.b La.sub.1-b).sub.1-a x (Fe.sub.1-z Co.sub.z).sub.100-x-y-w B.sub.y M.sub.w
(R is at least one rate earth element except for La and Ce but including Y, 5.5≦x<12, 2≦y<15, 0 ≦z≦0.7, 0 <w≦108 0.80≦a≦1.00, 0≦b≦1, M is at least one element selected from the group consisting of Zr, Nb, Mo, Hf, Ta, W, Ti, and V); and, fine crystals and mixed phases of fine crystals and amorphous phases.
The permanent magnet according to the present invention is obtained by rapidly cooling and solidifying the R-Fe-B or R-Fe(Co)-B alloy melt having the above composition by means of so-called liquid-rapid cooling methods. In these rapid cooling methods, melt is injected onto a rotary metallic body cooled by, for example, water, to cool and solidify the melt at a high speed and to obtain material in the form of a ribbon. In this connection, the disc method, single roll method, and twin roll method can be used. In the present invention, the single roll method, i.e., the method of directly injecting the melt onto the circumferential surface of a single rotary roll, is most appropriate. The circumferential speed of the water-cooled, cooling roll is desirably in the range of from 2 to 100 m/sec when a single roll method is employed, to obtain the magnet according to the present invention, because at a circumferential speed of less than 2 m/sec and more than 100 m/sec, the coercive force (iHc) tends to be low. A circumferential speed of from 5 to 30 m/sec is desirable for obtaining a high coercive force (iHc) and energy product. By rapidly cooling and solidifying the alloy melt having the composition as described above by a single roll method at a circumferential speed of 2 to 100 m/sec, it is possible to obtain a magnet exhibiting a coercive force (iHc) up to 20 kOe, and a magnetization (σ) of from 65 to 150 emu/gr. By rapid cooling directly from the melt, an amorphous or extremely fine crystalline structure, and thus a magnet having improved prperties as described above, are obtained. The structure obtained by rapid cooling depends on the cooling condition and is amorphous or is composed of a mixed phase of amorphous and fine crystals. The fine crystalline structure or the mixed phase structure of amrophous and fine crystals, and the size of the constituent phases of the structure, can be further controlled by annealing, to enhance the magnetic properties. The magnetic properties are enhanced when at least 50% of the fine crystals has a size in the range of from 0.01 to less than 3 μm, preferably from 0.01 to less than 1 μm. The amorphous-free structure provides higher magnetic properties than the mixed phase structure.
The annealing of a magnet rapidly cooled and solidified by the liquid-rapid cooling method is carried out at a temperature range of from 300° to 900° C. for 0.001 to 50 hours in an inert gas atmosphere or a vacuum. The rapidly cooled magnet having a composition according to the present invention and subjected to the annealing, becomes insensitive to the conditions for rapid cooling, thereby stabilizing the magnetic properties. Annealing at a temperature of less than 300° C. will not stabilize the properties, and annealing at a temperature exceeding 900° C. results in a drastic decrease of the coercive force (iHc). Annealing for less than 0.001 hour will not stabilize the magnetic properties, and an annealing exceeding 50 hours does not further improve the magnetic properties but merely causes economic disadvantages. It is possible to further improve the magnetic properties by applying a magnetic field to the magnet during annealing.
The magnet obtained by the rapid cooling method is usually in the form of a ribbon. This ribbon is pulverized to form powder preferably into particles having a diameter of from 30 to 500 μm. The obtained powder is usually cold-pressed or warm-pressed to obtain a bulk magnet having a high density. Namely, the bonded magnet can be produced by using the ribbon magnet obtained by the liquid-rapid cooling method. In this case, a powder which may be occasionally obtained by the rapid cooling method, is also used for producing the bonded magnet, by pulverizing and then annealing the powder, if necessary, followed by bonding with the aid of an organic resin, metallic binder and the like. Anisotropy may be imparted to the magnet by hot-pressing, extrusion, rolling, swaging, or forging.
The composition according to the present invention will now be described.
The content (x) of the rare earth element is from 5.5 to less than 12%, since the coercive force (iHc) is reduced at a content of less than 5.5%, and further, the energy product is high at a content of less than 12% in the case of an isotropic magnet, to which category the magnet according to the present invention belongs. A further high energy product can be obtained at a rare earth element content of less than 10%. When the sum of La and Ce in the case of a combined addition exceeds 20% of the total content of rare earth elements, the energy product is disadvantageously reduced. Accordingly, 0.80≦a≦1.00 is set as the preferable content. Sm decreases the anisotropic constant, and thus is preferably kept at a content of 20% at the highest. The content (y) of boron (B) is from 2% to less than 15%, since at a content of less than 2%, the coercive force (iHc) is low, and further, at a content of 15% or more, the residual magnetization (Br) is reduced. Up to 50% of the boron content may be replaced with one or more of Si, Ga, Al, P, N, Ce, S, and the like; the effects of which are similar to those of B, Co, which may replaced Fe, improves the magnetic properties and enhances the Curie point. When, however, the replaced amount (z) exceeds 0.7%, the coercive force (iHc) is reduced. The M content (w) of any one of Zr, Nb, Mo, Hf, Ta, W, Ti, and V is less than 10%, since the magnetization is drastically decreased at a content of more than 10%. A content (w) of 0.1% or more is preferred in view of the coercive force (iHc), and a content (w) of 0.5% or more, especially 1% or more, is preferred in view of the corrosion resistance. A composite addition of two or more of the elements M gives a greater enhancement of the coercive force (iHc) than a single addition. The upper limit for an additive amount of two or more of the elements M is 10%.
The preferred contents for obtaining a high energy product are: 5.5≦x<10; 4≦y≦12, more preferably 4≦y≦10; 0.1≦W≦10; 0≦z≦0.6; and, 2≦w≦10. The preferred contents for obtaining an improved magnetizing characteristic are: 6≦x<12, preferably 6≦x<10; 4≦y≦12; 0.1≦W≦10; more preferably 4≦y≦10; 0≦z≦0.6; and, 2≦w≦10. In addition to the Melement(s), Cr, Mn, Ni, Cu, and/or Ag may be added in such an amount not degrading the effects of the Melement(s).
The present invention is further described with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating the magnetizing characteristic.
FIG. 2 is a graph illustrating the relationship between the coercive force (iHc) and maximum energy product ( (BH)max), and the content of the rare earth element.
FIG. 3 is an X-ray diffraction chart of the 8Nd-4.5Zr-7.5B-bal Fe when rapidly cooled followed by heating at 700° C. for 10 minutes.
FIG. 4 is an X-ray diffraction chart of an ingot with the same composition as in FIG. 3, heated at 1150° C. for 4 hours.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Note, the magnet in the form of a ribbon obtained by the liquid-rapid cooling method, the magnet obtained by pulverizing the ribbon and shaping the powder into a bulk, as well as the bonded magnet, are known, for example, in Japanese Unexamined Patent Publication No. 59-211549. However, the conventional magnet needs, in order to carry out magnetizing until a saturation magnetization is reached, a magnetizing field of not less than 40 kOe and up to 100 kOe, as described in J.A.P. 60 (10), vol. 15 (1986), page 3685. The conventional magnet, therefore, cannot be magnetized until the saturation magnetization is realized by an ordinary electromagnet at a magnetic field of from 15 to 20 kOe.
Referring to FIG. 1, Fe-13.5Nd-5B is an example of the conventional magnet, and Fe-9.5Nd-8B-4Zr is an example of the magnet according to the present invention. In the figure, the abscissa indicates the magnetizing field (kOe), and the ordinate indicates the ratio of residual magnetization (Br(40k)) at a magnetizing field of 40 kOe, relative to a given magnetic field (Hex). This ratio is referred to as the magnetizing ratio. As illustrated in FIG. 1, a full magnetizing in terms of 95% or more is advantageously possible at a low magnetizing field of approximately 20 kOe.
Referring to FIG. 2, the mutual effect of the element M and content of the rare earth element is illustrated. In FIG. 1, the coercive force (iHc) and maximum energy product ((BH)max) of the magnets by the methods of Example 1 are shown. The compositions were Nd-8B-balance Fe (comparative-A), and Nd-8B-(2˜6) Zr-(0˜15)Co-bal Fe (invention-B). As is evident from FIG. 2, the element M, i.e., Zr, is very effective for enhancing the maximum energy product ((BH)max) at a rare earth element content of less than 12%. This effect of Zr upon the maximum energy product ((BH)max) does not appear at a rare earth element content of 12% or more, but is exerted on the coercive force (iHc). The similar effects as illustrated in FIG. 2 are attained by the elements M other than Zr.
The M element will enhance the coercive force (iHc) in a range of a rare earth element content of from approximately 3% to 15%.
It is believed that, at a rare earth element content of less than 12%, particularly less than 10%, the coercive force is generated not by the R 2 Fe 14 B compound, which is a stable tetragonal phase, as in the conventional R-Fe-B alloy, but by a microstructure mainly composed of a metastable R 2 F 14 B compound with a solute M element, which is supersaturated in the main phase as a result of the rapid cooling. Usually, the M element in an amount of up to 2 atomic % can be stably solid-dissolved at a high temperature. The solid-solution in an amount of more than 2% of the M element is impossible, unless done by rapid cooling. In this case, the M element is present in the metastable compound. These considerations are supported by the result of an X-ray diffraction, as illustrated in FIGS. 3 and 4.
FIG. 3 shows the X-ray diffraction chart of a magnet which has been rapidly cooled at a speed of 10 m/sec and consists substantially of the R 2 Fe 14 B phase. FIG. 4 shows the X-ray diffraction chart of the as-cast ingot and the ingot which was subjected to homogenizing at a temperature of 1150° C. for 4 hours. This diffraction pattern is clearly different from that of FIG. 3, and the main constituent phase of the cast ingot is RFe 7 . Accordingly, the M element has the effect of stabilizing the R 2 Fe 14 B phase at even a small content of the rare earth element. This effect is attained only in the rapid cooling method, and not in the sintering method, and is outstanding at 5.5≦x<12, particularly, 6≦x<10; 4≦y<12, more preferably 4≦y≦10; and, 2≦w≦10.
The additive element M appears further to form and strengthen a sub-phase acting as the boundary phase for pinning the magnetic domain walls. The α-phase and other phases may be present as subphases.
It is noteworthy that, notwithstanding a low R content of less than 10%, the maximum energy product ((BH)max) attained according to the present invention is superior to that attained at an R content of 10% or more.
The present invention is further described by way of examples and comparative examples.
EXAMPLE 1
The alloys having the compositions as given in Table 1 were prepared by arc melting. The obtained alloys were formed into ribbons by the liquid-rapid cooling method, in which the alloy melt was injected onto the surface of a roll rotating at 10˜80 m/sec, through a quartz nozzle under a presure of argon. The resultant ribbon was amorphous or finely crystalline. The ribbons were then annealed at a temperature range of from 550° to 900° C. The highest magnetic properties of each composition are given in Table 1.
TABLE 1__________________________________________________________________________ Br iHc (BH).sub.max No. Composition (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 10.5Nd--5B--4Nb--bal Fe 8.5 16.0 14.5" 2 10.5Nd--5B--2Nb--bal Fe 8.3 13.1 13.1" 3 10.5Nd--5B--4Nb--10Co--bal Fe 8.4 15.1 14.4" 4 10.5Nd--5B--2Nb--10Co--bal Fe 8.3 12.8 13.0" 5 8Nd--2.5Pr--5B--4Nb--bal Fe 8.4 16.5 14.3" 6 8Nd--2.5Pr--5.5B--4Nb--10Co--bal Fe 8.3 15.3 14.5" 7 10.5Nd--5B--6Nb--bal Fe 8.2 17.0 13.5" 8 10.5Nd--7B--3.5Nb--7Co--bal Fe 8.3 14.0 13.7" 9 10.5Nd--5B--4Zr--bal Fe 8.4 15.8 14.4" 10 10.5Nd--5B--2Zr--bal Fe 8.2 13.0 13.0" 11 10.5Nd--5B--4Zr--10Co--bal Fe 8.3 14.9 14.3" 12 10.5Nd--5B--2Zr--10Co--bal Fe 8.2 12.7 13.0" 13 8Nd--2.5Pr--5B--4Zr--bal Fe 8.3 16.3 14.2" 14 8Nd--2.5Pr--5.5B--4Zr--10Co--bal Fe 8.3 15.1 14.4" 15 10.5Nd--5B--6Zr--bal Fe 8.2 17.0 13.5" 16 10.5Nd--7B--3.5Zr--bal Fe 8.4 14.4 14.2" 17 10.5Nd--5.5B--3Nb--1Zr--bal Fe 8.5 19.2 14.5" 18 10Nd--1Pr--6B--3Zr--1Hf--bal Fe 8.4 15.3 14.2" 19 11Nd--6B--2Nb--2Ta--bal Fe 8.3 14.9 14.0" 20 10.5Nd--6B--2Nb--1Mo--bal Fe 8.5 16.4 14.3" 21 9Nd--1.5Pr--6B--2.5Nb--1W--bal Fe 8.5 14.7 14.1" 22 10Nd--1Pr--6B--10Co--2Nb--2Ta--bal Fe 8.4 14.8 13.9Comparative 23 10.5Nd--5B--bal Fe 8.4 4.1 7.5" 24 10.5Nd--5B--10Co--bal Fe 8.2 3.7 7.0__________________________________________________________________________
As is apparent from Table 1, the coercive force (iHc) and maximum energy product ((BH)max) are improved by the addition of the M element.
The samples Nos. 1 through 22 according to the present invention, and the comparative samples 23 and 24, were exposed at a temperature of 40° C. for 100 hours in an atmosphere having a humidity of 90%. Rust particles 0.1˜1.0 mm in size were generated on the comparative samples. Conversely, virtually no rust formed on the samples according to the present invention. Thus, it could be seen that the addition of the M element also improves the corrosion resistance.
EXAMPLE 2
The same process including exposure to a humid atmosphere as in Example 1 was carried out for the compositions R x (Fe 1-z Co z ) 100-x-y--w B y M w given in Table 2. The same results as in Example 1 were obtained.
TABLE 2__________________________________________________________________________ Br iHc (BH).sub.max No. Composition (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 10.5Nd--5B--2Mo--bal Fe 8.3 12.1 13.9" 2 10.5Nd--5B--4Mo--bal Fe 7.9 12.6 13.0" 3 10.5Nd--5B--2Hf--bal Fe 8.3 12.8 13.1" 4 10.5Nd--5B--4Hf--bal Fe 8.4 14.0 14.1" 5 10.5Nd--5B--2Ta--bal Fe 8.4 13.0 14.1" 6 10.5Nd--5B--4Ta--bal Fe 8.1 14.1 13.5" 7 10.5Nd--5B--2W--bal Fe 8.3 12.2 13.8" 8 10.5Nd--5B--4W--bal Fe 8.0 12.7 13.1" 9 8Nd--2.5Pr--5B--2mo--bal Fe 8.3 12.2 13.8" 10 8Nd--2.5Pr--5B--2Hf--bal Fe 8.2 12.9 13.0" 11 8Nd--2.5Pr--5B--2Ta--bal Fe 8.3 13.1 14.0" 12 8Nd--2.5Pr--5B--2W--bal Fe 8.2 12.3 13.9" 13 10.5Nd--5B--2Mo--7Co--bal Fe 8.3 12.0 13.8" 14 10.5Nd--5B--4Mo--10Co--bal Fe 7.9 12.5 13.1" 15 10.5Nd-- 5B--2Hf--7Co--bal Fe 8.4 12.7 13.2" 16 10.5Nd--5B--4Hf--10Co--bal Fe 8.4 14.0 14.0" 17 10.5Nd--5B--2Ta--7Co--bal Fe 8.4 13.1 14.0" 18 10.5Nd--5B--4Ta--10Co--bal Fe 8.2 13.9 13.3" 19 10.5Nd--5B--2W--7Co--bal Fe 8.3 12.4 13.7" 20 10.5Nd--5B--4W--10Co--bal Fe 8.0 12.8 13.0" 21 8Nd--2.5Pr--5B--2Mo--bal Fe 8.3 12.3 13.8" 22 8Nd--2.5Pr--5B--2Hf--bal Fe 8.2 12.8 12.9" 23 8Nd--2.5Pr--5B--2Ta--bal Fe 8.4 13.0 14.1" 24 8Nd--2.5Pr--5B--2W--bal Fe 8.2 12.2 13.8Comparative 25 10.5Nd--5B--bal Fe 8.4 4.1 7.5" 26 10.5Nd--5B--10Co--bal Fe 8.2 3.7 7.0__________________________________________________________________________
EXAMPLE 3
The same process except for the exposure to humid atmosphere as in Example 1 was carried out for the compositions Nd x (Fe 1-z Co z ) 100-x-y-w B y M w given in Table 3. The same results as in Example 1 were obtained.
TABLE 3__________________________________________________________________________ Br iHc (BH).sub.max No. Composition (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 9Nd--5B--3.5Nb--bal Fe 8.8 16.3 16.4" 2 9Nd--5B--3.5Zr--bal Fe 8.8 16.2 16.4" 3 9Nd--5B--3.5Nb--12Co--bal Fe 8.9 16.4 16.6" 4 9Nd--5B--3.5Zr--12Co--bal Fe 9.0 16.3 16.6" 5 9Nd--8.5B--4Zr--bal Fe 8.7 14.0 17.0" 6 9Nd--8.5B--4Nb--bal Fe 8.6 15.0 16.4" 7 9.5Nd--7.5B--4Zr--7Co--bal Fe 8.7 12.5 16.8" 8 8Nd--5B--3Nb--bal Fe 9.0 15.8 16.9" 9 8Nd--5B--3Zr--15Co--bal Fe 9.2 11.1 17.2" 10 8Nd--5B--3Zr--bal Fe 9.2 16.0 17.0" 11 8Nd--5B--3Nb--16Co--bal Fe 9.0 15.9 17.1" 12 7.5Nd--9b--4.5Zr--bal Fe 8.5 11.0 15.4" 13 7.5Nd--9B--4.5Nb--bal Fe 8.5 11.0 15.3" 14 7.5Nd--5.5B--3.5Zr--bal Fe 9.7 15.0 18.7" 15 7.5Nd--5B-- 3.5Nb--bal Fe 9.7 15.2 18.8" 16 7.5Nd--5B--2Nb--2Zr--bal Fe 9.7 16.6 19.2" 17 7.5Nd--5.5B--3.5Zr--14Co--bal Fe 10.0 15.1 19.5" 18 7.5Nd--5B--3.5Nb--12Co--bal Fe 9.9 15.3 19.3" 19 7.5Nd--5B--2Nb--2Zr--13Co--bal Fe 9.9 16.4 18.0" 20 7.5Nd--9B--4.5Zr--10Co--bal Fe 8.6 11.0 15.7" 21 6.5Nd--9.5B--6.5Zr--bal Fe 8.3 10.0 15.0" 22 9.5Nd--6.5B--4Mo--bal Fe 8.7 13.2 15.7" 23 9.5Nd--6.5B--4W--bal Fe 8.7 13.3 15.9" 24 7.5Nd--8.5B--4Ta--bal Fe 8.6 11.5 15.7" 25 7.5Nd--8.5B--4Hf--bal Fe 8.8 12.0 15.8Comparative 26 8Nd--5B--bal Fe 9.0 4.7 8.0" 27 8Nd--5B--15Co--bal Fe 9.0 4.7 8.0" 28 9Nd--7B--bal Fe 8.9 4.4 7.5__________________________________________________________________________
EXAMPLE 4
The same process except for the exposure to humid atmosphere as in Example 1 was carried out for the compositions shown in Table 4. The samples were first magnetized by a vibrating magnetometer at 18 kOe and then pusle-magnetized at 40 kOe. The residual magentizations were measured after the respective magnetization procedures, and compared to obtaine the magnetization ratio of Br 18k /Br 40k . The results are given in Table 4.
TABLE 4__________________________________________________________________________ No. Composition (KG)Br (KOe)iHc (MGOe)(BH).sub.max ##STR1##__________________________________________________________________________Invention 1 10.5Nd--6B--4Nb--10Co--bal Fe 8.4 14.1 14.4 0.97" 2 10.5Nd--7B--4Zr--bal Fe 8.4 13.8 14.4 0.97" 3 10.5Nd--8B--4Zr--10Co--bal Fe 8.3 12.8 14.3 0.98" 4 10.5Nd--6B--4Hf--bal Fe 8.3 12.8 13.1 0.96" 5 9Nd--6.5B--3.5Nb--bal Fe 8.8 11.5 16.4 0.98" 6 7.5Nd--8.5B--5Zr--bal Fe 9.0 10.2 15.2 0.99" 7 6.5Nd--9.5B--6.5Zr--bal Fe 8.4 9.0 14.9 0.99" 8 9Nd--8B--4Ta--7Co--bal Fe 8.7 11.0 15.8 0.98Comparative 9 13.5Nd--6B--bal Fe 7.8 12.0 12.5 0.92__________________________________________________________________________
As apparent from Table 4, the magnets according to the present invention are easily magnetizable.
EXAMPLE 5
The alloy having composition of 9.5Nd-8B-4Zr-bel Fe was prepared by arc melting. The obtained alloy was formed into ribbons by the liquid-rapid cooling method, in which the alloy melt was injected onto the surface of a roll rotating at 7.5˜30 m/sec, through a quartx nozzle under the pressure of argon. The obtained ribbon was amorphous of finely crystalline. The ribbons were annealed at 750° C. for 10 minutes in an argon atomsphere. The obtained magnetic properties are given in Table 5.
TABLE 5______________________________________ Substrate Speed Br iHc (BH).sub.maxNo. (m/sec) (KG) (KOe) (MGOe)______________________________________1 7.5 8.7 11.3 16.22 10 8.8 11.4 16.53 15 8.7 11.8 16.34 20 8.7 11.7 16.15 30 8.5 11.6 15.6______________________________________
For comparison, an alloy having the composition 9.5Nd-8B-bal Fe was prepared by the same process as above, except for annealing at 700° C. for 10 minutes. The obtained highest energy product ((BH)max) was 7 MGOe.
The above samples Nos. 1 through 5 were subjected to measurement of the temperature coefficient of the coercive force (iHc) and maximum energy product ((BH)max) in a temperature range of from 20° to 110° C. As a result, the following values, dBr/dT=0.08˜0.11%/°C. and diHc/dT=0.34˜0.40%/°C., were obtained.
EXAMPLE 6
Ribbon magnets having the compositions as given in Table 6 were pulverized into particles approximately 100 μm in size, mixed with a thermosetting resin, and pressed to produce bonded magnets having a density of about 6 gr/cc. The magnetic properties measured after pulse magnetizing are shown in Table 6.
TABLE 6__________________________________________________________________________ Composition Br iHc (BH).sub.max No. (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 9.5Nd--8B--4Zr--bal Fe 7.1 12.0 10.5" 2 9.5Nd--6B--4Nb--bal Fe 6.8 12.5 9.6" 3 7.5Nd--9B--4Zr--bal Fe 6.7 9.2 9.3" 4 7.5Nd--9B--10Co--4Nb--bal Fe 6.7 9.5 9.3Comparative 5 9.5Nd--8B--bal Fe 5.7 5.0 5.7" 6 7.5Nd--8.5B--bal Fe 4.5 3.4 2.3" 7 13.5Nd--5B--bal Fe 6.0 13.0 6.8__________________________________________________________________________
The magnetic properties of magnets Nos. 1 through 4 according to the present invention, when magnetized at 18 kOe, are 97% or more of the pulse-magnetized properties, and were excellent. In addition, the temperature characteristics were as excellent as those obtained in Example 5. The magnetic properties of the comparative magnet No. 7, when magnetized at 18 kOe, were 92% of the pulse-magnetized properties. The comparative sample was subjected to measurement of the temperature coefficient of the coercive force (iHc) and maximum energy product ((BH)max) in a temperature range of from 20° to 110° C. As a result, the following values, dBr/dT=0.14%/°C. and diHc/dT=0.41%/°C., were obtained.
EXAMPLE 7
The same process as in Example 1, including exposure to humid atmosphere, was carried out for the composition as given in Table 7.
TABLE 7__________________________________________________________________________ Br iHc (BH).sub.max No. Composition (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 10.5Nd--5B--2Ti--bal Fe 8.5 11.5 14.1" 2 10.5Nd--5B--4Ti--bal Fe 8.4 12.0 14.0" 3 10.5Nd--5B--2V--bal Fe 8.4 12.0 14.0" 4 10.5Nd--5B--4V--bal Fe 7.9 12.5 13.8" 5 10.5Nd--7B--4Ti--bal Fe 8.2 13.5 13.4" 6 8Nd--2.5Pr--5B--2V--bal Fe 8.3 12.2 14.0" 7 8Nd--2.5Pr--5B--2Ti--bal Fe 8.4 11.8 14.0" 8 10.5Nd--5B--2Ti--7Co--bal Fe 8.5 11.4 14.0" 9 10.5Nd--5B--4Ti--10Co--bal Fe 8.4 12.0 13.9" 10 10.5Nd--5B--2V--7Co--bal Fe 8.4 12.1 14.0" 11 10.5Nd--5B--4V--10Co--bal Fe 8.0 12.4 13.7" 12 8Nd--2.5Pr--5B--2V--7Co--bal Fe 8.3 12.2 13.9" 13 8Nd--2.5Pr--5B--2Ti--7Co--bal Fe 8.4 11.9 14.1" 14 10Nd--0.5Pr--6B--2.5Ti--1V--bal Fe 8.2 14.2 14.0Comparative 15 10.5Nd--5B--bal Fe 8.4 4.1 7.5" 16 10.5Nd--5B--10Co--bal Fe 8.2 3.7 7.0__________________________________________________________________________
The magnetic properties are also given in Table 7. The same corrosion resistance as in Example 1 was obtained.
EXAMPLE 8
The same process except for exposure to humid atmosphere as in Example 1 was carried out for the compositions Nd x (Fe 1-z Co z ) 100-x-y-w B y M w as given in Table 8.
TABLE 8__________________________________________________________________________ Br iHc (BH).sub.max No. Composition (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 7.5--1.5Pr--5B--3Ti--bal Fe 9.2 15.1 16.6" 2 8.5N--5B--3V--bal Fe 9.0 15.4 16.4" 3 8Nd--1Pr--5.5B--3Ti--12Co--bal Fe 9.3 15.3 16.9" 4 9Nd--0.5Pr--5.5B--3V--12Co--bal Fe 9.1 15.3 16.5" 5 7.5Nd--8B--4Ti--bal Fe 8.5 9.0 15.2" 6 7.5Nd--8B--5Ti--10Co--bal Fe 8.6 9.8 15.4" 7 7.5Nd--9B--4V--bal Fe 8.3 8.5 15.1" 8 9Nd--7B--4Ti--bal Fe 9.0 12.7 15.4" 9 9Nd--6.5B--3Ti--1V--bal Fe 8.7 12.5 15.3Comparative 10 8Nd--5B--bal Fe 9.0 4.7 8.0" 11 8Nd--5B--15Co--bal Fe 9.0 4.7 8.0" 12 9Nd--7B--bal Fe 8.9 4.4 7.5" 13 8Nd--8B--bal Fe 8.9 4.5 7.5__________________________________________________________________________
EXAMPLE 9
The same process as in Example 6 was carried out. The result is given in Table 9.
TABLE 9__________________________________________________________________________ No. Composition (KG)Br (KOe)iHc (MGOe)(BH).sub.max ##STR2##__________________________________________________________________________Invention 1 10.5Nd--6B--4Ti--bal Fe 8.3 13.5 13.4 0.97" 2 10.5Nd--7B--4V--bal Fe 8.3 12.5 13.5 0.97" 3 10.5Nd--6.5B--4Ti--10Co--bal Fe 8.4 12.4 13.9 0.98" 4 9Nd--7B--4Ti--bal Fe 8.8 12.7 15.4 0.97" 5 9Nd--7B--4Ti--10Co--bal Fe 8.8 12.0 15.5 0.98" 6 7.5Nd--8B--4Ti--bal Fe 8.5 9.1 15.2 0.97" 7 9Nd--7B--4V--bal Fe 8.7 11.0 15.3 0.97Comparative 8 13.5Nd--6B--bal Fe 7.8 12.0 12.5 0.92__________________________________________________________________________
EXAMPLE 10
The same process as in Example 4 was carried out. The result is given in Table 10.
TABLE 10__________________________________________________________________________ Br iHc (BH).sub.max No. Composition (atomic percentage) (KG) (KOe) (MGOe)__________________________________________________________________________Invention 1 9.5Nd--7B--4Ti--bal Fe 6.8 12.0 9.4" 2 9.5Nd--7B--4V--bal Fe 6.9 10.5 9.7" 3 7.5Nd--8B--4Ti--bal Fe 6.8 9.1 9.0" 4 9Nd--7B--4.5Ti--10Co--bal Fe 6.9 11.8 10.0Comparative 5 9.5Nd--7B--bal Fe 5.7 5.0 5.7" 6 7.5Nd--8B--bal Fe 4.5 3.4 2.3" 7 13.5Nd--5B--bal Fe 6.0 13.0 6.8__________________________________________________________________________
The magnetic properties of magnets Nos. 1 through 4 according to the present invention, when magnetized at 18 kOe, were 97% or more of the pulse-magnetized properties, and were excellent. In addition, the temperature characteristics were as excellent as those obtained in Example 5. The magnetic properties of comparative magnet No. 7, when magnetized at 18 kOe, were 92% of the pulse-magnetized properties. The comparative sample was subjected to measurement of the temperature coefficient of the coercive force (iHc) and maximum energy product ((BH)max) in a temperature range of from 20° to 110° C. As a result, the following values, dBr/dT=0.14%/°C. and diHc/dT=0.41%/°C., were obtained. | In an R-Fe-B permanent magnet produced by a process including a rapid cooling, a composition of
{R.sub.a (Ce.sub.b La.sub.1-b).sub.1-a }x(Fe.sub.1-z
Co z ) 100-x-y-w B y M w
(R is at least one rare earth element except for La and Ce but including Y, 5.5≦x<12, 2≦y<15, 0≦z≦0.7, 0<w≦10, 0.80≦a≦1.00, 0≦b≦1, M is Zr, Nb, Mo, Hf, Ta, W, Ti, and/or V) is proposed. The presence of the M element increases a ((BH)max) to a value higher than that of a composition wherein x is higher than 12 and makes the magnet more easily magnetizable. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application for patent is a continuation of U.S. Non-Provisional application Ser. No. 11/687,624 of the same title and filed Mar. 16, 2007; and claims the benefit of U.S. Provisional Application Ser. No. 60/783,647 of the same title and filed Mar. 17, 2006, both of which are incorporated herein by reference. This application additionally incorporates two applications by reference: PCT/U.S. 2005/015973 (WO 2005/107425: “Offshore Windmill Electric Generator”), filed May 6, 2005, and its parent U.S. Provisional Application Ser. No. 60/569,077, filed May 6, 2004.
BACKGROUND
[0002] Wind velocities are generally increased at higher elevations. In order to maximize the capture of energy from winds blowing over, for example, ocean water, mounting wind turbines at elevated levels (e.g., between 200 to 500 feet above sea level) on tower structures is generally desirable. However, a commercial or industrial wind turbine generator and its housing typically form a massive unit (e.g., having an average weight of 70 tons). Marine equipment capable of lifting a 70 ton wind turbine generator unit for mounting on a tower structure 200 to 500 feet above sea level is extremely expensive. Embodiments disclosed herein bypass the need to use such expensive equipment.
SUMMARY
[0003] Various disclosed embodiments facilitate the operation at various locations, including offshore locations, of wind turbine generators on towers capable of being elevated and retracted. A wind turbine generator may be mounted (and serviced) on such a tower with relative ease when the tower is in a retracted or service mode configuration. In particular, various disclosed embodiments relate generally to structures and methods for elevating a wind turbine into winds that blow at higher levels than sea level (e.g., typically 200 feet or more above sea level) in order to facilitate the turbine's capture of kinetic energy from the wind. Other disclosed embodiments relate generally to structures and methods for retracting a wind turbine from elevated levels in order to service the wind turbine, as well as to protect it from storm damage. Commonly the wind turbine is an offshore wind turbine. Some disclosed embodiments further relate generally to structures and methods for unfolding blades of a wind turbine from a compact cluster into a balanced, extended blade arrangement in order to put the turbine in a condition for harvesting wind energy. Other disclosed embodiments further relate generally to structures and methods for folding blades (typically at least two of three blades) of a wind turbine into a compact cluster in order to protect the blades (and the turbine) from damage during storms or other high-wind weather events.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The foregoing and other advantages will become apparent from the following detailed description and upon reference to the drawings, wherein:
[0005] FIG. 1 illustrates a wind turbine generator mounted on a support tower that is in an extended or operating mode configuration; the tower extends from the ocean floor to a height some distance above sea level;
[0006] FIG. 2A illustrates a tower that is in a retracted or service mode configuration, and
[0007] FIG. 2B illustrates three different tower configurations (the left tower is in an extended or operating mode configuration, the center tower is in a retracted or service mode configuration, and the right tower is in a storm mode configuration);
[0008] FIG. 3A (side view) and FIG. 3B (cross section at A-A of FIG. 3A ) illustrate a tubular member of a tower; standard gear racks are welded to the tubular member;
[0009] FIG. 4A illustrates the mounting of a turbine assembly on a tower that is in a retracted or service mode configuration; FIGS. 4B-40 illustrate various tower embodiments;
[0010] FIG. 5 illustrates a locking assembly located at a lower end of a movable tubular member of the tower;
[0011] FIG. 6 illustrates a tower power train that includes a pinion gear, a gear reducer and a hydraulic motor;
[0012] FIG. 7 illustrates a service vessel equipped with a hydraulic power source; hydraulic power lines from the service vessel connect to hydraulic motors on the elevator tower;
[0013] FIG. 8 illustrates a hinge point assembly of a folding blade wherein the folding blade is in an extended position (i.e., in an operating mode position);
[0014] FIG. 9 illustrates a hinge point assembly of a folding blade wherein the folding blade is in a folded position (e.g. in a storm mode position);
[0015] FIG. 10 illustrates a compact cluster of folded blades with tips attached to a storm brace (e.g., where the cluster of folded blades is in a storm mode configuration); and
[0016] FIG. 11 illustrates a bore hole (i.e., stinger hole) into which the lower end of sealed caisson of a tower may be placed.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1 , three blades attach to a wind turbine generator mounted on a tower that is in an extended or operating mode configuration. As noted previously in Application PCT/U.S. 2005/015973, wind machines typically have three major components: 1) a variable pitch, usually three-bladed fan; 2) a generation system with a gearbox and mounting means usually housed in a nacelle; and 3) a support tower. In the depicted embodiment, the tower extends upward from a platform that stands on the ocean bottom. The tower elevates the fan and turbine generator some distance above sea level. In other embodiments, the tower may extend from a base that is submerged, but instead of standing on an ocean bottom, is buoyant. In still other embodiments, the tower may extend from a base that stands on dry land.
[0018] Referring to FIG. 2A , the depicted tower is in a retracted or service mode configuration. In this embodiment, the bounds of the circle defined by the path of the ends of the fan blades approach the ocean surface. The fan blades and turbine generator can typically be mounted or serviced more easily when the tower is in a retracted or service mode configuration than when the tower is in an extended or operating mode configuration. In particular, when a wind machine that is located offshore is in such a retracted or service mode configuration, low-cost marine equipment (or at least standard-cost marine equipment, instead of high-cost marine equipment) may be utilized to access the fan blades, the turbine generator and other nearby components of the wind machine.
[0019] Referring to FIG. 2B , a comparison of towers in three different configurations highlights that the blades of a tower in a storm mode configuration (as depicted on the right) are folded into a compact cluster. To the degree that folding of blades identifies a storm mode configuration, only two of the three blades must be in a folded position in order for a tower carrying a three-blade fan to be placed in a storm mode configuration.
[0020] Wind machines are commonly equipped with three blades that are designed to rotate a turbine drive shaft so as to maximize the capture of kinetic energy from the wind. Blades are typically not fixed in attitude but may be adjusted while in use in order to maximize energy capture at various wind velocities. Blades made of fiberglass and carbon fiber materials in cantilever beam designs are common. Length-to-depth ratios are typically quite large, which results in slender structural members. Contemporary wind turbines can produce a sweep area from 200 feet to 400 feet in diameter. Blades of three-blade fans are spaced 120.degree.apart, and the blades will tolerate storm winds up to certain velocities. However, blade vibration at certain harmonic levels yet occurs and can cause blade failure.
[0021] The capacity of blades to be folded into a compact cluster (as in disclosed embodiments) in particular allows blade outer tips to be secured. Blade vibration during storm gusts can thus be dampened and blade failure avoided. The capacity for blades to be folded into a compact cluster, as well as for blade outer tips to be secured during storage, greatly facilitates the survival through storms of blades and associated equipment.
[0022] Referring to FIG. 3A , a side view of a tubular member of a typical tower assembly reveals that standard gear racks are welded on sides of the tubular member. The gear racks are used as means to elevate (and lower) a turbine generator mounted on the tower. Referring to
[0023] FIG. 3B , a cross-section of a tubular member at plane A-A of FIG. 3A reveals that the gear racks are welded on the sides of the tubular member at positions 180 degree opposite each other. The cross-section further reveals the tubular member to be generally circular, and the gear racks to be generally rectangular, although these cross-sectional shapes may vary in other embodiments.
[0024] Referring to FIG. 4A , a 200-ton capacity derrick barge with a 150-foot boom may be used to mount a VESTAS® (Vestas Wind Systems A/S, Randers, Denmark; see also www.vestas.com) V47-660 kW generator on a tower that is in a retracted or service mode configuration. Needless to say, calm seas are preferred for the accomplishment of such an operation.
[0025] Before a generator is mounted on a tower, the tower itself is assembled and, in the embodiment depicted in FIG. 4A , placed on the ocean floor. The platform section of the tower depicted in FIG. 4A includes stiffened caisson jackets that extend from the ocean floor upward though 20 feet of water to a height of 62 feet above sea level. A spool capable of rotating 360 degrees is attached on top of a tubular member, which only partially extends from a central region or structure of the platform section of the tower in this embodiment. A small, inexpensive lift boat or derrick barge can then be used to install the turbine and blade assembly on the spool of the tower when the tower is in a retracted or service mode configuration.
[0026] In some embodiments similar to the embodiment depicted in FIG. 4A , the bottom of a central caisson is sealed and provides a protective, water-excluding environment for the lower end of the tubular member of an extension tower. In some embodiments, the caisson is longer than a support jacket, so that the caisson extends below the mudline into the seabed (see FIG. 2A and FIG. 7 ). In preparing a location for the installation of a tower having a central caisson of this kind, a void slightly larger in diameter than the diameter of the caisson is prepared in the seabed to an appropriate depth. After the sealed caisson has been placed in the prepared void (i.e., bore hole or stinger hole; see FIG. 11 ) and its placement set (e.g., by filling surviving void spaces with previously excavated material), the sealed caisson contributes to the stability of the tower platform despite water turbulence that is often associated with an ocean environment. In the depicted embodiment, four pilings that each had been driven into the seabed are located at the corners of the tower platform. These pilings markedly further enhance the stability of the tower platform.
[0027] Referring to FIGS. 4B-40 , various tower embodiments are illustrated. Each of these tower embodiments may be identified by a descriptive name, as follows: TABLE-US-00001 FIG. Tower Descriptive Name 4 B Gravity-based structure 4 C Piled jacket 4 D Jacket-monopile hybrid 4 E Harvest jacket 4 F Gravity-pile structure 4 G Tripod 4 H Monopile 41 Supported monopile 4 J Bucket suction pile 4 K Guided tower 4 L Suction bucket 4 M Lattice tower 4 N Floater 40 Tension leg platform
[0028] Referring to FIG. 5 , on at least two sides (at positions 180 degrees opposite each other), a threaded section with a locking pin assembly joins to a movable tubular member at a lower end of a tower. Above each locking pin assembly, a cam-anchored latch (controlled by an air cylinder) fits into a groove of a track. Each latch is located below each of the gear racks that is welded to the tubular member, and each locking pin and latch (or pall assembly) secures the tubular member of the elevator tower to the central region or structure of the platform section of the tower in this embodiment. At the same time, each pall assembly aligns the tubular member within that central region. Though two pall assemblies are shown, additional assemblies in various spacing arrangements may be used (e.g., in order to provide more secure connections or to improve alignments between tower components).
[0029] Each pall assembly is of machine-tool quality. The use in various embodiments of pall assemblies represents a significant improvement over the traditional use of bolts (e.g., in a series) to secure tower sections to each other. In particular, the use of pall assemblies allows an operator to lock (or unlock) an elevator tower for re-positioning with greater ease than would be possible if bolts were used to secure tower sections to each other.
[0030] Referring to FIG. 6 , a hydraulic motor in a power train powers the elevation or retraction of an elevator tower (i.e., in this embodiment, by elevation or retraction of a tubular member). The hydraulic motor acts via a gear reducer (i.e., transmission) and a pinion gear to drive cogs that intercalate with ridges on each gear rack that is welded to a side of the tubular member. By means of a control panel (not shown), an operator may regulate the flow through hydraulic lines of hydraulic fluid into the motor. In this way, an operator may control movement (e.g., elevation or retraction) of the elevator tower. Depending on settings chosen by the operator, the hydraulic motor may power the elevator tower to move upward at various slow speeds (e.g., from 50 to 120 feet per hour). As the tower nears its full extension, the speed of the tower's upward movement is reduced in order to allow the locking assemblies to be engaged or activated.
[0031] Because the engagement of locking assemblies is positive, an operator can activate hydraulic cylinders to release the engagement if, for example, the operator wishes to retract the elevator tower. An elevator tower generally can be retracted from an extended or operating mode configuration to a retracted or service mode configuration in less than 90 minutes. The capacity of embodiments to be converted relatively quickly from an extended or operating mode configuration to a retracted or service mode configuration facilitates maintaining (or upgrading) a turbine and blade assembly. Because embodiments can similarly be converted relatively quickly to a storm mode configuration, the protection of turbine and blade assemblies is similarly facilitated. Other elevator tower embodiments may borrow structures from oilfield jackup rig assemblies known to those of skill in the art in view of the present disclosure.
[0032] In some embodiments, a hydraulic power source is located on the maintenance jackup vessel. Because use of the hydraulic cylinders and jacking system to lower or raise tower structures may occur only two (or fewer) times per year, a hydraulic power source need not be maintained on the tower (e.g., aboard a tower platform). Rather, a hydraulic power source may be mounted on the deck of a maintenance barge, and hydraulic hoses may be connected from the hydraulic power source on the maintenance barge to a hydraulic motor system associated with the tower. In order to facilitate the control of a tower hydraulic motor system by on operator on the maintenance barge, directional controls for the hydraulic motor system may also be located on the maintenance barge (e.g., near or on the hydraulic power source assembly).
[0033] Referring to FIG. 7 , a service vessel can be raised on poles to an elevated level near that of a turbine generator mounted on an elevator tower. Hydraulic power lines from the service vessel equipped with a hydraulic power source connect to hydraulic motors on the elevator tower. By controlling the hydraulic power source, an operator on the service vessel may control the elevation or retraction of the elevator tower.
[0034] Referring to FIG. 8 , a mechanical (self-locking) jack screw assembly in a contracted position minimizes any centerline separation between a blade base and a pivoting blade extension (i.e., in an operating mode position). A hinge point joins the blade base to a corresponding pivoting blade extension independent of whether the mechanical jack screw assembly is in a contracted or an extended position. An electric motor (or, in other embodiments, another source of power for extending the mechanical jack assembly) is connected via a gear box to the mechanical jack assembly in the blade base.
[0035] Referring to FIG. 9 , a mechanical (self-locking) jack screw assembly in an expanded position generates centerline separation (e.g., of about 90 degrees in the illustrated example) between a blade base and a pivoting blade extension in a folded position (e.g., a storm mode position). The electric motor connected via a gear box to the mechanical jack assembly in the blade base has rotated components of the jack screw assembly so as to generate centerline separation between the blade base and the pivoting blade extension.
[0036] Referring to FIG. 10 , a compact cluster of folded blades with tips attached to a storm brace (i.e., a cluster of blades in a storm mode configuration) is collapsed around a turbine tower. The centerline separation that is present between a blade base and an associated pivoting blade extension for at least two hinge points (e.g., of blades A and C) need not be present for the third hinge point (e.g., of blade B, which is already in a position parallel to the vertical tower that supports the turbine). As noted previously, the capacity of blades to be folded into a compact cluster in particular allows blade outer tips to be secured (e.g., to a storm brace that folds out from the tower that supports the wind turbine) and, accordingly, allows blade vibration during storm gusts to be dampened. The capacity for blades to be folded into a compact cluster, as well as for blade outer tips to be secured during storage (e.g., when a cluster of blades is in a storm mode configuration) thus greatly facilitates the survival through storms of blades and associated equipment.
[0037] Referring to FIG. 11 , a typical stinger hole (i.e., a bore hole in the seabed) is illustrated. In some embodiments, a sealed caisson of the lower end of an extension tower is placed in the stinger hole. As previously noted, having a sealed caisson set in the seabed contributes to the stability of the tower platform.
[0038] Following long-standing patent law convention, the terms “a” and “an” mean “one or more” when used in this application, including the claims. Even though embodiments have been described with a certain degree of particularity, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the present disclosure. For example, a person of ordinary skill in the art may see, in the light of the present disclosure, other assembly arrangements that may be used to accomplish tower elevation and retraction as well as other structures and methods for blade folding and unfolding. Accordingly, it is intended that all such alternatives, modifications, and variations which fall within the spirit and scope of the described embodiments be embraced by the defined claims. | Structures and methods for elevating and retracting offshore wind turbine assemblies. Structures and methods are presented for elevating and retracting offshore wind turbine assemblies mounted on a tower in order to facilitate both service of the assemblies at any time, as well as preservation of the assemblies through storms or other high-wind weather events. Among the structures presented are folding wind turbine blades that may be folded into compact clusters and secured to braces in order to minimize damage during storms or other high-wind events. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electrophotographic printer which makes a print mixed with data different in linear density.
2. Prior Art
In a conventional electrophotographic printer, the resolution is generally a dot density of 240 dots per inch (corresponding to a linear density of 9.4 lines/mm), and EDP (electronic data processing) data such as characters are formed with a dot density of 240 dpi (dots per inch). On the other hand, image data such as figures are generally read with the resolution of a dot density of 400 dots per inch (corresponding to a linear density of 16 lines/mm).
The conventional electrophotographic printer will be described with reference to FIGS. 1 and 2. FIG. 1 shows the arrangement of and electrophotographic printing system, and FIG. 2 is an explanatory diagram showing one example of a print which is to be made by the printing system.
A central processing unit (CPU) 12 applies EDP data having a dot density of 240 dpi to a print control unit 16. An image scanner 13 and a communication terminal 14 applies image data having a dot density of 400 dpi through an image data memory unit 15 to the print control unit 16. The data applied to the print control unit 16 are printed out with a dot density of 240 dpi by an electrophotographic printer 17.
When, in the above-described printing system, data different in dot density are printed out on one and the same page, the data supplied as image data of 400 dpi are printed out with a dot density of 240 dpi. Therefore, the printed image is larger than the original image, as a result of which it is lower in linear density; that is, it is low in picture quality. In the case where image data is read with a dot density of 240 dpi similarly as in the case of EDP image, the image read with an image scanner or the like is different in resolution from the original image, with the results that the printed image is different from the original image in impression, and is lower in picture quality.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to eliminate the above-described difficulties accompanying a conventional electrophotographic printer.
More specifically, an object of the invention is to provide an electrophotographic printer which can print out a plurality of data different in linear density on one and the same page.
The foregoing objects and other objects of the invention have been achieved by the provision of an electrophotographic printer in which a photo-conductive drum is canned with a light spot provided by scanning means to electrostatically form a latent image with dot on it; in which the scanning light source means comprises at least two scanning light sources different in dot density, to print out data different in linear density.
The nature, principle and utility of the invention will become more apparent from the following detailed description and the appended claims when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings;
FIG. 1 is an explanatory diagram showing the arrangement of a data printing system;
FIG. 2 is an explanatory diagram showing one example of a material to be printed with an electrophotographic printer according to this invention;
FIG. 3 is an explanatory diagram showing the arrangement of one example of the electrophotographic printer according to the invention;
FIG. 4 is an explanatory diagram showing the arrangement of one modification of the electrophotographic printer shown in FIG. 3; and
FIG. 5 is a time chart for a description of the operation of the electrophotographic printer according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of this invention will be described with reference to the accompanying drawings.
One example of a electrophotographic printer according to the invention is as shown in FIG. 1.
The surface of a photo-conductive drum 1 is uniformly charged by a charging unit 2, and the latent images of print data are formed on it with LED print heads 3. The LED print heads 3 have SELFOC lens arrays 5, respectively, which are image-forming lenses for focusing light beams emitted from LED arrays 4 on the photoconductive drum 1. The latent images are developed by a developing unit 6 into a toner image on the photoconductive drum 1. The toner image thus formed is transferred onto a printing sheet 8 by a transferring unit 7, and it is pressed and heated by a fixing unit 11 so as to be fixed on the printing sheet. The photo-conductive drum 1, from which the toner image has been transferred, is cleaned with a cleaning unit 9 and discharged with a discharging unit 10. Thus, the electrophotographic printer becomes ready for the following printing operation.
The latent image of EDP data is formed on the photo-conductive drum 1 with the LED print head A having a linear density of 240 dpi, whereas the latent image of image data is formed on the drum 1 by using the LED print head B having a linear density of 400 dpi. That is, the latent images different in linear density are simultaneously formed on the photo-conductive drum and developed, and therefore it is possible to print out data different in dot density on one and the same page.
FIG. 5 is a time chart for a description of the operation of the electrophotographic printer according to the invention.
In FIG. 5, reference character DVS-P designates a synchronizing signal for synchronization of a sheet feeding operation with respect to a print start position, and reference character PPOS-P designates a signal for determining a print start position, which is set at the rise of the signal DVS-P and reset when n clock signals CLK-P are counted.
Further in FIG. 5, reference character PRINT1-P designates a gate signal for permitting the print head A to operate which is adapted to print EDP data. The rise of the signal PRINT1-P corresponds to the print start position.
Upon permission of the operation of the print head A by the gate signal PRINT1-P, print signals 1 for printing out EDP data are successively supplied to perform a printing operation. The timing of driving the print head A in the direction of line of the printing sheet is determined by a synchronizing signal SCAN1-P.
Further in FIG. 5, reference character PRINT2-P designates a gate signal for permitting the print head B to operate which is adapted to print image data. The print head B is so positioned that it forms an angle θ with the print head A. Therefore, the gate signal rises as follows: That is, it is set when m clock signals CLK-P are counted from the time instant that the signal PPOS-P reset.
Upon permission of the operation of the print head B by the gate signal PRINT2-P, print signals for printing out image data are successively supplied to perform a printing operation. The timing of driving the print head B is determined by a synchronizing signal SCAN2-P.
As is apparent from the above description, in the electrophotographic printer of the invention, the optical systems and the data memory units are provided separately for the EDP data and the image data; however, the remaining components are operated simultaneously as two different printers were operated simultaneously.
In the above-described embodiment, data having a linear density of 240 dpi and those having a linear density of 400 dpi are printed out. However, it should be noted that the invention is not limited thereto or thereby. For instance, the technical concept of the invention is applicable to the combination of 200 dpi (corresponding to 8 lines/mm) and 240 dpi for FAX data, or of 200 dpi, 240 dpi and 400 dpi.
Furthermore, in the above-described embodiment, LED print heads different in dot density are provided. However, the printer heads may be modified as shown in FIG. 4. In the modification, two LED arrays different in linear density are provided on one ceramic board, to form one LED print head.
The gist of the invention resides in that data different in linear density are printed out on one and the same page; however, the electrophotographic printer of the invention may be utilized as follows: When the print signal for printing out EDP data is applied to the LED printer head adapted to print out image data instead of the LED printer head for EDP data, then the data can be printed out with a scale-down of about 0.6. In contrast, when the print signal for printing out image data is applied to the LED print head adapted to print out EDP data instead of the LED printer head for image data, then the data can be printed out with a scale-up of about 1.67.
As is apparent from the above description, the electrophotographic printer according to the invention, having the optical systems different in linear density for processing data different in linear density, can print out an image having different linear densities, as it is. | In an electrophotographic printer, a photoconductive drum is scanned with a light spot provided by scanning light sources to electrostatically form a latent image with dot on it. The light sources comprise at least two LED print heads different in linear density are provided to print out data different in linear density on one and the same page. | 6 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein maybe manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
BACKGROUND OF THE INVENTION
The present invention generally relates to capture and release devices and more particularly to a device for launching and/or recovering mobile targets.
Horizontally floating Anti-Submarine Warfare (ASW) mobile targets represent an integral part of Navy Technical Certification programs (TCP's), which involve various classes of surface ships, submarines and torpedoes. Present methods for launching ASW targets vary from submarine and surface tube firings, to launches from the rear of torpedo retriever boats (TRB's), to inflight release from helicopters. Recovery methods range from surface retrieval craft, to helicopter deployment of drivers with lifting straps, to helicopter use of a snare hook.
Due to range demands and fleet commitments, it is imperative that TCP's function as efficiently as possible with the least number of delays and postponements. In obtaining this desired efficiency, target deployment/recovery techniques and equipment must be independent of adverse weather conditions (e.g. high sea states). Furthermore, they must function in such a way that the programs' results are not influenced by their implementation. For example, one drawback of retriever, submarine and surface tube firings is that the position of the ASW target is often already known at deployment, because of either sonar tracking of the launch craft or reception of the noise due to firing. In addition, surface launch and retrieval is at many times impossible because of prohibitive sea states which can cause equipment damage and injury to personnel.
Use of a helicopter for launch and recovery increases the capability for rapid turnaround of targets, and in most cases decreases the danger to which personnel are exposed. One exception is the deployment of recovery divers with lifting straps, whereas this represents a potentially hazardous situation and requires a special landing procedure to protect the target from damage.
Another system incorporates a bombrack which hard-mounts the target to a helicopter for launch. In flight, the target is released from its hard-mount as the helicopter pitches forward, producing the desired water entry angle. Recovery is accomplished by using a snare hook (i.e. a long pole with a hook end, which is attached to the helicopters' cargo hook). The snare hook is placed through a lifting ring deployed at target end-of-run, and the unit is flown back to be deposited in a specially cushioned landing area.
Air launches, such as the one just described, significantly reduce the amount of noise associated with target deployment, thereby decreasing the chances of discovery by sonar. However, the accomplishment of a successful launch and the safety of the crew depends to a larger measure than necessary to the skill of the helicopter pilot. In the case of capture, not all horizontally floating ASW targets are equipped with, or designed for lifting rings.
SUMMARY OF THE INVENTION
Accordingly, it is a general purpose and object of the present invention to provide a device having improved launching and capturing capabilities. It is a further object that the device be operable from a helicopter for use in launching a target and capturing a horizontally floating target at sea. Another object is that it be suitable to be returned to land without damage to the captured target. Other objects are that the device be light in weight, rugged, durable and dependable in operation, have ease and safety in handling and yield speed and efficiency at relatively low cost.
The above is attained in accordance with the present invention by providing a system suspended from a helicopter that releases a target, at a predetermined angle, on signal from the helicopter for deployment at sea. The system is also capable of capturing the target by the use of adjustable wedges that reposition for holding the target once the target is properly positioned with relation to the system. The target can then be returned to land or a ship having portions of the system function as landing frames.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the system suspended from a helicopter following a recovery operation;
FIG. 2 is a side view of the system of FIG. 1 as it appears suspended from a helicopter prior to launch;
FIG. 3 is a front view of the system of FIG. 1 as it appears suspended from a helicopter following recovery; and
FIG. 4 is an enlarged side view of the bomb shackle of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 there is shown a mobile target 10 after capture enclosed in forward and aft U clamps 12. The U clamps 12 comprise an upper semicircular section 14 and legs 16. Two of the legs 16 differ from the other two legs 16 in that they are of opposite hand. This is apparent in the drawing.
The semicircular sections 14 are separated from each other and held in place by means of an I beam strongback 18. The strongback 18 is affixed to section 14 by means of nuts and bolts (not shown) and bracket 20.
A float system 22 has a plurality of floats 24 that are mounted on tubular piece 26. A pair of horizontal tubular pieces 28 are bolted to legs 16. Tubular pieces 30 connect horizontal tubular pieces 28 to tubular piece 26.
Rope cables 32 provide additional support to keep U clamps 12 from separating. The cables 32 are in tension for providing this support. Turnbuckles can be connected to the rope cables 32 for providing adjustable tension is necessary.
Skirts 34, comprised of tubular grids welded together are rigidly connected to flat plates 36. The plates 36 are rotatably connected to legs 16. A slot 38 is located on the inner surface of each of the legs 16. The flat plates 36 are free to rotate back and forth, but have an inward stop provided by welded inner plates 40 on legs 16.
Wedges 42 grip target 10 from its underneath portion. The wedges 42 are operated by recovery control lines 44. Main lifting lines 46 are connected to strongback 18.
FIG. 2 is a side view showing the device in the launch mode. The mobile target 10 is held in place by lines 50 respectively held by two bomb shackles 52. The bomb shackles 52 are supported on either end and opposite sides of strongback 18. When the system is used for recovery purposes only the bomb shackles 52 need not be included. The main lifting lines 46 are connected from yoke 54 to strongback 18. Yoke 54 connects to the helicopter cargo hook (not shown).
The recovery control lines 44 connect to an orientation control triangle 58 which in turn is connected to a weak link 60. The weak link 60 comprises a strip of metal or a shear pin. As the name implies the weak link 60 ruptures if called upon to support the structure if a fault occurs as great as or greater than the breaking of one of the main lifting lines 46. The weak link 60 connects to rescue hoist 62 which in turn is controlled from a helicopter (not shown). The recovery control lines 44, in addition, connect to respective sheaves 64. The sheaves 64 have rings 65 connected thereto. Lines 67 extend from rings 65, around sheaves 69, to wedges 42. The wedges 42 are raised in the launch mode as shown in FIG. 2 by applying tension to the recovery control lines 44 and lowered by releasing tension as shown in FIG. 1.
The lower part of each leg 16 has a bell crank 70 having a fulcrum 72 connected to a piece 73 so as to have an end 74 protrude through slot 38 upon the raising of a wire 76. The wire 76 is connected from the wedge 42 to an aperture 78 in bell crank 70. A retaining spring 80 connected between an inner plate 82 of 16 and bell crank 70 holds bell crank 70 in the inactivated position upon release of tension on wire 76. Upon the wedge 42 being raised the end 74 of bell crank 70 protrudes through slot 38 to provide a stop for skirt panel 34 so that a predetermined angle is maintained between the two skirt panels 34.
A typical breakaway electrical cable 84 having a finger section 86 is connected to target 10. Upon tension being placed upon section 86 by the release of target 10 the cable 84 separates from target 10 in a well known manner. The cable 84 connects to an electrical junction box 88. An electrical cable 90 connects junction box 88 to the helicopter. Box 88 receives signals from the helicopter that are supplied to the bomb shackles 52 and the target 10. The signals to target 10 are for presetting instrumentation that is well known and not within the scope of the present invention.
The legs 16 of U clamp 12 are each comprised of an inner plate 82, outer plate 92 and connecting plate 94. The inner connecting plate 94 does not run the entire length of leg 16 due to an inner opening necessary for operation of wedge 42. The plate 94 is welded to both inner and outer plates 82 and 92, respectively, and protrudes slightly beyond inner plate 82 for providing a positive stop for skirt 34 at all times.
The semicircular section 14 of each U clamp 12 comprises inner and outer plates 96 and 98, respectively, and connecting plate 100. The connecting plate 100 is welded to the inner circumferential surface of plates 96 and 98 and extends the entire length of plates 96 and 98. Nuts and bolts 102 connect bracket 20 to section 14 and leg 16 to section 14. The bolt 102 can be provided with inner collars or nuts for giving additional support to hold their respective plates 82, 92 and 96, 98 separated.
FIG. 3 is a front view of the system following a recovery operation. The wedges 42 are lowered for holding the target 10. A cork and rubber compound 104 extends along the entire inner surface of each of the U clamp 12 for cushioning purposes to prevent damage to the target 10. The compound 104 can be affixed to the U clamp by cementing or any other well known method. The compound 104 extends along two surfaces of the wedges 42 so as to provide cushioning in either the launching or recovery position.
FIG. 4 shows one of the typical bomb shackles 52 mounted to the strongback 18 by means of nuts 120 and bolts 122. A solenoid 124 is mounted to the frame 126 of bomb shackle 52 at a position so that energization of the solenoid 124 fires trigger 128. Lines 50 that hold target 10 are held by hooks 130. Upon firing trigger 128 the hooks 130 release dropping target 10 and lines 50 in a manner well known in the art. A reset switch 132 is provided for resetting the position of hooks 130. Electrical wires 134 supply the electrical energy to solenoid 124 for actuation purposes. The wires 134 are controlled from the helicopter and are connected to the solenoids through cable 90 and junction box 88.
In launch operation the orientation triangle is raised causing wedges 42 to lift up and be enclosed by U clamp 12. This provides a clearance path for the launching of target 10. The target 10 is secured by lines 50 that are held by bomb shackle 52. In the actual launch the solenoids 124 that release the target 10 are normally actuated sequentially with a time delay used for the aft bomb shackle solenoid 124. This gives target 10 an appropriate water entry angle.
In recovery operation the wedges 42 are raised during the first part of the capture to enable the forward and aft U clamps to enclose the target 10 as the system is lowered over target 10. At this time the raising of the wedges 42 causes the end 74 of bell crank 70 to protrude through slot 38 so that skirt panels 34 maintain a predetermined angle. Following the enclosure of target 10 the wedges 42 are lowered to hold the enclosed target 10.
There has therefore been shown a system suitable for both launching and recovering targets at sea. The system is self sufficient without utilization of personnel, in the sea, for assistance. In operation the system is suspended from a helicopter that uses either a ship or land for its home base. The system has thus far proven to be safe, quick and reliable in the performance of all expected functions.
It will be understood that various changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. | A system suspended from a helicopter is utilized for unrestricted launchingf cylindrical bodies and recovering these bodies while they are floating in a horizontal position. The system comprises a cage having a pair of axially separated U-shaped clamps with panels extending from the open portion of the clamps. Pivotable wedgs protrude to the inside of each clamp, allowing a cylindrical body to slip into the cage and be captured. In addition an electrical circuit is connected to bomb shackles in the system for providing the launch capability. | 1 |
FIELD OF THE INVENTION
The present invention relates to an arthropod-controlling composition.
BACKGROUND OF THE INVENTION
Many arthropod-controlling compositions are on the market at present. However, the objected harmful arthropods have many kinds and the situations for controlling them are in many ways. Therefore, the arthropod-controlling composition having practically high effectiveness and safety is desired.
Though pyrethroid insecticides having rapid knock-down efficacy are excellent agents for controlling harmful arthropods, progress of pyrethroid resistance to some arthropods has been reported in various places recently. Under these circumstances, non-pyrethroid compounds having excellent knock-down efficacy are earnestly desired.
On the other hand, it is known that some α-pyrone compounds are effective for controlling harmful acarina and houseflies in Japanese Unexamined Patent Publication No. sho-51-19126. However, the compounds described in the publication do not necessarily give a sufficient effect.
SUMMARY OF THE INVENTION
The present invention provides 4-hydroxy-6-methyl-3-(3-methylbutanoyl)-2-pyrone shown by the formula:
an arthropod-controlling composition comprising it as an active ingredient and a method for controlling arthropods by using it.
DETAILED DESCRIPTION OF THE INVENTION
Examples of the arthropods against which 4-hydroxy-6-methyl-3-(3-methylbutanoyl)-2-pyrone (hereinafter referred as to The Pyrone Compound) exhibits a control effect include the following Insecta, Acarina, Chilognatha, Epimorpha and Isopoda:
Hemiptera Insects:
Delphacidae (planthoppers) such as Laodelphax striatellus (small brown planthopper), Nilaparvata lugens (brown planthopper), Sogatella furcifera (white-backed rice planthopper) and so on; Deltocephalidae (leafhoppers) such as Nephotettix cincticeps (green rice leafhopper), Recilia dorsalis (zig-zag rice leaf hopper), Nephotettix virescens (green rice leafhopper) and so on; Aphididae (aphids); stink bugs; Aleyrodidae (whiteflies); scales; Tingidae (lace bugs); Psyllidae (suckers) and so on.
Lepidoptera Insects:
Pyralidae such as Chilo suppressalis (rice stem borer), Cnaphalocrocis medinalis (rice leafroller), Plodia interpunctella (Indian meal moth) and so on; Noctuidae such as Spodoptera litura (tobacco cutworm), Pseudaletia separata (rice armyworm), Mamestra brassicae (cabbage armyworm) and so on; Pieridae such as Pieris rapae crucivora (common cabbageworm) and so on; Tortricidae such as Adoxophyes spp. and so on; Carposinidae; Lyonetiidae; Lymantriidae; Plusiinae; Agrotis spp. such as Agrotis segetum (turnip cutworm), Agrotis ipsilon (black cutworm) and so on; Helicoverpa spp.; Heliothis spp.; Plutella xylostella; Parnara guttata (rice skipper); Tinea pellionella (casemaking clothes moth); Tineola bisselliella (webbing clothes moth) and so on.
Diptera Insects:
Culex spp. such as Culex pipiens pallens (common mosquito), Culex tritaeniorhynchus and so on, Aedes spp. such as Aedes aegypti, Aedes albopictus and so on; Anopheles spp. such as Anopheles sinensis and so on; Chironomidae (midges); Muscidae such as Musca domestica (housefly), Muscina stabulans (false stablefly), Fannia canicularis (little housefly) and so on; Calliphoridae; Sarcophagidae; Anthomyiidae such as Delia platura (seedcorn maggot), Delia antiqua (onion maggot) and so on; Tephritidae (fluit flies); Drosophilidae; Psychodidae (moth flies); Tabanidae; Simuliidae (black flies); Stomoxyidae (stable flies); Phoridae; Ceratopogonidae (biting midges) and so on.
Coleoptera Insects (Beetles)
Corn rootworms such as Diabrotica virgifera (western corn rootworm), Diabrotica undecimpunctata howardi (southern corn rootworm) and so on; Scarabaeidae (scarabs) such as Anomala cuprea (cupreous chafer), Anomala rufocuprea (soybean beetle) and so on; Curculionidae (weevils) such as Sitophilus zeamais (maize weevil), Lissorhoptrus oryzophilus (ricewater weevil), ball weevil, Callosobruchus chinensis (adzuki bean weevil) and so on; Dermestidae such as Authrenus verbasci (varied carpet beetle), Attagenus unicolor japonicus (black carpet beetle) and so on; Tenebrionidae (darkling beetles) such as Tenebrio molitor (yellow mealworm), Tribolium castaneum (red flour beetle) and so on; Chrysomelidae (leaf beetles) such as Oulema oryzae (rice leaf beetle), Phyllotreta striolata (striped flea beetle), Aulacophora femoralis (cucurbit leaf beetle) and so on; Anobiidae; Epilachna spp. such as Epilachna vigintioctopunctata (twenty-eight-spotted ladybird) and so on; Lyctidae (powderpost beetles), Bostrychidae (false powderpost beetles), Cerambycidae, Paederus fuscipes (robe beetle) and so on.
Dictyoptera Insects:
Blattella germanica (German cockroach); Periplaneta fuliginosa (smokybrown cockroach); Periplaneta americana (American cockroach); Periplaneta brunnea (brown cockroach); Blatta orientalis (oriental cockroach) and so on.
Thysanoptera Insects (Thrips):
Thrips palmi, Flankliniella occidentalis (western flower thrips), Thrips hawaiiensis (flower thrips) and so on.
Hymenoptera Insects:
Formicidae (ants); Vespidae (hornets); Polistes spp. (long-legged wasps); Bethylidae; Tenthredinidae (sawflies) such as Athalis rosae ruficornis (cabbage sawfly) and so on.
Orthoptera Insects:
Gryllotalpidae (mole crickets); Acrididae (grasshoppers) and so on.
Siphonaptera Insects (Fleas):
Ctenocephalides canis (dog flea); Ctenocephalides felis (cat flea); Pulex irritans ; and so on.
Anoplura Insects (Lice):
Pediculus corporis (body louse); Pediculus humanus (head louse); Pthirus pubis (crab louse) and so on.
Isoptera Insects:
Reticulitermes speratus; Coptotermes formosanus (Formosan subterranean termite); and so on.
Harmful Acarina:
Ixodidae (Ticks):
Boophilus microplus; Haemaphysalis longiconis and so on Tetranychidae (spider mites):
Tetranychus cinnabarinus (carmine spider mite); Tetranychus urticae (two-spotted spider mite); Tetranychus kanzawai (Kanzawa spider mite); Panonychus citri (citrus red mite); Panonychus ulmi (European red mite) and so on.
House-dust Mites:
Acaridae such as Tyrophagus putrescentiae (copra mite), Aleuroglyphus ovatus (brown legged grain mite) and so on; Dermanyssidae such as Dermatophagoides farinae (American house dust mite), Dermatophagoides pteronyssinus and so on; Glycyphagidae such as Glycyphagus privatus, Glycyphagus domesticus, Glycyphagus destructor and so on; Cheyletidae such as Chelacaropsis malaccensis, Cheyletus fortis and so on; Tarsonemidae; Chortoglyphus spp.; Haplochthonius spp. and so on.
Chilognatha (millipedes) such as Oxydus spp.; Chilopoda (centipedes) such as red centipede; wood lice such as Porcellio spp., Porcellionides spp.; and pill bugs such as Armadillidium spp. ;and so on.
As The Pyrone Compound, which is an active ingredient of the present controlling agent, gives an efficacy by contacting the objective harmful arthropods including insects and acarina, it is usually to be formulated as described below for use.
Namely, The Pyrone Compound or its solution can be formulated to the present controlling agent such as oil solution, emulsifiable concentrate, wettable powder, flowable (aqueous suspension or aqueous emulsion), granule, dust and so on, by mixing with solid carrier, liquid carrier or liquefied gaseous carrier and optionally surfactant, the other formulation auxiliaries.
The present controlling agent described above contains usually 0.001 to 95% by weight of The Pyrone Compound as an active ingredient.
Examples of the solid carrier used in the formulation described above include fine granules or granules of inorganic carriers such as clays (e.g. kaolin clay, diatomaceous earth, synthetic hydrated silicon oxide, bentonite, Fubasami clay, acid clay, etc.), talc, ceramics, sericite, quartz, calcium carbonate and so on; synthetic resins such as polyethylene, polypropylene and so on; and carriers originated from plants such as wood powder, activated carbon and so on. Examples of the liquid carrier include water, alcohols (e.g. methanol, ethanol, higher alcohols, etc.), ketones (e.g. acetone, methyl ethyl ketone, etc.), aromatic hydrocarbons (e.g. benzene, toluene, xylene, ethylbenzene, methylnaphthalene, etc.), aliphatic hydrocarbons (e.g. hexane, cyclohexane, kerosene, gas oil, etc.), esters (ethyl acetate, butyl acetate, etc.), nitriles (e.g. acetonitrile, isobutyronitrile, etc.), ethers (e.g. diisopropyl ether, dioxane, etc.), acid amides (e.g. N,N-dimethylformamide, N,N-dimethylacetamide, etc.), halogenated hydrocarbons (e.g. dichloromethane, trichloroethane, carbon tetrachloride, etc.), dimethyl sulfoxide, vegetable oils (e.g. soybean oil, cottonseed oil, etc.) and so on. Examples of the liquefied gaseous carrier include fluorocarbon, fluorohydrocarbon, LPG (liquefied petroleum gas), dimethyl ether and carbon dioxide and so on.
Examples of the surfactant optionally used in the formulation include alkyl sulfate salts, alkylsulfonate salts, alkylarylsulfonate salts, alkyl aryl ethers, polyoxyethylenealkyl aryl ethers, polyethylene glycol ethers, polyhydric alcohol esters and sugar alcohol derivatives and so on.
The other formulation auxiliaries are exemplified by sticking agent, dispersant, stabilizer and so on. Examples of sticking agent and dispersant include casein, gelatin, polysaccharides (e.g. starch powder, gum arabic, cellulose derivatives, alginic acid etc.), lignin derivatives, bentonite, sugars and synthetic water-soluble polymers (e.g. polyvinyl alcohol, polyvinylpyrrolidone, polyacrylic acids, etc.). Examples of stabilizer include phenol type antioxidants such as BHT (2,6-di-tert-butyl-4-methyphenol), BHA (mixture of 2-tert-butyl-4-methoxyphenol and 3-tert-butyl-4-methoxyphenol), amine type antioxidants such as diphenylamine, organic sulfur type antioxidants such as 2-mercaptobenzimidazole, PAP (acid isopropyl phosphate), vegetable oils, mineral oils, surfactants, fatty acids, esters of fatty acid and so on.
The flowable formulations (aqueous suspension or aqueous emulsion) usually comprise The Pyrone Compound, dispersant, suspension assistant (for example, protective colloid or a compound giving thixotropy), suitable auxiliaries (for example, antifoamer, rust preventive agent, stabilizer, developing agent, penetrating assistant, antifreezing agent, bactericide, fungicide, etc.) and water. Examples of the protective colloid include gelatin, casein, gums, cellulose ethers, polyvinyl alcohol and so on, and examples of the compound giving thixotropy include bentonite, aluminum magnesium silicate, xanthan gum, polyacrylic acids and so on. Use of the oil which can rarely dissolve The Pyrone Compound in place of water can give suspension-in-oil formulation.
The formulations of emulsifiable concentrate, wettable powder, flowable and so on obtained above are usually diluted with water and so on, and applied at 0.1 to 10000 ppm of the concentration of The Pyrone Compound. The formulations of oil solution, granule, dust and so on are usually applied to harmful arthropods by distributing or spraying as they are.
Further, The Pyrone Compound or its formulation can be used after making the forms below.
A mixture of The Pyrone Compound or its liquid formulation and a propellant can be charged into a pressure container with a spray nozzle to afford an aerosol of the present controlling agent. Further, The Pyrone Compound or its liquid formulation can be impregnated into a base material of mosquito-coil, mosquito-mat, ceramic board and so on to afford a heating volatile formulation such as mosquito-coil and mosquito-mat for electric heater; a heating fumigant formulation such as self-combustible fumigant, chemical reaction type fumigant and porous ceramic board fumigant; a non-heating volatile formulation such as resin volatile formulation and paper volatile formulation; a smoking formulation such as fogging; and an ULV formulation of the present controlling agent. Furthermore, a liquid formulation of The Pyrone Compound can be charged into a container with an absorptive wick in the upper part to afford a bottle containing insecticidal liquid for volitilization by heating the absorptive wick.
These present controlling agents include The Pyrone Compound as an active ingredient in an amount of 0.001% to 95% by weight.
Examples of the propellant for aerosols include propane, butane, isobutane, dimethyl ether, methyl ethyl ether and methylal.
An example of the base material of the mosquito-coil is a mixture of raw plant powder such as wood powder and Pyrethrum marc and a binding agent like Tabu powder (powder of Machilus thunbergii ), starch or gluten.
An example of the base material of the mosquito-mat for electric heating fumigation is a plate of compacted fibrils of cotton linters or a mixture of pulp and cotton linters.
The base material of the self-combustible fumigant includes, for example, an exothermic agent (e.g. nitrate, nitrite, guanidine salt, potassium chlorate, nitrocellulose, ethylcellulose, wood powder, etc.), a pyrolytic stimulating agent (e.g. alkali metal salt, alkaline earth metal salt, dichromate, chromate, etc.), an oxygen source (e.g. potassium nitrate, etc.), a combustion assistant (e.g. melanin, wheat starch, etc.), a bulk filler (e.g. diatomaceous earth, etc.) and a binding agent (e.g. synthetic glue, etc.).
The base material of the chemical reaction type fumigant includes, for example, an exothermic agent (e.g. alkali metal sulfide, polysulfide, hydrogensufide and hydrated salt, calcium oxide, etc.), a catalytic agent (e.g. carbonaneous substance, iron carbide, activated clay, etc.), an organic foaming agent (e.g. azodicarbonamide, benzenesulfonylhydrazide, dinitrosopentamethylenetetramine, polystyrene, polyurethane, etc.) and a filler (e.g. natural or synthetic fibers, etc.).
An example of the base material of the resin volatile formulation is thermoplastic resin, and examples of the base material of the paper volatile formulation include filter paper and Japanese paper.
The present controlling agent can be used simultaneously with the other insecticide, the other acaricide, repellent or synergist under non-mixed conditions or pre-mixed conditions.
Examples of the insecticides and acaricides include organophosphorus compounds such as fenitrothion [O,O-dimethyl O-(3-methyl-4-nitrophenyl)phosphorothioate], fenthion [O,O-dimethyl O-(3-methyl-4-(methythio)phenyl)phosphorothioate], diazinon [O,O-diethyl O-2-isopropyl-6-methylpyrimidin-4-yl phosphorothioate], chlorpyrifos [O,O-diethyl O-3,5,6-trichloro-2-pyridyl phosphorothioate], DDVP [2,2-dichlorovinyl dimethyl phosphate], cyanophos [O-4-cyanophenyl O,O-dimethyl phosphorothioate], dimethoate [O,O-dimethyl S-(N-methylcarbamoylmethyl) dithiophosphate], phenthoate[ethyl2-dimethoxyphosphinothioylthio(phenyl)acetate], malathion[diethyl(dimethoxyphosphinothioylthio)succinate], and azinphos-methyl [S-3,4-dihydro-4-oxo-1,2,3-benzotriazin-3-ylmethyl O,O-dimethyl phosphorodithioate];carbamate compounds such as BPMC (2-sec-butylphenyl methylcarbamate), benfracarb [ethyl N-[2,3-dihydro-2,2-dimethylbenzofuran-7-yloxycarbonyl (methyl)aminothio]-N-isopropyl-β-alaninate], propoxur [2-isopropoxyphenyl N-methylcarbamate] and carbaryl [1-naphthyl N-methylcarbamate]; pyrethroid compounds such as etofenprox [2-(4-ethoxyphenyl)-2-methylpropyl-3-phenoxybenzyl ether], fenvalerate [(RS)-α-cyano-3-phenoxybenzyl (RS)-2-(4-chlorophenyl)-3-methyl-butyrate], esfenvalerate [(S)-α-cyano-3-phenoxybenzyl (S)-2-(4-chlorophenyl)-3-methylbutyrate], fenpropathrin [(RS)-α-cyano-3-phenoxybenzyl2,2,3,3-tetramethylcyclopropanecarboxylate], cypermethrin [(RS)-α-cyano-3-phenoxybenzyl (1RS)-cis,trans-3-(2,2-dichlorovinyl)-2,2-dimethylcyclopropanecarboxylate], permethrin [3-phenoxybenzyl (1RS)-cis,trans-3-(2,2-dichlorovinyl)-2,2-dimethylcyclopropanecarboxylate], cyhalothrin [(RS)-α-cyano-3-phenoxybenzyl(Z)-(1RS)-cis-3-(2-chloro-3,3,3-trifluoroprop-1-enyl)-2,2-dimethylcyclopropanecarboxylate], deltamethrin [(S)-α-cyano-3-phenoxybenzyl(1R)-cis-3-(2,2-dibromovinyl)-2,2-dimethylcyclopropanecarboxylate], cycloprothrin [(RS)-α-cyano-3-phenoxybenzyl (RS)-2,2-dichloro-1-(4-ethoxyphenyl)cyclopropanecarboxylate], fluvalinate[α-cyano-3-phenoxybenzyl N-(2-chloro-α,α,α-trifluoro-p-tolyl)-D-valinate], bifenthrin [2-methylbiphenyl-3-ylmethyl(Z)-(1RS)-cis-3-(2-chloro-3,3,3-trifluoroprop-1-enyl)-2,2-dimethylcyclopropanecarboxylate], 2-methyl-2-(4-bromodifluoromethoxyphenyl)propyl 3-phenoxybenzyl ether, tralomethrin [(S)-α-cyano-3-phenoxybenzyl(1R-cis)-3-{(1RS)(1,2,2,2-tetrabromoethyl)}-2,2-dimethylcyclopropanecarboxylate], silafluofen[(4-ethoxyphenyl){3-(4-fluoro-3-phenoxyphenyl)propyl}dimethylsilane], d-phenothrin [3-phenoxybenzyl (1R-cis, trans)-chrysanthemate], cyphenothrin[(RS)-α-cyano-3-phenoxybenzyl (1R-cis, trans)-chrysanthemate], d-resmethrin[5-benzyl-3-furylmethyl (1R-cis,trans)-chrysanthemate], acrinathrin [(S)-α-cyano-3-phenoxybenzyl(1R,cis(Z))-2,2-dimethyl-3-{3-oxo-3-(1,1,1,3,3,3-hexafluoropropyloxy)propenyl}cyclopropane-carboxylate], cyfluthrin[(RS)-α-cyano-4-fluoro-3-phenoxybenzyl 3-(2,2-dichlorovinyl)-2,2-dimethylcyclopropanecarboxylate], tefluthrin [2,3,5,6-tetrafluoro-4-methylbenzyl (1RS-cis(Z))-3-(2-chloro-3,3,3-trifluoroprop-1-enyl)-2,2-dimethylcyclopropanecarboxylate], transiluthrin [2,3,5,6-tetrafluorobenzyl (1R-trans)-3-(2,2-dichlorovinyl)-2,2-dimethylcyclopropanecarboxylate], tetramethrin [3,4,5,6-tetrahydrophthalimidomethyl (1RS)-cis,trans-chrysanthemate], allethrin [(RS)-3-allyl-2-methyl-4-oxocyclopent-2-enyl (1RS)-cis,trans-chrysanthemate], prallethrin [(S)-2-methyl-4-oxo-3-(2-propynyl) cyclopent-2-enyl (1R)-cis,trans-chrysanthemate], empenthrin [(RS)-1-ethynyl-2-methyl-2-pentenyl (1R)-cis,trans-chrysanthemate], imiprothrin [2,5-dioxo-3-(prop-2-ynyl)imidazolidin-1-ylmethyl (1R)-cis,trans-2,2-dimethyl-3-(2-methylprop-1-enyl)cyclopropanecarboxylate], d-furamethrin [5-(2-propynyl)furfuryl (1R)-cis,trans-chrysanthemate] and 5-(2-propynyl)furfuryl 2,2,3,3-tetramethylcyclopropanecarboxylate; nitroimidazolidine derivatives such as imidacloprid (1-(6-chloro-3-pyridylmethyl)-N-nitroimidazolidin-2-ylideneamine); N-cyanoamidine derivatives such as N-cyano-N′-methyl-N′-(6-chloro-3-pyridylmethyl) acetamidine; nitenpyram [N-(6-chloro-3-pyridylmethyl)-N-ethyl-N′-methyl-2-nitrovynylidenediamine]; thiacloprid [1-(2-chloro-5-pyridylmethyl)-2-cyanoiminothiazoline]; thiamethoxam [3-((2-chloro-5-thiazolyl)methyl)-5-methyl-4-nitroiminotetrahydro-1,3,5-oxadiazine]; 1-methyl-2-nitro-3-((3-tetrahydrofuryl)methyl)guanidine; 1-(2-chloro-5-thiazolyl)methyl-3-methyl-2-nitroguanidine; nitroiminohexahydro-1,3,5-triazine derivatives; chlorinated hydrocarbons such as endosulfan [6,7,8,9,10,10-hexachloro-1,5,5a,6,9,9a-hexahydro-6,9-methano-2,4,3-benzodioxathiepine oxide], γ-BHC [1,2,3,4,5,6 -hexachlorocyclohexane] and 1,1-bis(chlorophenyl)-2,2,2-trichloroethanol; benzoylphenylurea compounds such as chlorfluazuron [1-(3,5-dichloro-4-(3-chloro-5-trifluoromethylpyridyn-2-yloxy)phenyl)-3-(2,6-difluorobenzoyl)urea], teflubenzuron [1-(3,5-dichloro-2,4-difluorophenyl)-3-(2,6-difluorobenzoyl)urea] and flufenoxuron [1-(4-(2-chloro-4-trifluoromethylphenoxy)-2-fluorophenyl)-3-(2,6-difluorobenzoyl)urea]; juvenile hormone like compounds such as pyriproxyfen [4-phenoxyphenyl2-(2-pyridyloxy)propyl ether], methoprene [isopropyl (2E,4E)-11-methoxy-3,7,11-trimethyl-2,4-dodecadienoate] and hydroprene [ethyl (2E,4E)-11-methoxy-3,7,11-trimethyl-2,4-dodecadienoate]; thiourea derivatives such as diafenthiuron [N-(2,6-diisopropyl-4-phenoxyphenyl)-N′-tert-butylcarbodiimide]; phenylpyrazole compounds; 4-bromo-2-(4-chlorophenyl)-1-ethoxymethyl-5-trifluoromethylpyrrol-3-carbonitrile [chlorfenapil]; metoxadiazone [5-methoxy-3-(2-methoxyphenyl)-1,3,4-oxadiazol-2(3H)-one], bromopropylate [isopropyl 4,4′-dibromobenzilate], tetradifon [4-chlorophenyl 2,4,5-trichlorophenyl sulfone], chinomethionat [S,S-6-methylquinoxaline-2,3-diyldithiocarbonate], pyridaben [2-tert-butyl-5-(4-tert-butylbenzylthio)-4-chloropyridazin-3(2H)-one], fenpyroximate [tert-butyl (E)-4-[(1,3-dimethyl-5-phenoxypyrazol-4-yl)methyleneaminooxymethyl]benzoate], tebufenpyrad [N-(4-tert-butylbenzyl)-4-chloro-3-ethyl-1-methyl-5-pyrazolecarboxamide], polynactins complex [tetranactin, dinactin and trinactin], pyrimidifen [5-chloro-N-[2-{4-(2-ethoxyethyl)-2,3-dimethylphenoxy}ethyl]-6-ethylpyrimidin-4-amine], milbemectin, abamectin, ivermectin and azadirachtin [AZAD]. Examples of the synergists include bis-(2,3,3,3-tetrachloropropyl) ether (S-421), N-(2-ethylhexylbicyclo[2.2.1]hept-5-ene-2,3-dicarboximide (MGK-264) and α-[2-(2-butoxyethoxy)ethoxy] -4,5-methylenedioxy-2-propyltoluene (piperonyl butoxide).
The application amount and concentration of the present controlling agent can be suitably designed according to the type of the formulations, time, place, and method of application, kind of noxious pests and damage.
EXAMPLES
The present invention will be further illustrated in more details by the production examples and test examples, although the present invention is not limited in any sense to these examples. Parts represent parts by weight in the following examples.
Production Example 1
Twenty parts of The Pyrone Compound are dissolves in 65 parts of xylene, mixed with 15 parts of emulsifier Sorpol 3005X (registered trademark of Toho Chemical Co., Ltd.), and stirred sufficiently to give 20% emulusifiable concentrate.
Production Example 2
Forty parts of The Pyrone Compound are mixed first with 5 parts of Sorpol 5060 (registered trademark of Toho Chemical Co., Ltd.) and then with 32 parts of Carplex #80 (registered trademark of Shionogi & Co., Ltd.; fine powder of synthetic hydrated silicon oxide) and 23 parts of 300-mesh diatomaceous earth, and stirred with a juice mixer to give 40% wettable powder.
Production Example 3
One and a half (1.5) parts of The Pyrone Compound are mixed with 98.5 parts of AGSORB LVM-MS 24/48 (granular carrier of calcined montmorillonite having the particle diameter of 24- to 48-mesh provided by OIL DRI Corp.) sufficiently to give 1.5% granule.
Production Example 4
A mixture of 10 parts of The Pyrone Compound, 10 parts of phenylxylylethane and 0.5 part of Sumidule L-75 (tolylenediisocyanate provided by Sumika Bayer Urethane Co., Ltd.) is added to 20 parts of a 10% aqueous solution of gum arabic, and stirred with a homomixer to give an emulsion having the mean particle diameter of 20 μm. The emulsion is further mixed with 2 parts of ethylene glycol and allowed to react on a water bath of 60° C. for 24 hours to give a microcapsule slurry. On the other hand, a thicking agent solution is prepared by dispersing 0.2 part of xanthan gum and 1.0 part of Veegum R (aluminum magnesium silicate provided by Sanyo Chemical Co., Ltd.) in 56.3 parts of ion-exchanged water.
Forty-two and a half parts (42.5 parts) of the above microcapsule slurry and 57.5 parts of the above thicking agent solution are mixed to give 10% microencapsulated formulation.
Production Example 5
A mixture of 10 parts of The Pyrone Compound and 10 parts of phenylxylylethane is added to 30 parts of a 10% aqueous solution of polyvinyl alcohol and stirred with a homomixer to give an emulsion having the mean particle diameter of 3 μm. On the other hand, a thicking agent solution is prepared by dispersing 0.2 part of xanthan gum and 0.4 part of Veegum R (aluminum magnesium silicate provided by Sanyo Chemical Co., Ltd.) in 49.4 parts of ion-exchanged water.
Fifty parts of the above emulsion and 50 parts of the above thicking agent solution are mixed to give 10% flowable formulation.
Production Example 6
Five parts of The Pyrone Compound are mixed with 3 parts of Carplex #80 (registered trademark of Shionogi & Co., Ltd.; fine powder of synthetic hydrated silicon oxide), 0.3 parts of PAP and 91.7 parts of 300-mesh talc, and stirred with a juice mixer to give 5% dust.
Production Example 7
A half (0.5) part of The Pyrone Compound was dissolved in 10 parts of dichloromethane and mixed with 89.5 parts of Isoper M (isoparaffin provided by Exxon Chemical Corp.) to give 0.5% oil solution.
Production Example 8
An aerosol vessel was filled with 0.1 g of The Pyrone Compound and 49.9 g of Neotiozol (Chuokasei Company). The vessel was then equipped with a valve, and 25 g of dimethyl ether and 25 g of LPG were charged and shaken. The aerosol vessel was equipped with an actuator and to give oil-based aerosol.
Production Example 9
An aerosol vessel was filled with 0.2 g of The Pyrone Compound and 49.8 g of Neotiozol (Chuokasei Company). The vessel was then equipped with a valve, and 25 g of dimethyl ether and 25 g of LPG were charged and shaken. The aerosol vessel was equipped with an actuator and to give oil-based aerosol.
Production Example 10
An aerosol vessel was filled with 0.4 g of The Pyrone Compound and 49.6 g of Neotiozol (Chuokasei Company). The vessel was then equipped with a valve, and 25 g of dimethyl ether and 25 g of LPG were charged and shaken. The aerosol vessel was equipped with an actuator and to give oil-based aerosol.
Production Example 11
An aerosol vessel was filled with 0.8 g of The Pyrone Compound and 49.2 g of Neotiozol (Chuokasei Company). The vessel was then equipped with a valve, and 25 g of dimethyl ether and 25 g of LPG were charged and shaken. The aerosol vessel was equipped with an actuator and to give oil-based aerosol.
Production Example 12
An aerosol vessel was filled with 1.6 g of The Pyrone Compound and 48.4 g of Neotiozol (Chuokasei Company). The vessel was then equipped with a valve, and 25 g of dimethyl ether and 25 g of LPG were charged and shaken. The aerosol vessel was equipped with an actuator and to give oil-based aerosol.
Production Example 13
An aerosol vessel is filled with 50 parts of purified water and a dissolved mixture of 0.6 part of The Pyrone Compound, 0.01 part of BHT, 5 parts of xylene, 3.39 parts of deodorized kerosene and 1 part of Atmos 300 (registered trademark of Atlas Chemical Co.). The vessel is then equipped with a valve and 40 parts of propellant (liquefied petroleum gas) is charged through the valve into the aerosol vessel under pressure to give water-based aerosol.
Production Example 14
A solution prepared by dissolving 0.5 g of The Pyrone Compound in 20 ml of acetone is homogeneously mixed with 99.5 g of a carrier for a mosquito-coil (mixture of Tabu powder, Pyrethrum marc and wood powder at the ratio of 4:3:3). After 120 ml of water is added, the mixture is kneaded sufficiently, molded and dried to give mosquito-coil.
Production Example 15
One hundred and twenty grams (120 g) of water dissolving 0.3 g of Malachite Green dye and 0.2 g of sodium dehydroacetate were added to a carrier for a mosquito-coil (mixture of Tabu powder, Pyrethrum marc and wood powder at the ratio of 5:3:2), kneaded sufficiently, molded and dried to give a base material for mosquito-coil. One hundred milligrams (100 mg) of The Pyrone Compound were dissolved in 5 ml of acetone. A quarter milliliter (0.25 ml) of the solution was painted on 0.5 g of the above base material for mosquito-coil and sufficiently air-dried to give 1% mosquito-coil.
Production Example 16
One hundred and twenty grams (120 g) of water dissolving 0.3 g of Malachite Green dye and 0.2 g of sodium dehydroacetate are added to a carrier for a mosquito-coil (mixture of Tabu powder, Pyrethrum marc and wood powder at the ratio of 5:3:2), kneaded sufficiently, molded and dried to give a base material for mosquito-coil. In 0.7 g of deodorized kerosene, 0.3 g of The Pyrone Compound is dissolved. One gram (1 g) of the solution is painted on 29 g of the above base material for mosquito-coil and sufficiently air-dried to give 1% mosquito-coil.
Production Example 17
A solution prepared by dissolving lg of The Pyrone Compound in 20 ml of acetone is homogeneously mixed with 99 g of a carrier for a mosquito-coil (mixture of Tabu powder, Pyrethrum marc and wood powder at the ratio of 5:3:2) and 120 ml of water dissolving 0.3 g of Malachite Green dye and 0.2 g of sodium dehydroacetate. The mixture is kneaded sufficiently, molded and dried to give mosquito-coil.
Production Example 18
Acetone is added to 0.2 g of The Pyrone Compound, 0.1 g of BHT and 0.4 g of piperonyl butoxide to make the total 10 ml. A hgalf milliliter (0.5 ml) of the obtained solution is impregnated with a base material (a plate of compacted fibrils of a mixture of pulp and cotton linters: 2.5 cm×1.5 cm, 0.3 cm in thickness) for mosquito-mat homogeneously to give a mosquito-mat for electric heater.
Production Example 19
One-fifth part (0.2 part) of The Pyrone Compound and 0.1 part of BHT are dissolved in 99.7 parts of deodorized kerosene to give a solution. The solution is charged in a vessel of polyvinyl chloride. In the vessel is inserted an absorptive wick which is inorganic powder solidified with a binder and then calcined, the upper portion of which wick can be heated with a heater, to give a part of electric heating fumigation device using a liquid.
Production Example 20
A solution prepared by dissolving 100 mg of The Pyrone Compound in an appropriate amount of acetone is impregnated with a porous ceramic plate (4.0 cm×4.0 cm, 1.2 cm in thickness) to give a heating fumigant.
Next, a method for preparing The Pyrone Compound is shown as Reference preparation example.
Reference Preparation Example
Ten grams (10.0 g, 79.3mmol) of 4-hydroxy-6-methyl-2-pyrone were suspended in 100 ml of toluene at room temperature. To the suspension, 1.22 g (10.0 mmol) of N,N-dimethylaminopyridine, 8.79 g (86.1 mmol) of isovaleric acid and 18.5 g (89.7mmol) of dicyclohexylcarbodiimide were added subsequently. The mixed solution was stirred for 1 hour at room temperature, and then heated to 70° C. and stirred for 20 hours under heating. After the mixed solution was allowed to stand at room temperature, the precipitated insoluble dicyclohexylurea was filtered off, and washed with 1N hydrochloric acid once and 10% brine twice. The organic layer was dried over magnesium sulfate and evaporated under reduced pressure to give a crude oily product.
The crude oily product was subjected to silica gel column chromatography (eluent: hexane/ethyl acetate=6/1) to give 7.01 g of The Pyrone Compound (yield 42%).
1 H-NMR (CDCl 3 /TMS): 0.96 (6H, d), 2.22 (1H, m), 2.27 (3H, s), 2.96 (2H, d), 5.93 (1H, s), 16.99 (1H, s).
The effect of the present controlling agent is shown in the following Test Examples. For showing an efficacy of the present controlling agent enough, 4-hydroxy-6-methyl-3-(2-methylpropanoyl-2-pyrone (hereinafter, referred to as Reference compound 1) described in Japanese Unexamined Patent Publication No. sho-51-19126 (Compound No. 3) of the formula:
4-hydroxy-6-methyl-3-(2-ethylbutanoyl)-2-pyrone (hereinafter, referred to as Reference compound 2) described in Japanese Unexamined Patent Publication No. sho-51-19126 (Compound No. 5) of the formula:
and 4-hydroxy-6-methyl-3-(cyclopropanecarbonyl)-2-pyrone (hereinafter, referred to as Reference compound 3) described in Japanese Unexamined Patent Publication No. sho-51-19126 (Compound No. 11) of the formula:
were used as references.
Test example 1
According to Production example 7, each of the 0.5% oil solutions of The Pyrone Compound and Reference compound 1 was prepared.
A square of paper (side: 20 cm) was covered on the iron net set on the bottom of the metallic chamber (46 cm×46 cm, 70 cm in height). A container (8.75 cm in diameter, 7.5 cm in height, having 16-mesh net at the bottom and spreading butter on the wall for preventing escape) was set on the paper. In the container, ten (5 males and 5 females) adult German cockroaches were released. By means of spray gun, 1.5 ml of the above oil solution was applied to the test insects at pressure of 4.1×10 4 Pa from the upper part of the chamber. The container was taken out of the chamber 30 seconds after spraying and the test insects were transferred to a plastic cup. Two minutes after spraying, the knocked-down cockroaches were counted.
The results are given in Table 1.
TABLE 1
Knock-down percentage (%)
The Pyrone Compound
100
Reference compound 1
10
Test Example 2
According to Production example 7, each of the 0.25% oil solutions of The Pyrone Compound and Reference compounds 2 and 3 was prepared. The same procedures as Test Example 1 gave the knock-down percentages and KT 50 values (minutes for knocked-down 50% of cockroaches) in Table 2.
TABLE 2
Knock-down
percentage (%)
KT 50 (minutes)
The Pyrone Compound* 1
95
0.85
Reference compound 2* 2
0
more than 10
Reference compound 3* 2
6.7
more than 10
* 1 average of 6 repetitions
* 2 average of 3 repetitions | 4-Hydroxy-6-methyl-3-(3-methylbutanoyl)-2-pyrone has a rapid controlling effect against arthropods such as Dictyoptera insects (e.g. German cockroach, smokybrown cockroach). | 2 |
This is a continuation of application Ser. No. 057,401, filed July 13, 1979, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cutting torch tips. More particularly, this invention relates to a cutting torch tip that can be employed for beveling high strength steels as well as common carbon steels when cutting at angles greater than 45° with respect to the perpendicular and produce a smooth cut.
2. Description of the Prior Art
The prior art has seen the development of a wide variety of torch tips, including cutting torch tips. As is recognized, cutting oxygen passes through an orifice, usually centrally located, in the tip. Surrounding the orifice are a plurality of smaller orifices called preheat orifices that pass a mixture of fuel gas and oxygen to preheat the metal for cutting. The admixture of fuel gas and oxygen burn to insulate the cutting oxygen from contamination by surrounding air. Consequently, the preheat orifices must be located precisely around the cutting orifice in a proper orientation. Torch tips for these features have in the past been made by three basic methods producing two basic styles of tips.
The older style is a single piece torch tip. One way of making this style of tip is by drilling. First, a solid blank of material, such as copper, is shaped in the form of a torch tip. Next, the cutting orifice and the preheat orifices are formed in the blank by drilling. Since drilled holes are limited in the minimum diameter obtainable, it is often desirable to make the orifices smaller. This improves combustion properties such that the fuel gas burns more efficiently, heating the work piece better. In this method, holes have also been formed by inserting piano wires in the drill holes and swaging the tip around the wires, then pulling the wires free. The problem with this method is that it is slow, the drills do not drill straight enough to optimally locate the orifices and the drills frequently break. Moreover, the number of preheat orifices that can be located about the cutting orifice is limited because of the disadvantages of this method. Another method of making single piece type torch tip is by swaging or drawing together two separate pieces. U.S. Pat. Nos. 3,716,902, and 2,254,757 reveal such a method. This method is less expensive than the first but also has problems in that the number and shape of the preheat orifices is still limited and the precise orientation of preheat orifices is less than optimal.
The other style of torch tip is a two piece design. An example of this type of tip is revealed in U.S. Pat. No. 2,468,824. The outer piece of this tip is made by forming a shell of smooth interior. The inner piece is made by milling rectangular slots in the exterior of a blank piece of metal and drilling a cutting orifice through the center thereof. The smooth inner surface of the outer piece and the mill slots of the inner piece combine to form the preheat orifices. This method is advantageous in that an increased number of preheat orifices is possible. In the prior art of this type, however, the tips not been satisfactory when trying to form a smooth, beveled cut where the degree of bevel is more than 45° with respect to the perpendicular; for example, in the range of 45°-90° with respect to a vertical plane when the work surface is horizontal. Apparently, there has been a concentrated flame from which the heat was reflected from the cutting surface of the work piece such that even if cutting was possible at all, it was a ragged cut that had to supplementarily processed; particularly, with high strength steels.
Typical of other prior art patents are U.S. Pat. Nos. 3,838,820; 3,558,062; 2,351,787; 1,731,265; and 1,186,962. These patents were thought to have possibilities; but when tested they all developed the same reflecting heat problem such that even where a beveled cut was possible, it was a jagged cut that required supplemental working.
From the foregoing, it can be seen that none of the prior art torch tips produced a type flame that would bevel and produce a smooth cut when the angle of bevel was between 45°-90° with respect to the perpendicular, or line perpendicular to the surface of the work piece at the point of beveling.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a torch tip that can be employed in a cutting torch and effect a beveled cut that is satisfactorily smooth and alleviate the difficulties of the prior art.
It is a specific object of this invention to provide a torch tip that produces a bulbous flame that does not reflect off the work piece to too great a degree; and produce a relatively smooth beveled cut even at angles greater than 45° with respect to the perpendicular.
These and other objects will become apparent from the descriptive matter hereinafter, particularly when taken in conjunction with the appended drawings.
In accordance with this invention there is provided a torch tip for use with a cutting torch in beveling high strength steels at angles greater than 45° with respect to the perpendicular, or less than 45° with respect to the tangentto the surface of the work piece at the point of beveling; the torch tip comprising:
a. an inner piece having a plurality of slots, or grooves, preferably eight or more spaced equally around the periphery of its effluent end and extending toward its other end a sufficient distance to terminate in a chamber to which fuel and oxygen are supplied for preheating; having a plurality of longitudinally extending apertures for supplying preheat fuel and oxygen; the inner piece conformably fitting interiorly of an outer shell; the inner piece having a centrally disposed cutting oxygen passageway penetrating longitudinally therethrough; the cutting oxygen passageway having a diameter dco; the inner piece terminating in a squared off effluent end and having its other end conformingly coengaging an inner end of an outer shell and adapted to be sealingly received within the cutting torch;
b. an outer shell disposed concentricly about said inner piece and conformingly coengaging said center piece adjacent its inner and effluent ends, having a generally tubular configuration with an outer frusto conical section toward its effluent end, having its other end engaging said other end of said inner piece and adapted to be spealingly received in the cutting torch; the outer shell having a chamber passageway larger in diameter than said inner piece therealong so as to define an annular chamber for preheat fuel and oxygen; the outer shell having a second passageway conformingly receiving the first end of said inner piece and its slots so as to define preheat apertures; the outer shell extending beyond the effluent end of said inner piece so as to define an effluent chamber having a first section, such as a cylindrical section of diameter du, and at least one frusto-conical section downstream of the cylindrical section; and having an exit diameter de smaller than the upstream diameter du of the effluent chamber; the outer shell having at least one frusto conical section making the transition from the effluent chamber diameter du to the exit diameter de; the effluent chamber having a length L no greater than du;
such that operationally the combination produces a bulbous flame that will satisfactorily smoothly cut high strength steel at a bevel angle within the range of 45°-90° with respect to the perpendicular line at the line of beveling. The details of constructing the torch of this invention are described in the preferred embodiment later herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial side elevational view showing a cutting torch tip of the prior art.
FIG. 2 is a partial side elevational view showing the cutting torch tip of this invention.
FIG. 3 is a side elevational view, partly in section, of the cutting torch tip of this invention.
FIG. 4 is a magnified cross sectional view of the outer shell of the torch tip of FIG. 3.
FIG. 5 is a cross sectional view of the inner piece of the torch tip of FIG. 3.
FIG. 6 is a partial end view of the inner piece of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The technology of properly designing and manufacturing cutting torch tips is less a science and more an art. The reasons why certain things work are not fully understood. For example, as shown in FIG. 1, cutting torch tips that work satisfactorily at angles approximating the perpendicular, or less than 45° with respect thereto, cease to work satisfactorily when the angle becomes 45° or greater. The reason is not completely understood but appears to be related to the fact that the slim flame 11 emanating from the torch tip 13 is reflected from the surface 15 of the work piece 17. Even if the tip is made large enough that sufficient heat could be generated to cut the steel plate of the work piece 17, the cut will be uneven, jagged and not satisfactory.
In contrast, with the tip 19 of this invention, the flame is a bulbous flame 21 that produces a satisfactory bevel 23 in the work piece 17. Moreover, the tip will cut completely through the high strength steel plate readily, as shown by the effluent molten steel 25.
The invention may be understood completely by referring to FIGS. 3-6. Referring to FIG. 3, the torch tip 19 is shown assembled ready to be included in the cutting torch (not shown). The torch tip 19 comprises the inner piece 27 and the outer shell 29. The two pieces are ordinarily formed of similar materials. For example, the outer shell may be formed of highly heat conductive copper and the inner piece formed of brass so as to resist oxidation, conduct heat away from the tip readily, and the like. Other materials may be employed in the construction of the pieces as long as they will meet the exacting requirements of the cutting torch tips.
The inner piece 27 has a plurality of slots, or grooves, 31, FIGS. 3 and 5, spaced equally around the periphery of its effluent end. The grooves 31 extend toward its other end a sufficient distance to terminate in a mixing chamber 33 to which is supplied preheat fuel and oxygen admixed. The grooves, or slots, 31, as can be seen in FIG. 6, have a full radius bottom having a radius R. The sides of the grooves 31 are disposed parallel with each other and at a distance of 2R from each other. In the embodiment illustrated in FIG. 6, there are ten such grooves 31 that are disposed apart at 36°, centerline to centerline. Slots may be milled into the inner piece 27 before the cutting oxygen aperture is drilled therethrough. Near the other end, the center piece 27 has a plurality of apertures 35 drilled longitudinally thereof for supplying preheat fuel and oxygen admixture into the mixing chamber 33.
The inner piece 27 has a centrally disposed passageway 37, FIGS. 5 and 6 for cutting oxygen. The cutting oxygen passageway 37 penetrates longitudinally through the center piece 27 and has a diameter dco at the effluent end. The passageway 37 may be larger at its other end.
The inner piece 27 terminates in a squared off end 39 at the effluent end and has its other end conformingly coengaging an inner end of the outer shell 29, all adapted to be sealingly received within the cutting torch. The other end 41 of the inner piece is adapted to be sealingly received in the cutting torch so as to allow the cutting oxygen to proceed down the cutting oxygen passageway 37 while the admixture of fuel and oxygen preheat is passed through the annular passageway. The inner piece 27 has a shoulder 43 that comprises an outer annular step shoulder 45 for engaging the outer rim 47 of the shell, FIG. 4. The shoulder 43 has a second stepped shoulder 49 for engaging the recess shoulder 51 interiorly of the ring 47 of the outer shell 29, FIG. 4.
The outer shell 29 has generally tubular configuration and is disposed about the inner piece 27 with the respective ends in coengaging relationship. The outer shell 29 has a frusto conical section 53 toward its effluent end. In fact, as illustrated, it has a first frusto conical section of a somewhat greater angle frustum than a second section 55.
As indicated hereinbefore, it has its other end 57 adapted to conformingly coengage the other end of the inner piece by the respective rings and shoulders 45, 47, 49 and 51. The other end 57 is adapted to be sealingly received within the cutting torch, as is the other end 41 of the inner piece.
The outer shell has a chamber passageway 59 that is larger in diameter than the inner piece along this section when the two are conformingly coengaged for operation. Consequently, an annular chamber 33 is formed for the preheat fuel and oxygen admixture. The outer shell has a second passageway 61 conformably receiving the first end 63, FIG. 5, of the inner piece 27 so as to define, in combination with the slots 31, preheat apertures. The outer shell extends beyond the effluent end of the inner piece; shown in phanton line 40, FIG. 4; so as to define an effluent chamber 63, FIGS. 3 and 4. As illustrated in FIGS. 3 and 4, the chamber 63 has a first section defined by interior walls of the outer shell 29 at a first angle and having a diameter du and at least one frusto-conical section downstream thereof defined by interior walls of the outer shell 29 at a second angle greater than the first angle. The angles are measured with respect to longitudinal axis of the outer shell and are within the range of 0°-90°, inclusive. In FIG. 3, the chamber includes a cylindrical section, the walls of which are at 0° angle, and a downstream frusto-conical section, the walls of which are at an angle greater than 0°. As can be seen in FIG. 4 there is also a small frusto-conical third section at an angle alpha (α) that is greater than beta (β). As illustrated the angle alpha is about 30° with respect to the longitudinal axis of the outer shell and the angle beta is greater than ten degrees but less than thirty degrees. The outer shell has an effluent aperture 65 having a diameter de smaller than the diameter du of the effluent chamber 63 upstream thereof.
The effluent chamber has a length L that is less than the diameter du, although it is at least twice as great as the length of any chambers formed by extensions of shells in the torch tips of the prior art.
In manufacturing the torch tips 19, it has been found that the diameter of the section 63 of the inner piece and the diameter du of the second passageway 61 of the outer shell can be made relatively constant. Moreover, the length L of the effluent chamber 63 can be maintained relatively constant. Greater or lesser cutting capacity and inverse sensitivity can be achieved by altering the diameter of the cutting oxygen passageway dco and the diameter of the exit aperture de. For example, in the specific series of cutting torch tips, it has been found that the slots that have been employed can be 0.038 inch in diameter with a full radius bottom of 0.019 inch radius; the diameter of the section 63 of the inner piece can be about 0.26 inch and the diameter du about 0.2615-0.2635 inch. The following table gives an example of how the diameter of the cutting oxygen passageway at the effluent end necessitates a variation in the diameter of the exit aperture if the cutting torch of this invention is to function properly.
TABLE______________________________________DCO DE______________________________________0.121 inch (in.) 0.196 in.0.100 in. 0.190 in.0.080 in. 0.185 in.______________________________________
It is noteworthy that each time the diameter of the cutting oxygen torch tip increases by a factor of about 0.02 inch, the diameter of the effluent aperture must increase about 0.06 inch. It also appears that the ratio of the diameter of the cutting oxygen passageway to the diameter of the effluent aperture must be in the range of about 0.4-0.7.
From the foregoing it can be seen that this invention is advantageous in providing torch tips that can be employed with cutting torches to cut at a beveled angle in the range of 45°-90° with respect to the perpendicular to the surface of the work piece at the location where the bevel is to be cut. It thereby accomplishes the object delineated hereinbefore.
Although the invention has been described with a certain degree of particularity, it is understood that the present disclosure is made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention, reference for the latter being had to the appended claims. | What is disclosed is a tip for a cutting torch for beveling steels at angles greater than 45° with respect to the perpendicular and characterized by an inner piece having a cutting oxygen aperture drilled through the center and fluted around its periphery and conformably fitting within an outer piece, the outer piece extending beyond the inner piece and with an exit diameter smaller than the chamber downstream of the inner piece and with critical relationships between the diameter of the exit aperture, the cutting oxygen aperture and diamensions of the chamber defined downstream of the inner piece and upstream of the exit aperture of the outer piece such that a bulbous flame is obtained at the tip of the outer piece that will cut smoothly at beveled angles of from 45° to 90° with respect to the perpendicular. | 5 |
This is a division of application U.S. Ser. No. 842,295 filed Mar. 26, 1986, which is now U.S. Pat. No. 4,801,327 which is a continuation-in-part of U.S. Ser. No. 739,232 filed May 30, 1985, which is now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to certain sulfonylurea compounds having a carbocyclic or heterocyclic ring linked indirectly ortho to the sulfonylurea linkage, compositions thereof and a method of their use as herbicides or plant growth regulants.
New compounds effective for controlling the growth of undesired vegetation are in constant demand. In the most common situation, such compounds are sought to selectively control the growth of weeds in useful crops such as cotton, rice, corn, wheat and soybeans, to name a few. Unchecked weed growth in such crops can cause significant losses, reducing profit to the farmer and increasing costs to the consumer. In other situations, herbicides are desired which will control all plant growth. Examples of areas in which complete control of all vegetation is desired are areas around fuel storage tanks, ammunition depots and industrial storage areas. There are many products commercially available for these purposes, but the search continues for products which are more effective, less costly and environmentally safe.
U.S. Pat. Nos. 4,127,405 and 4,169,719 disclose herbicidal benzenesulfonylureas.
European patent application (EP-A) No. 83,975, published July 20, 1983, discloses herbicidal benzenesulfonamides of formula ##STR1## wherein Q is selected from various five or six-membered aromatic or partially unsaturated heterocyclic rings containing 2 or 3 heteroatoms selected from O, S or NR.
European patent application (EP-A) No. 85/476, published Aug. 10, 1983, discloses herbicidal benzenesulfonamides of formulae ##STR2## wherein Q is selected from various 5-membered aromatic heterocycles, and their dihydro and tetrahydro analogs, which contain one heteroatom selected from O, S or NR, or Q is a saturated or partially unsaturated 6-membered ring containing one heteroatom selected from O or S; and
Q 1 is a 6-membered aromatic heterocycle containing one to three N atoms.
South African patent application No. 83/8416, published May 12, 1984, discloses herbicidal benzenesulfonamides of formula ##STR3## wherein A is an unsaturated or only partially saturated 5- or 6-membered heterocyclic ring system which is bonded through a carbon atom and contains 1, 2 or 3 heteroatoms.
European patent application No. 116,518, published Aug. 22, 1984, discloses herbicidal sulfonamides of formula ##STR4## wherein X is NR 6 R 7 , N(SO 2 R 9 ) 2 or ##STR5## A is CO, SO 2 , CONR 23 or CO 2 ; B is C 1 -C 4 alkyl or C 2 -C 4 alkenyl; and
C is CO, CR 21 R 22 or SO 2 .
U.S. Pat. No. 4,475,944 discloses herbicidal sulfamates, possessing an ortho-heterocyclic ring, such as those of formula ##STR6## wherein W is O, S or NR 1 .
European patent application (EP-A) No. 141,777 (Swiss priority 9/9/83, published 6/15/85) discloses herbicidal sulfonamides of formula ##STR7## wherein R 3 is H, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl or CN;
R 4 is H or C 1 -C 4 alkyl;
A is Y(CH 2 ) n R 17 or ##STR8## R 17 is a 5-6-membered heterocyclic radical; Y is O, S or a direct bond; and
n is 0 or 1.
South African patent application No. 83/0441 (Swiss priority 1/25/82) discloses herbicidal benzenesulfonamides of formula ##STR9## wherein R 1 is H, halogen, NO 2 , C 1 -C 4 haloalkyl,
C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 2 -C 5 alkenyl or C 1 -C 4 alkoxycarbonyl;
R 2 is C 1 -C 3 alkyl or C 1 -C 3 alkoxy, each unsubstituted or substituted by 1 to 3 halogen atoms;
R 3 is halogen, H, NR 4 R 5 , C 1 -C 3 alkyl, unsubstituted or substituted by 1 to 3 halogen atoms or C 1 -C 4 alkoxy, or is C 1 -C 3 alkoxy, unsubstituted or substituted by methoxy, ethoxy, or 1 to 3 halogen atoms;
A is C 1 -C 4 alkylene or C 2 -C 4 alkenylene, each unsubstituted or substituted by C 1 -C 4 alkyl;
m is 0 or 1;
E is N or CH;
X is oxygen, sulfur, SO or SO 2 ; and
Q is, in part, a 5- or 6-membered heterocyclic ring or a fused homologue thereof, each linked through a carbon atom to the bridge --X--A m -- or, if the heterocyclic ring contains nitrogen, is also bound through a nitrogen atom, and which is unsubstituted or mono- to trisubstituted by halogen, cyano, nitro, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio, C 2 -C 5 alkenyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxycarbonyl, --NR 15 R 16 or --SO--NR 17 R 18 .
SUMMARY OF THE INVENTION
Now new herbicidal compounds and compositions thereof have been found that function as preemergent or postemergent herbicides or as plant growth regulants. The compounds of the invention are compounds of Formula I ##STR10## wherein J is ##STR11## W is O or S; R is H or CH 3 ;
E 1 is O, S, SO, SO 2 or a single bond;
X a is CH 2 , CH(CH 3 ), CH 2 CH 2 , CH 2 CH 2 CH 2 or CO;
E is a single bond, CH 2 or O;
Q is a 5- or 6-membered carbocyclic ring containing either one or two carbonyl groups and 0-1 endocyclic double bonds; a 5-membered heterocyclic ring, containing 2-4 atoms of carbon and 1-3 heteroatoms selected from the group consisting of 0-2 oxygen, 0-2 sulfur or 0-3 nitrogen, wherein sulfur may take the form of S, SO or SO 2 , and containing one or two carbonyl or sulfonyl (SO 2 ) groups, or one carbonyl and one sulfonyl group and 0-1 endocyclic double bonds; or a 6-membered heterocyclic ring, containing 2-5 atoms of carbon and 1-3 heteroatoms selected from the group consisting of 0-2 oxygen, 0-2 sulfur or 0-3 nitrogen, wherein sulfur may take the form of S, SO or SO 2 , and containing one or two carbonyl or sulfonyl (SO 2 ) groups, or one carbonyl and one sulfonyl group and 0-2 endocyclic double bonds; said Q value may further be optionally substituted with 1-2 substituent groups; substituents on carbon may be selected from the group consisting of halogen, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, CH 2 (C 2 -C 3 alkenyl), CH 2 (C 2 -C 3 alkynyl), C 2 -C 4 alkoxycarbonyl, CN, OH, C 1 -C 3 alkoxy, C 1 -C 3 alkylthio, C 1 -C 3 alkylsulfinyl, C 1 -C.sub. 3 alkylsulfonyl or C 2 -C 4 alkylcarbonyl; substituents on nitrogen may be selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, CH 2 (C 2 -C 3 alkenyl), CH 2 (C 2 C 3 alkynyl), C 2 -C 4 alkoxycarbonyl or C 2 -C 4 alkylcarbonyl;
R 1 is H, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, halogen, nitro, C 1 -C 3 alkoxy, SO 2 NR a R b , C 1 -C 3 alkylthio, C 1 -C 3 alkylsulfinyl, C 1 -C 3 alkylsulfonyl, CH 2 CN, CN, CO 2 R c , C 1 -C 3 haloalkoxy, C 1 -C 3 haloalkylthio, C 2 -C 4 alkoxyalkyl, C 2 -C 4 alkylthioalkyl, CH 2 N 3 or NR d R e ;
R a is H, C 1 -C 4 alkyl, C 2 -C 3 cyanoalkyl, methoxy or ethoxy;
R b is H, C 1 -C 4 alkyl or C 3 -C 4 alkenyl; or
R a and R b may be taken together as --(CH 2 ) 3 --, --(CH 2 ) 4 --, --(CH 2 ) 5 -- or --CH 2 CH 2 OCH 2 CH 2 --;
R c is C 1 -C 4 alkyl, C 3 -C 4 alkenyl, C 3 -C 4 alkynyl, C 2 -C 4 haloalkyl, C 2 -C 3 cyanoalkyl, C 5 -C 6 cycloalkyl, C 4 -C 7 cycloalkylalkyl or C 2 -C 4 alkoxyalkyl;
R d and R e are independently H or C 1 -C 2 alkyl;
A is ##STR12## X is H, c 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 1 -C 4 haloalkyl, C 1 -C 4 haloalkylthio, C 1 -C 4 alkylthio, halogen, C 2 -C 5 alkoxyalkyl, C 2 -C 5 alkoxyalkoxy, amino, C 1 -C 3 alkylamino, di(C 1 -C 3 alkyl)amino or C 3 -C 5 cycloalkyl;
Y is H, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 1 -C 4 haloalkylthio, C 1 -C 4 alkylthio, C 2 -C 5 alkoxyalkyl, C 2 -C 5 alkoxyalkoxy, amino, C 1 -C 3 alkylamino, di(C 1 -C 3 alkyl)amino, C 3 -C 4 alkenyloxy, C 3 -C 4 alkynyloxy, C 2 -C 5 alkylthioalkyl, C 1 -C 4 haloalkyl, C 2 -C 4 alkynyl, azido, cyano, C 2 -C 5 alkylsulfinylalkyl, C 2 -C 5 alkylsulfonylalkyl, ##STR13## or N(OCH 3 )CH 3 ; m is 2 or 3;
L 1 and L 2 are independently O or S;
R 2 is H or C 1 -C 3 alkyl;
R 3 and R 4 are independently C 1 -C 3 alkyl;
Z is CH, N, CCH 3 , CC 2 H 5 , CCl or CBr;
Z 1 is CH or N;
Y 1 is O or CH 2 ;
X 1 is CH 3 , OCH 3 , OC 2 H 5 or OCF 2 H;
X 2 is CH 3 , C 2 H 5 or CH 2 CF 3 ;
Y 2 is OCH 3 , OC 2 H 5 , SCH 3 , SC 2 H 5 , CH 3 or CH 2 CH 3 ;
X 3 is CH 3 or OCH 3 ;
Y 3 is H or CH 3 ;
X 4 is CH 3 , OCH 3 , OC 2 H 5 , CH 2 OCH 3 or Cl; and
Y 4 is CH 3 , OCH 3 , OC 2 H 5 or Cl;
and their agriculturally suitable salts; provided that
(a) when Q contains 2 heteroatoms selected from 0-2 oxygen and 0-2 sulfur, said heteroatoms are not bonded directly to one another unless in the form O--SO 2 , and when Q contains 3 nitrogen heteroatoms, only two of these may be bonded directly together;
(b) when X is Cl, F, Br or I, then Z is CH and Y is OCH 3 , OC 2 H 5 , N(OCH 3 )CH 3 , NHCH 3 , N(CH 3 ) 2 or OCF 2 H;
(c) when X or Y is C 1 haloalkoxy, then Z is CH;
(d) when J is J-2 or J-3, the substituents E 1 X a Q and the sulfonylurea bridge are on adjacent carbon atoms;
(e) when E is O, then J is J-1 and W is O;
(f) when W is S, then R is H, A is H, A is A-1, Z is CH or N and Y is CH 3 , OCH 3 , OC 2 H 5 , CH 2 OCH 3 , C 2 H 5 , CH 3 , SCH 3 , OCH 2 CH═CH 2 , OCH 2 C.tbd.CH, OCH 2 CH 2 OCH 3 , CH(OCH 3 ) 2 or 1,3-dioxolan-2-yl;
(g) when the total number of carbon atoms of X and Y is greater than four, then the number of carbons of R 1 must be less than or equal to two, and the number of carbons of the substituent on Q must also be less than or equal to two;
(h) X 4 and Y 4 are not simultaneously Cl;
(i) when A is A-1 and J is J-1 wherein E is a single bond, X a is CH 2 , CH(CH 3 ) or CH 2 CH 2 and Q is a 5-membered heterocyclic ring containing one endocyclic double bond or a 6-membered heterocyclic ring containing 1 or 2 endocyclic double bonds which is unsubstituted or substituted by one or more C 1 -C 4 alkyl groups then said heterocycle must contain at least one nitrogen and be bound to X a through nitrogen; and
(j) when X a is CO, then E 1 is a single bond.
Representative examples of preferred Q include: ##STR14## wherein Q-1 through Q-87 may be optionally substituted with 1 or 2 groups selected from C 1 -C 2 alkyl or C 1 -C 2 haloalkyl;
R 5 and R 6 are independently H or C 1 -C 3 alkyl;
X b is O or NR 5 ; and
X c is O, S, SO, SO 2 or NR 5 .
In the above definitions, the term "alkyl", used either alone or in compound words such as "alkylthio" or "haloalkyl", denotes straight chain or branched alkyl, e.g. methyl, ethyl, n-propyl, isopropyl or the different butyl, pentyl, hexyl, heptyl, octyl, nonyl or decyl isomers.
Alkoxy denotes methoxy, ethoxy, n-propoxy, isopropyloxy and the different butyl isomers.
Alkenyl denotes straight chain or branched alkenes, e.g. vinyl, 1-propenyl, 2-propenyl, 3-propenyl and the different butenyl isomers.
Alkynyl denotes straight chain or branch alkynes, e.g., ethynyl, 1-propynyl, 2-propynyl and the different butynyl isomers.
Alkylsulfonyl denotes methylsulfonyl, ethylsulfonyl and the different propylsulfonyl isomers.
Alkylthio, alkylsulfinyl, alkylamino, alkylsulfamoyl, etc. are defined in an analogous manner.
Cycloalkyl denotes cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
The term "halogen", either alone or in compound words such as "haloalkyl", denotes fluorine, chlorine, bromine or iodine. Further, when used in compound words such as "haloalkyl" said alkyl may be partially halogenated or fully substituted with halogen atoms which may be the same or different. Examples of haloalkyl include CH 2 CH 2 F, CF 2 CH 3 and CH 2 CHFCl.
Alkylcarbonyl denotes acetyl, propionyl, and the different butyryl isomers.
Alkoxycarbonyl denotes methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl and isopropoxycarbonyl.
The total number of carbon atoms in a substituent group is indicated by the C i -C j prefix where i and j are numbers from 1 to 10. For example, C 2 cyanoalkyl would designate CH 2 CN, C 3 cyanoalkyl would designate CH 2 CH 2 CN and CH(CN)CH 3 , and C 2 -C 3 alkylthioalklyl would designate CH 2 SCH 3 , CH 2 SC 2 H 5 , CH 2 CH 2 SCH 3 or CH(CH 3 )SCH 3 , and C 2 -C 5 alkoxyalkoxy would represent OCH 2 OCH 3 through O(CH 2 ) 4 OCH 3 or OCH 2 O(CH 2 ) 3 CH 3 and the various structural isomers embraced therein.
Preferred for reasons of increased ease of synthesis and/or greater herbicidal efficacy are:
1. Compounds of Formula I where E is a single bond and Z is CH or N;
2. Compounds of Formula I where E is CH 2 , W is O, Z is CH or N and E 1 is a single bond;
3. Compounds of Formula I where E is O, Z is CH or N and E 1 is a single bond.
4. Compounds of Preferred 1 where Q is Q-1 to Q-87;
wherein
Q-1 through Q-87 may be optionally substituted with 1 or 2 groups selected from C 1 -C 2 alkyl or C 1 -C 2 haloalkyl;
R 5 and R 6 are independently H or C 1 -C 3 alkyl;
X b is O or NR 5 ; and
X c is O, S, SO, SO 2 or NR 5 .
5. Compounds of Preferred 4 where
W is O;
E 1 is a single bond;
X a is CH 2 or CH 2 CH 2 ;
R is H;
R 1 is H, F, Cl, Br, C 1 -C 2 alkyl, C 1 -C 3 alkoxy, C 1 -C 3 alkylthio, or C 1 -C 2 alkyl, C 1 -C 3 alkoxy or C 1 -C 3 alkylthio substituted with 1-3 atoms of F, Cl or Br;
X is C 1 -C 2 alkyl, C 1 -C 2 alkoxy, Cl, F, Br, I, OCF 2 H, CH 2 F, CF 3 , OCH 2 CH 2 F, OCH 2 CHF 2 , OCH 2 CF 3 , CH 2 Cl or CH 2 Br; and
Y is H, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, CH 2 OCH 3 , CH 2 OCH 2 CH 3 , NHCH 3 , N(OCH 3 )CH 3 , N(CH 3 ) 2 , CF 3 , SCH 3 , OCH 2 CH═CH 2 , OCH 2 C.tbd.CH, OCH 2 CH 2 OCH 3 , CH 2 SCH 3 , ##STR15## OCF 2 H, SCF 2 H, cyclopropyl, C.tbd.CH or C.tbd.CCH 3 ; 6. Compounds of Preferred 5 where A is A-1;
7. Compounds of Preferred 6 where J is J-1;
8. Compounds of Preferred 6 where J is J-2;
9. Compounds of Preferred 6 where J is J-3;
10. Compounds of Preferred 6 where J is J-4;
11. Compounds of Preferred 6 where J is J-5;
12. Compounds of Preferred 6 where
J is J-1;
R 1 is H, Cl, CH 3 or OCH 3 ;
X is CH 3 , OCH 3 , Cl or OCF 2 H; and
Y is CH 3 , OCH 3 , C 2 H 5 , CH 2 OCH 3 , NHCH 3 , CH(OCH 3 ) 2 or cyclopropyl;
13. Compounds of Preferred 12 where Q is Q-1;
14. Compounds of Preferred 12 where Q is Q-2;
15. Compounds of Preferred 12 where Q is Q-3;
16. Compounds of Preferred 12 where Q is Q-4;
17. Compounds of Preferred 12 where Q is Q-5;
18. Compounds of Preferred 12 where Q is Q-6;
19. Compounds of Preferred 12 where Q is Q-7;
20. Compounds of Preferred 12 where Q is Q-8;
21. Compounds of Preferred 12 where Q is Q-9;
22. Compounds of Preferred 12 where Q is Q-10;
23. Compounds of Preferred 12 where Q is Q-11;
24. Compounds of Preferred 12 where Q is Q-12;
25. Compounds of Preferred 12 where Q is Q-13;
26. Compounds of Preferred 12 where Q is Q-14;
27. Compounds of Preferred 12 where Q is Q-15;
28. Compounds of Preferred 12 where Q is Q-16;
29. Compounds of Preferred 12 where Q is Q-17;
30. Compounds of Preferred 12 where Q is Q-18;
31. Compounds of Preferred 12 where Q is Q-19;
32. Compounds of Preferred 12 where Q is Q-20;
33. Compounds of Preferred 12 where Q is Q-21;
34. Compounds of Preferred 12 where Q is Q-22;
35. Compounds of Preferred 12 where Q is Q-23;
36. Compounds of Preferred 12 where Q is Q-24;
37. Compounds of Preferred 12 where Q is Q-25;
38. Compounds of Preferred 12 where Q is Q-26;
39. Compounds of Preferred 12 where Q is Q-27;
40. Compounds of Preferred 12 where Q is Q-28;
41. Compounds of Preferred 12 where Q is Q-29;
42. Compounds of Preferred 12 where Q is Q-30;
43. Compounds of Preferred 12 where Q is Q-31;
44. Compounds of Preferred 12 where Q is Q-32;
45. Compounds of Preferred 12 where Q is Q-33;
46. Compounds of Preferred 12 where Q is Q-34;
47. Compounds of Preferred 12 where Q is Q-35;
48. Compounds of Preferred 12 where Q is Q-36;
49. Compounds of Preferred 12 where Q is Q-37;
50. Compounds of Preferred 12 where Q is Q-38;
51. Compounds of Preferred 12 where Q is Q-39;
52. Compounds of Preferred 12 where Q is Q-40;
53. Compounds of Preferred 12 where Q is Q-41;
54. Compounds of Preferred 12 where Q is Q-42;
55. Compounds of Preferred 12 where Q is Q-43;
56. Compounds of Preferred 12 where Q is Q-44;
57. Compounds of Preferred 12 where Q is Q-45;
58. Compounds of Preferred 12 where Q is Q-46;
59. Compounds of Preferred 12 where Q is Q-47;
60. Compounds of Preferred 12 where Q is Q-48;
61. Compounds of Preferred 12 where Q is Q-49;
62. Compounds of Preferred 12 where Q is Q-50;
63. Compounds of Preferred 12 where Q is Q-51;
64. Compounds of Preferred 12 where Q is Q-52;
65. Compounds of Preferred 12 where Q is Q-53;
66. Compounds of Preferred 12 where Q is Q-54;
67. Compounds of Preferred 12 where Q is Q-55;
68. Compounds of Preferred 12 where Q is Q-56;
69. Compounds of Preferred 12 where Q is Q-57;
70. Compounds of Preferred 12 where Q is Q-58;
71. Compounds of Preferred 12 where Q is Q-59;
72. Compounds of Preferred 12 where Q is Q-60;
73. Compounds of Preferred 12 where Q is Q-61;
74. Compounds of Preferred 12 where Q is Q-62;
75. Compounds of Preferred 12 where Q is Q-63;
76. Compounds of Preferred 12 where Q is Q-64;
77. Compounds of Preferred 12 where Q is Q-65;
78. Compounds of Preferred 12 where Q is Q-66;
79. Compounds of Preferred 12 where Q is Q-67;
80. Compounds of Preferred 12 where Q is Q-68;
81. Compounds of Preferred 12 where Q is Q-69;
82. Compounds of Preferred 12 where Q is Q-70;
83. Compounds of Preferred 12 where Q is Q-71;
84. Compounds of Preferred 12 where Q is Q-72;
85. Compounds of Preferred 12 where Q is Q-73;
86. Compounds of Preferred 12 where Q is Q-74;
87. Compounds of Preferred 12 where Q is Q-75;
88. Compounds of Preferred 12 where Q is Q-76;
89. Compounds of Preferred 12 where Q is Q-77;
90. Compounds of Preferred 12 where Q is Q-78;
91. Compounds of Preferred 12 where Q is Q-79;
92. Compounds of Preferred 12 where Q is Q-80;
93. Compounds of Preferred 12 where Q is Q-81;
94. Compounds of Preferred 12 where Q is Q-82;
95. Compounds of Preferred 12 where Q is Q-83;
96. Compounds of Preferred 12 where Q is Q-84;
97. Compounds of Preferred 12 where Q is Q-85;
98. Compounds of Preferred 12 where Q is Q-86;
99. Compounds of Preferred 12 where Q is Q-87;
100. Compounds of Preferred 2 where
R is H;
J is J-1;
R 1 is H;
A is A-1;
X is CH 3 , OCH 3 , OCH 2 CH 3 , Cl or OCF 2 H;
Y is CH 3 , OCH 3 , C 2 H 5 , CH 2 OCH 3 , NHCH 3 , CH(OCH 3 ) 2 or cyclopropyl; Z is CH or N; and Q is Q-1, Q-4, Q-5, Q-7, Q-10, Q-11, Q-12, Q-17, Q-19, Q-20, Q-24, Q-25, Q-27, Q-28, Q-36, Q-38, Q-46, Q-47, Q-54, Q-56, Q-59, Q-60, Q-63, Q-71, Q-74, Q-76, Q-78 and Q-79;
101. Compounds of Preferred 3 where
R is H;
R 1 is H;
A is A-1;
X is CH 3 , OCH 3 , OCH 2 CH 3 , Cl or OCF 2 H;
Y is CH 3 , OCH 3 , C 2 H 5 , CH 2 OCH 3 , NHCH 3 , CH(OCH 3 ) 2 or cyclopropyl; Z is CH or N; and Q is Q-1, Q-4, Q-5, Q-7, Q-10, Q-11, Q-12, Q-17, Q-19, Q-20, Q-24, Q-25, Q-27, Q-28, Q-36, Q-38, Q-46, Q-47, Q-54, Q-56, Q-59, Q-60, Q-63, Q-71, Q-74, Q-76, Q-78and Q-79.
102. Compounds of Formula I wherein
E 1 is a single bond.
X a is CH 2 , CH(CH 3 ), CH 2 CH 2 or CH 2 CH 2 CH 2 ;
Q is a saturated or partially saturated 5- or 6-membered carbocyclic ring, containing either one or two carbonyl groups, or a saturated or partially saturated 5- or 6-membered heterocyclic ring, containing 2-5 atoms of carbon and 1-3 heteroatoms selected from the group consisting of 0-2 oxygen, 0-2 sulfur or 0-3 nitrogen, wherein sulfur may take the form of S, SO or SO 2 , and containing one or two carbonyl or sulfonyl (SO 2 ) groups, or one carbonyl and one sulfonyl group; Q may further be optionally substituted with 1-2 substituent groups; substituents on carbon may be selected from the group consisting of halogen, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, CH 2 (C 2 -C 3 alkenyl), CH 2 (C 2 -C 3 alkynyl), C 2 -C 4 alkoxycarbonyl, CN, OH, C 1 -C 3 alkoxy, C 1 -C 3 alkylthio, C 1 -C 3 C 1 -C 3 alkylsulfinyl, C 1 -C 3 alkylsulfonyl or C 2 -C 4 alkylcarbonyl, substituents on nitrogen may be selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, CH 2 (C 2 -C 3 alkenyl), CH 2 (C.sub. 2 -C 3 alkynyl), C 2 -C 4 alkoxycarbonyl or C 2 -C 4 alkylcarbonyl;
R 1 is H, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, halogen, nitro, C 1 -C 3 alkoxy, SO 2 NR a R b , C 1 -C 3 alkylthio, C 1 -C 3 alkylsulfinyl, C 1 -C 3 alkylsulfonyl, CH 2 CN, CN, CO 2 R c , C 1 -C 3 haloalkoxy or C 1 -C 3 haloalkylthio;
A is ##STR16##
Specifically Preferred for reasons of greatest ease of synthesis and/or greatest herbicidal efficacy are:
N-[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)benzenesulfonamide, m.p. 185°-187° C.;
N-[(4,6-dimethoxy-1,3,5-triazin-2-yl)aminocarbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)benzenesulfonamide, m.p. 194°-195° C.;
N-[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2-oxo-3-oxazolidinylmethyl)-3-thiophenesulfonamide, m.p. 157°-160° C.; and
N-[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)aminocarbonyl]-2-(2-oxo-3-oxazolidinylmethyl)-3-thiophenesulfonamide, m.p. 155°-161° C.
DETAILED DESCRIPTION OF THE INVENTION
Synthesis
Compounds of Formula I, wherein E is CH 2 or a single bond, can be synthesized by one or more of the procedures outlined in Equation 1. ##STR17## wherein J, R, and A are as previously defined, provided E is CH 2 or a single bond.
The reaction of Equation 1a can be carried out according to procedures described in U.S. Pat. No. 4,127,405.
The sulfonyl isocyanates II are prepared from the corresponding sulfonamides of Formula IV according to procedures described in U.S. Pat. No. 4,238,621 or by the procedure of H. Ulrich, B. Tucker, and A. Sayigh, J. Org. Chem., 34, 3200 (1969).
Sulfonyl isothiocyanates (II, W is S) are known in the art and are prepared from the corresponding sulfonamides (IV) by reaction with carbon disulfide and potassium hydroxide followed by treatment of the resulting dipotassium salt VI with phosgene. Such a procedure is described in Arch. Pharm. 299, 174 (1966).
Alternatively compounds of Formula I can be prepared according to Equation 1b or by the reaction of Equation 1c as described in U.S. Pat. No. 4,443,243.
The sulfonylureas of Formula I, wherein E is O, can be prepared by one or both of the procedures described in Equation 2. ##STR18## wherein J is as previously defined, provided E is O.
Phenols of Formula VII react with chlorsulfonylisocyanate (CSI) under elevated temperatures (Equation 2a) to provide the sulfonyl isocyanates II, which react with heterocyclic amines of Formula III to yield the sulfonylureas I according to the procedure in U.S. Pat. No. 4,475,944. Alternatively, the reaction of Equation 2b may be employed according to the procedure described in U.S. Pat. No. 4,391,976.
Agriculturally suitable salts of compounds of Formula I are also useful herbicides and can be prepared in a number of ways known to the art. For example, metal salts can be made by contacting compounds of Formula I with a solution of an alkali or alkaline earth metal salt having a sufficiently basic anion (e.g., hydroxide, alkoxide or carbonate).
Quaternary amine salts can be made by similar techniques.
Salts of compounds of Formula I can also be prepared by exchange of one cation for another. Cationic exchange can be effected by direct contact of an aqueous solution of a salt of a compound of Formula I (e.g., alkali or quaternary amine salt) with a solution containing the cation to be exchanged. This method is most effective when the desired salt containing the exchanged cation is insoluble in water and can be separated by filtration.
Exchange may also be effected by passing an aqueous solution of a salt of a compound of Formula I (e.g., an alkali metal or quaternary amine salt) through a column packed with a cation exchange resin containing the cation to be exchanged for that of the original salt and the desired product is eluted from the column. This method is particularly useful when the desired salt is water-soluble, e.g., a potassium, sodium or calcium salt.
Acid addition salts, useful in this invention, can be obtained by reacting a compound of Formula I with a suitable acid, e.g., p-toluenesulfonic acid, trichloroacetic acid or the like.
The synthesis of heterocyclic amines such as those represented by Formula III has been reviewed in "The Chemistry of Heterocyclic Compounds," a series published by Interscience Publ., New York and London. Aminopyrimidines are described by D. J. Brown in "The Pyrimidines," Vol. XVI of the series mentioned above which is herein incorporated by reference. The 2-amino-1,3,5-triazines of Formula III, where A is A-1 and Z is N, can be prepared according to methods described by E. M. Smolin and L. Rapaport in "s-Triazines and Derivatives," Vol. XIII.
Pyrimidines of Formula III, where A is A-1 and Y is an acetal or thioacetal substituent, can be prepared by methods taught in European patent application No. 84,224 (published July 27, 1983).
Pyrimidines of Formula III, where A is A-1 and Y is cyclopropyl of OCF 2 H can be synthesized according to the methods taught in U.S. Pat. No. 4,515,626 and U.S. Pat. No. 4,540,782, respectively.
Compounds of Formula III, where A is A-2 or A-3, can be prepared by procedures disclosed in U.S. Pat. No. 4,339,267.
Compounds of Formula III, where A is A-4, can be prepared by methods taught in U.S. Pat. No. 4,487,626.
Additional references dealing with the synthesis of bicyclic pyrimidines of Formula III, where A is A-2, A-3, or A-4 are Braker, Sheehan, Spitzmiller and Lott, J. Am. Chem. Soc., 69, 3072 (1947); Mitler and Bhattachanya, Quart. J. Indian Chem. Soc., 4, 152 (1927); Shrage and Hitchings, J. Org. Chem., 16, 1153 (1951); Caldwell, Kornfeld and Donnell, J. Am Chem. Soc., 63, 2188 (1941); and Fissekis, Myles and Brown, J. Org. Chem., 29, 2670 (1964).
Compounds of Formula III, where A is A-5, can be prepared by methods taught in U.S. Pat. No. 4,421,550.
Compounds of Formula III, where A is A-6, can be prepared by methods taught in the U.S. Pat. No. 4,496,392.
The required sulfonamides of Formula IV, provided E is not oxygen, can be conveniently prepared by amination of the corresponding sulfonyl chlorides with ammonia or ammonium hydroxide by methods known to those skilled in the art. Alternatively deprotection of N-t-butylsulfonamides with polyphosphoric acid (PPA) or trifluoroacetic acid (TFA) as described by J. D. Lombardino, J. Org. Chem., 36, 1843 (1971) or J. D. Catt and W. L. Matier, J. Org. Chem., 39, 566 (1974), respectively, provides compounds of Formula IV.
In addition, deprotection of N-t-butyldimethylsilylsulfonamides with fluoride ion, provides sulfonamides of Formula IV, wherein E is not oxygen.
The intermediate sulfonyl chlorides of Formula X, as depicted in Equation 3, can be prepared from aromatic amines via a diazotization process, as described in EPO Publication Nos. 83,975 and 85,476; or by oxidative chlorination of thiols or thioethers with chlorine and water as reviewed in Gilbert, "Sulfonation and Related Reactions," pp. 202-214, Interscience Publishers, New York, 1965; when R 7 =H or benzyl, the oxidative chlorination may be effected by sodium hypochlorite following procedures described by L. H. McKendry and N. R. Pearson in South African patent application No. 84/8845 (November 13, 1984); or by metal halogen exchange or directed lithiation of appropriately substituted aryl or heterocyclic substrates followed by trapping with sulfuryl chloride. The lithiation can be performed according to the procedure of S. H. Bhattacharya, et al., J. Chem. Soc. (C), 1265 (1968) or by procedures reviewed by H. Gscwend and H. Rodriquez in Organic Reactions, Vol. 26, Wiley, New York, 1979, and references cited within; or finally, when E is a CH 2 moiety, by a two step procedure involving the conversion of aromatic chloromethyl or bromomethyl compounds to isothiouronium salts, as described by Johnson and Spraque, J. Am. Chem. Soc., 58, 1348 (1936); 59, 1837 and 2439 (1937); 61, 176 (1939), followed by oxidative chlorination by the procedure of Johnson as described in J. Am. Chem. Soc., 61, 2548 (1939) to provide the sulfonyl chlorides X. ##STR19## wherein J is as previously defined provided E is not oxygen,
G is H. NH 2 , SR 7 , Br, CH 2 Cl, CH 2 Br, and
R 7 is H, C 1 -C 3 alkyl, benzyl.
Amines of the Formula IX, wherein G is NH 2 , can be prepared from the corresponding nitro compounds by various reduction procedures as described in U.S. Pat. Nos. 3,846,440 and 3,846,439 and in EP-A No. 83,975 and references cited therein.
Phenols of Formula VII can be prepared from amines of Formula IX (G═NH 2 ) via a diazotization process, as described in A. I. Vogel, "Practical Organic Chemistry," P. 595 (1956), 3rd Ed; U.S. Pat. No. 3,270,029; J. H. Finley, et al., J. Het. Chem., 6, 841 (1969); and M. Ohta, et al., J. Pharm. Soc. Japan, 73, 701 (1953).
Compounds of the Formula XII, which serve as intermediates to compounds of the Formula I as illustrated in Equations 1-3, can be prepared from precursors of the Formula XI by one or more of the procedures outlined below. ##STR20## wherein Q and R 1 are as originally defined;
R 8 is H or CH 3 , provided that when n is 2 or 3, R 8 is H;
m is 0 or 1, provided when m=1, n must be 0;
n is 0, 1, 2, or 3, provided that m and n cannot both be 0;
G is Cl, Br, CH 2 Cl, CH 2 Br, OH, NH 2 , NO 2 , SR 7 , SO 2 NH 2 , SO 2 NH-t-butyl or SO 2 NHSi(CH 3 ) 2 -t-butyl;
M is Cl, Br, I, NH 2 , NHOH, NHNH 2 , COOCH 3 , CONHNH 2 , CN, COCl, CHO or H or suitable leaving group, provided that when m=1, M is not Br or I;
R 7 is H, C 1 -C 3 alkyl or benzyl.
E 1 is O, S, SO, SO 2 or a single bond provided that when m=1, E 1 is a single bond.
The ten procedures are based on established literature methods precedented by the references cited in Table 2. The references cited have direct applicability to compounds of the Formula XII, wherein J is J-1. However, the procedures and experimental methods described in these references are equally applicable to the synthesis of compounds of Formula XII, wherein J is J-2 through J-5, by analogous procedures or slight modifications thereof. The chemistry of the thiophene, pyridine and pyrazole ring systems has been reviewed in "Chemistry of Heterocyclic Compounds," Volumes 3, 14, and 5, respectively. Wiley, New York 1952 and later.
It should be noted that the chemical compatibility of the wide variety of reactions and reaction conditions described throughout this disclosure with J, R 1 , Q, and G must be taken into account and as such requires a judicious choice of the appropriate methods for preparing compounds described within this disclosure. In addition, circumvention of instances of incompatibility may be achieved by the suitable selection of a protecting group, obvious to one skilled in the art. For a compilation of references describing the wide variety of protecting groups available, see T. W. Greene, "Protective Groups in Organic Synthesis," John Wiley and Sons, Inc., New York, 1981.
The synthesis of the starting materials of Formula XI are known in the general literature or can be prepared, by those skilled in the art, by simple modifications of established routes.
Procedure 1: Direct N-alkylation of intact heterocyclic compounds, containing an N--H moiety, with compound substrates of the Formula XI, wherein m=0 and M is Cl, Br, or Iodine; or N-benzoylation of heterocyclic, containing an N--H moiety, with benzoyl chlorides of the form XI, wherein m=1, M is Cl, and G is Cl, Br, CH 2 Cl, CH 2 Br, NO 2 or SR 7 .
Procedure 2: C-alkylation of heterocyclic compounds containing an acidic C--H moiety, i.e., activated by a carbonyl or sulfonyl group, by substrates of the Formula XI wherein M is Cl, Br, or iodine; or C-benzoylation with benzoyl chlorides of the Formula XI, wherein m=1, M is Cl, and G is Cl, Br, CH 2 Cl, CH 2 Br, NO 2 or SR 7 .
Procedure 3: Reactions of derivatives of Formula XI, wherein M is NH 2 , NHOH, or NHNH 2 , as nucleophiles with bifunctional acrylic and cyclic reagents, which ultimately are converted to various Q values.
Procedure 4: Use of acid-derivatives of Formula XI, wherein M is COOCH 3 , COHNNH 2 , CN, or COCl; see Example 4.
Procedure 5: Synthesis from dianions derived from N-protected-(o-methyl aromatic sulfonamides) of Formula XI, wherein M is H, n=1, R 8 =H, and G is SO 2 NH-t-butyl or SO 2 NHSi(CH 3 ) 2 -t-butyl. These benzyl or benzyl-like dianions can be prepared by reaction of the appropriate sulfonamide, as defined above, with two equivalents of n-butyllithium at low temperatures in an inert solvent. In some instances, conversion of the lithium dianions to copper-lithium species is dictated by the literature and can be accomplished by known procedures.
Procedure 6: Reactions of acyclic anions with aldehydes of the Formula XI, wherein M is CHO (m=0). Further transformations, as described in the cited literature (Table 2) provide compounds of the Formula XII.
Procedure 7: Reactions of anions derived from aromatic heterocycles such as thiophene, furan, pyrrole, and pyridine (or simple substituted analogues) which act as "masked" heterocycles of the form Q. For example, alkylation reactions of such anions with compounds of the Formula XI, wherein M is Cl, Br, or iodine, provide intermediates which upon reduction (see for example conversions B and K in Table 1) yield compounds of the Formula XII.
Procedure 8: Synthesis of compounds of the Formula XII wherein M is a vinyl group (m=0): see reference 37.
Procedure 9: This procedure involves the use of compounds which are related to XI, but are outside the defined limits of XI. These compounds may be prepared by literature procedures from compounds of the Formula XI as defined. Additional functional group manipulation is then required, the procedures of which are described in the references cited in Table 2, to convert these compounds to compounds of the Formula XII.
Procedure 10: This procedure is the conversion of the Q value, contained in the Formula XII to a different Q value. These conversion procedures are summarized in Table 1. When applicable, the conversion procedures of Table 1 are cited by their letter designation in Table 2.
TABLE 1______________________________________CONVERSION PROCEDURESConversionDesignation From To References______________________________________A lactone lactam 1-3B thiophene tetrahydro 4-6 furan derivative pyrroleC sulfide sulfoxide or 7 sulfoneD lactone, lactam, α-unsaturated 8, 84 sulfone or derivative sultamE lactam cyclic amine 9-11F cycloketone lactone 12-14G dihydro-γ- tetrahydro-γ- 15-19 pyrone pyroneH dihydro-γ- tetrahydro-γ- 20-22 pyridone pyridoneI γ-pyrone γ-pyridone 23-25J lactone tetrahydrofuran 26 or tetrahydropyranK pyridine piperidine or 27-28 (including N--substituted quaternary piperidines salts)L anhydride succinimide______________________________________
Table 2 sumarizes selected synthetic procedures viable for the synthesis of compounds of Formula XII. Table 2 is not meant to be all inclusive, but does provide synthetic routes, which are well established and precedented in the literature, through the known chemical procedures (1-10), conversions (A-L), and methods described in the references (1-84) or slight modifications thereof.
For example, the preparation of a compound of Formula XII, where Q is Q 1 and X b is NR 5 can be carried out according to the procedure outlined in line number 2 Table 2. Thus alkylation (procedure 2) of butyrolactone (QH=Q-1 where X b =0) with an appropriately substituted alkyl halide as described in references 29-31, followed by conversion of the lactone moiety to a lactam (conversion procedure A) provides the desired compound of Formula XII. Finally, compounds of Formula XII are converted to the desired sulfonylureas of Formula I via one or more of the procedures outlined in Equation 1 through 3.
TABLE 2__________________________________________________________________________Preparative Schemes for Compounds of the Formula XII Conv..sup.3No. Q X.sub. b X.sub.c Proc..sup.1 QH(X.sub.b(c)).sup.2 Proc. Ref. Comments__________________________________________________________________________1 Q-1 O -- 2 1(O) -- 29-312 Q-1 NR.sub.5 -- 2 1(O) A 29-313 Q-1 NR.sub.5 -- 2 1(NR.sub.5) 32-354 Q-2 O -- 5 365 Q-2 NR.sub.5 -- 5 A 366 Q-3 O 8 377 Q-3 NR.sub.5 8 A 378 Q-4 -- -- 1 4 -- See Example 19 Q-5 -- -- 2 5 38,3910 Q-6 5 18 40-42 1,4-Addition11 Q-7 -- -- 2 43-45 3812 Q-8 9 Cyclize a halo- sulfonamide with base13 Q-9 9 -- Cyclize a halo- sulfonamide with base14 Q-10 -- -- 1 -- 46 Analogous to Example 115 Q-11 NR.sub.5 2 4916 Q-11 S 2 38,5017 Q-11 SO 2 C 38,5018 Q-11 SO.sub.2 2 C 38,5019 Q-11 -- O 6 51,5220 Q-12 -- NR.sub.5 2 4921 Q-12 -- S 9 53,54 See also ref 5022 Q-12 -- SO 9 C 53,54 See also ref 5023 Q-12 -- SO.sub.2 9 C 53,54 See also ref 5024 Q-12 -- O 9 5525 Q-13 O 9 5526 Q-13 S 9 50, 52-5427 Q-13 SO 9 C 50, 52-5428 Q-13 SO.sub.2 9 C 50, 52-5429 Q-13 NR.sub.5 5 In addition to to appropriate pyrrolidinone See also ref. 5630 Q-14 -- -- 1 Protection of co may be necessary31 Q-15 O -- 5 D 3632 Q-15 NR.sub.5 -- 5 D,A 36 Conversion D then A33 G-16 O 8 D 3734 Q-16 NR.sub.5 8 D,A 37 Conversion D then A35 Q-17 -- -- 1 4 D See example 136 Q-17 -- -- 1 17 See example 137 Q-18 -- -- 5 20 D 58-60 1,4 Addition to QH-18 followed by in situ conversion D38 Q-19 -- -- 1 Use α, β unsaturated propane sultam39 Q-20 O 2 29-3140 Q-20 NR.sub.5 2 32-35 See ref 35. R = H41 Q-21 O 9 57 Ref 57 discusses lactonization of hydroxy- acids42 Q-21 NR.sub.5 9 D 5743 Q-22 O 9 5744 Q-22 NR.sub.5 9 A 5745 Q-23 O 2 5 F 38,3946 Q-23 -- -- 2 5 F,A Procedure E then A47 Q-24 -- -- 1 24 Modification of example 148 Q-25 -- -- 2 25 37,3949 Q-26 5 40-42 1,4 Addition50 Q-26 -- -- 9 Cyclization of halo- sulfonamides with base51 Q-27 -- -- 2 27 43-4552 Q-28 -- -- 1 Modification of Example 153 Q-29 NR.sub.5 2 29(NR.sub.5) 4954 Q-29 S 2,9 53,54, 5855 Q-29 SO 2,9 C 38,53, 5456 Q-29 SO.sub.2 2,9 C 38,53 5457 Q-29 O 2,9 3858 Q-30 -- O 5 41(O) 40-42 1,4 Addition59 Q-30 -- NR.sub.5 5 41(NR.sub.5) 40-42 1,4 Addition60 Q-30 -- S 5 41(S) 40-42 1,4 Addition61 Q-30 -- SO 5 41(S) C 40-42 1,4 Addition62 Q-30 -- SO.sub.2 5 41(S) C 40-42 1,4 Addition63 Q-31 -- S 9 -- 53-5464 Q-31 -- SO 9 -- C 53-5465 Q-31 -- SO.sub.2 9 -- C 53-5466 Q-31 -- O 9 -- -- --67 Q-31 -- NR.sub.5 9 -- -- --68 Q-32 -- NR.sub.5 2 -- -- 4969 Q-32 -- O 2 38 Modification of ref. 4970 Q-32 -- S 2 38 Modification of ref. 4971 Q-32 -- SO 2 38 Modification of ref. 4972 Q-32 -- SO.sub.2 2 38 Modification of ref. 4973 Q-33 1 33 C═O protection may be necessary74 Q-34 O 2 34(O) 3875 Q-34 S 2 34(S) 3876 Q-34 SO 2 34(S) C 3877 Q-34 SO.sub.2 2 34(S) C 3878 Q-34 NR.sub.5 2 34(NR.sub.5) 3879 Q-35 O 4 G 5980 Q-35 NR.sub.5 9 H 6181 Q-35 S 9 6282 Q-35 SO 9 C 6283 Q-35 SO.sub.2 9 C 6284 Q-36 1 36 C═O protection may be necessary85 Q-37 O 2 5 F,D 38,3986 Q-37 NR.sub.5 2 5 F,D,A 38,3987 Q-38 -- -- 2 38 Modification of Example 188 Q-39 -- -- 2 25 D 38,3989 Q-39 -- -- 2 39 3890 Q-40 -- -- 1 Modification of Example 191 Q-41 NR.sub.5 2 30(NR.sub.5) D 4992 Q-41 O D 3893 Q-41 S D 3894 Q-41 SO D,C 3895 Q-41 SO.sub.2 D,C 3896 Q-42 S 9 D 6297 Q-42 NR.sub.5 9 6198 Q-42 SO 9 D,C 6299 Q-42 SO.sub.2 9 D,C 6100 Q-42 -- O 2 38101 Q-43 -- -- 1 35 D102 Q-44 O -- 9 63-65103 Q-44 NR.sub.5 -- 9 63-65104 Q-45 3 Reaction of amine with γ-pyrone105 Q-46 4 66106 Q-47 4 67-69 Ref 69 contains N--alkylation procedures107 Q-48 4 70108 Q-49 4 71109 Q-50 4 72-73110 Q-51 4 74111 Q-52 4 75-77112 Q-53 4 78113 Q-54 1 54 79,80114 Q-55 1 55 81115 Q-56 1 56116 Q-57 9 82117 Q-58 8 83118 Q-59 1 59119 Q-60 1 60120 Q-61 9121 Q-62 1 62122 Q-63 3 M = NHOH123 Q-64 2 64 38 R.sub.5 = 16124 Q-65 1 65125 Q-66 2 66 38126 Q-67 1 67127 Q-68 2 68 38128 Q-69 1 69129 Q-69 3 M = NHOH130 Q-70 2 70 38131 Q-71 9132 Q-72 1 72133 Q-73 1 73134 Q-74 1 74135 Q-75 6 L136 Q-76 1 76137 Q-77 6 L,D138 Q-78 6 Anion from CH.sub.3 CO.sub.2 CH.sub.2 CH.sub.2 -- CO.sub.2 CH.sub.3 then ring close with acid139 Q-79 1 79140 Q-80 1 80141 Q-81 2 81 38142 Q-82 1 82143 Q-83 1 83144 Q-84 1 84145 Q-85 2 85 38146 Q-86 2 86 38147 Q-87 2 87 38__________________________________________________________________________ .sup.1 procedures of 1-10 .sup.2 for example when QH(X.sub.b) = 1(O); QH is Q.sub.1, and X.sub.b is oxygen which suggests butyrolactone would be a viable starting material .sup.3 conversion procedures (A-L) are described in Table I.
The preparation of the compounds of this invention is further illustrated by the following specific examples.
EXAMPLE 1
1-[(2-(Phenylmethylthio)phenylmethyl]-2-pyrrolidinone
To a solution of 1.35 g of potassium-tert-butoxide in 25 mL of dimethylformamide, cooled to 0° C., was added 0.92 mL of 2-pyrrolidinone. As a white precipitate formed, the mixture was stirred for 10 minutes, and 3.0 g of 2-phenylmethylthio chloromethyl benzene was added in one portion. The resulting solution was allowed to warm to room temperature, stirred for 1 hour, poured into water, and extracted with methylene chloride. The organic layer was washed well with water, dried over magnesium sulfate, filtered, and the filtrate evaporated to leave 3.0 g of a yellow oil.
______________________________________NMR (CDCl.sub.3) ppm: 7.3 (m, 9H, ArH) 4.5 (s, 2H, CH.sub.2) 4.0 (s, 2H CH.sub.2) 3.05 (t, 2H, --CH.sub.2 --) 2.3 (t, 2H, --CH.sub.2 --) 1.7-2.05 (m, 2H, CH.sub.2)______________________________________
EXAMPLE 2
2-(2-Oxo-1-pyrrolidinylmethyl)benzenesulfonamide
To a solution of 2.6 g of the compound of Example 1 dissolved in 100 mL of acetic acid, containing 0.5 mL of water, and cooled to 15° C., was bubbled in chlorine gas for 15 minutes. A slight exotherm of 5° C. was noted. The reaction was stirred for an additional 5 minutes, poured into ice water, and extracted with methylene chloride. The organic layer was washed with saturated sodium bicarbonate, dried over magnesium sulfate, filtered, and evaporated to an oil. The oil was immediately dissolved in 100 mL of tetrahydrofuran and treated with 2 mL of concentrated ammonium hydroxide and stirred for 1 hour. The tetrahydrofuran was removed on the rotaryevaporator to give a semisolid. The residue was then triturated with water to form a sticky solid which was filtered off and triturated with ether to provide 1.1 g of an off-white solid; m.p. 149°-151° C. IR (Nujol) 1660(C═O) cm -1 .
EXAMPLE 3
N-[((4,6-dimethoxypyrimidin-2-yl)aminocarbonyl)-2-(2-oxo-1-pyrrolidinylmethyl]-benzenesulfonamide
To a suspension of 254 mg of the product of Example 2 in 10 mL of acetonitrile, containing 275 mg of phenyl(4,6-dimethoxypyrimidin-2-yl)carbamate, was added 0.15 mL of 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU). The resultant solution was stirred for 2 hours, diluted with 20 mL of water and acidified with 5 drops of concentrated hydrochloric acid. n-Butylchloride (10 mL) was added, stirred, and the white precipitate was filtered. The collected white solid was washed with a little water, suction dried and finally dried in vacuo @ 70° C. overnight to afford 200 mg of a white solid, m.p. 185°-187° C.
______________________________________IR (Nujol) 1730 (C = O) 1668 (C = O) cm.sup.-1 ;NMR (CDCl.sub.3) ppm 12.76 (bs,1H, NH) 8.21 (m, 1H, ArH) 7.36-7.7 (m, 3H, ArH) 7.22 (bs, 1H, NH) 5.80 (s, 1H, PyH) 5.01 (s, 2H, CH.sub.2) 3.96 (s, 6H, OCH.sub.3) 3.32 (t, 2H, CH.sub.2) 2.46 (t, 2H, CH.sub.2) 2.03 (m, 2H, CH.sub.2)______________________________________
USE OF TABLES A, J, AND Q
For purposes of expediency and avoidance of voluminous pages of tables each sulfonylurea is divided into three structural pieces as illustrated below. ##STR21##
Each structural piece A, J, and Q is fully defined separately in Tables A, J and Q respectively and requires the designation of a particular structure from one of the structure(s) assigned to each of these tables. Thus to fully delineate a complete structure for a unique sulfonylurea it requires the information from one entry in each of the tables A, J, and Q and a designation of one of the structures assigned to that table. Note that only one structure, namely structure A, is assigned to Table A and need not be specifically designated.
The use of Tables A, J, and Q provides an alternative to listing individual compounds line by line as is done in a conventional table. It is the applicant's intent to specifically disclose each and every compound that can be constructed from Tables A, J and Q using the procedure described above and illustrated below.
The use of Tables A, J, and Q can be illustrated by the following. For example, specifically claimed is compound of Formula XIII and is ##STR22## listed in Tables A, J, and Q as entry number 4 of Table A; entry number one of Table J--Structure B; and entry number seven of Table Q--Structure J. As a shorthand notation, compound of Formula XIII can be listed in a matrix form as:
4; 1-B; 7-J
This provides a convenient method for listing the melting point of compounds as is done in the melting point table (AJQ) (see line number one of Table AJQ). Each compound for which a melting point is available is simply listed in the melting point table (AJQ) as the entry number of Table A; entry number-structure for Table J; and entry number-structure for Table Q in that order.
Also specifically claimed is compound of formula XIV shown below. ##STR23##
Compound of Formula XIV is found in Tables A, J, and Q as entry number four of Table A; entry number one of Table J-Structure B; and entry number one of Table Q-Structure J or in the convenient matrix form as:
4; 1-B; 1-J
By analogy compounds of Formula XV and XVI having structures as shown below ##STR24## have matrix designations of 2; 1-B; 19-L and 4; 1-B; 76-J respectively.
The structures assigned to Tables A, J, and Q are shown below followed by Tables A, J, and Q and finally the melting point Table AJQ. ##STR25##
______________________________________TABLE A FOR STRUCTURE AEntry X Y Z______________________________________1 CH.sub.3 CH.sub.3 CH2 CH.sub.3 OCH.sub.3 CH3 CH.sub.3 OCH.sub.3 N4 OCH.sub.3 OCH.sub.3 CH5 OCH.sub.3 OCH.sub.3 N6 Cl OCH.sub.3 CH7 CH.sub.3 C.sub.2 H.sub.5 CH8 CH.sub.3 CH.sub.2 OCH.sub.3 CH9 CH.sub.3 CH.sub.2 OCH.sub.3 N10 CH.sub.3 NHCH.sub.3 CH11 CH.sub.3 NHCH.sub.3 N12 CH.sub.3 CH(OCH.sub.3).sub.2 CH13 CH.sub.3 CH(OCH.sub.3).sub.2 N14 CH.sub.3 Cyclopropyl CH15 CH.sub.3 Cyclopropyl N16 OCH.sub.3 C.sub.2 H.sub.5 CH17 OCH.sub.3 C.sub.2 H.sub.5 N18 OCH.sub.3 CH.sub.2 OCH.sub.3 CH19 OCH.sub.3 CH.sub.2 OCH.sub.3 N20 OCH.sub.3 NHCH.sub.3 CH21 OCH.sub.3 NHCH.sub.3 N22 OCH.sub.3 CH(OCH.sub.3).sub.2 CH23 OCH.sub.3 CH(OCH.sub.3).sub.2 N24 OCH.sub.3 Cyclopropyl CH25 OCH.sub.3 Cyclopropyl N26 OCH.sub.2 CH.sub.3 CH.sub.3 CH27 OCH.sub.2 CH.sub.3 CH.sub.3 N28 OCH.sub.2 CH.sub.3 OCH.sub.3 CH29 OCH.sub.2 CH.sub.3 OCH.sub.3 N30 OCH.sub.2 CH.sub.3 CH.sub.2 OCH.sub.3 CH31 OCH.sub.2 CH.sub.3 CH.sub.2 OCH.sub.3 N32 OCH.sub.2 CH.sub.3 NHCH.sub.3 CH33 OCH.sub.2 CH.sub.3 NHCH.sub.3 N34 OCH.sub.2 CH.sub.3 CH(OCH.sub.3).sub.2 CH35 OCH.sub.2 CH.sub.3 CH(OCH.sub.3).sub.2 N36 Cl OCF.sub.2 H CH37 OCF.sub.2 H CH.sub.3 CH38 OCF.sub.2 H OCH.sub.3 CH39 OCF.sub.2 H C.sub.2 H.sub.5 CH40 OCF.sub.2 H CH.sub.2 OCH.sub.3 CH41 OCF.sub.2 H NHCH.sub.3 CH42 OCF.sub.2 H CH(OCH.sub.3).sub.2 CH43 OCF.sub.2 H Cyclopropyl CH______________________________________
______________________________________TABLE J FOR STRUCTURES B-I.sup.(a) .sup.R 1 No. refers to positionEntry E in Structure B only______________________________________1 -- H (Single bond)2 -- 5-CH.sub. 33 -- 5-CH.sub. 2 Cl4 -- 5-OCH.sub. 35 -- 5-SCH.sub. 36 -- 5-SCH.sub. 2 CH.sub.37 -- 5-Cl8 -- 6-F9 -- 5-NO.sub. 210 -- 6-SO.sub. 2 N(CH.sub.3).sub.211 -- 5-SOCH.sub. 312 -- 3-Cl13 -- 6-SO.sub. 2 CH.sub.314 -- 5-CH.sub. 2 CN15 -- 5-CN16 -- 6-CN -17 -- 5-CO.sub. 2 CH.sub.318 -- 5-CF.sub. 319 CH.sub.2 H20 CH.sub.2 5-CN21 CH.sub.2 5-SCH.sub. 322 CH.sub.2 5-OCH.sub. 323 CH.sub.2 5-Cl24 O H25 O 5-SCH.sub. 3______________________________________ .sup.(a) W = O, R = H
______________________________________TABLE Q FOR STRUCTURES J-Q Proviso (See end ofEntry .sup.Q .sup.X b .sup.X c .sup.R 5 .sup.R 6 Table)______________________________________1 Q-1 O -- -- -- a2 Q-1 NR.sub.5 -- CH.sub.3 -- --3 Q-2 O -- -- -- --4 Q-2 NR.sub.5 -- CH.sub.3 -- --5 O-3 O -- -- -- --6 Q-3 NR.sub.5 -- CH.sub.3 -- --7 Q-4 -- -- -- -- --8 Q-5 -- -- -- -- --9 Q-6 -- -- -- -- --10 Q-7 -- -- CH.sub.3 -- --11 Q-8 -- -- CH.sub.3 -- --12 Q-9 -- -- CH.sub.3 -- --13 Q-10 -- -- -- -- --14 Q-11 -- O -- -- --15 Q-11 -- NR.sub.5 CH.sub.2 CH.sub.3 -- --16 Q-12 -- NR.sub.5 CH.sub.2 CH.sub.3 -- --17 Q-12 -- O -- -- --18 Q-13 -- O -- -- --19 Q-14 -- -- -- -- --20 Q-15 O -- -- -- --21 Q-15 NR.sub.5 -- CH.sub.3 -- --22 Q-16 O -- -- -- b23 Q-16 NR.sub.5 -- CH.sub.3 -- b24 Q-17 -- -- -- -- --25 Q-18 -- -- -- -- --26 Q-19 -- -- -- -- --27 Q-20 O -- -- -- --28 Q-20 NR.sub.5 -- CH.sub.3 -- --29 Q-21 O -- -- -- --30 Q-22 O -- -- -- --31 Q-23 O -- -- -- --32 Q-23 NR.sub.5 -- CH.sub.3 -- --33 Q-24 -- -- -- -- --34 Q-25 -- -- -- -- --35 Q-26 -- -- CH.sub.3 -- --36 Q-27 -- -- CH.sub.3 -- --37 Q-28 -- -- -- -- --38 Q-29 -- NR.sub.5 CH.sub.3 -- --39 Q-30 -- O -- -- --40 Q-31 -- O -- -- --41 Q-32 -- NR.sub.5 CH.sub.3 -- --42 Q-33 -- -- -- -- --43 Q-33 -- O -- -- --44 Q-34 -- NR.sub.5 CH.sub.3 -- --45 Q-35 -- O -- -- --46 Q-36 -- -- -- -- --47 Q-37 O -- -- -- b48 Q-38 NR.sub.5 -- CH.sub.3 -- --49 Q-38 -- -- -- -- --50 Q-39 -- -- -- -- --51 Q-40 -- -- -- -- --52 Q-41 -- NR.sub.5 CH.sub.3 -- b53 Q-41 -- O -- -- b54 Q-42 -- O -- -- b55 Q-42 -- NR.sub.5 -- -- b56 Q-43 -- -- -- -- --57 Q-44 -- O -- -- b58 Q-44 -- NR.sub.5 CH.sub.3 -- b59 Q-45 -- -- -- -- b60 Q-46 -- -- CH.sub.3 -- b61 Q-46 -- -- H -- b62 Q-47 -- -- CH.sub.3 -- b63 Q-48 -- -- CH.sub.3 -- b64 Q-49 -- -- CH.sub.3 -- b65 Q-50 -- -- CH.sub. 3 CH.sub.3 b66 Q-51 -- -- -- -- b67 Q-52 -- -- -- -- b68 Q-53 -- -- -- CH.sub.3 b69 Q-54 -- -- -- -- --70 Q-54 -- -- -- -- a71 Q-55 -- -- -- -- a72 Q-56 -- -- -- -- --73 Q-57 -- -- CH.sub.3 -- --74 Q-58 -- -- H -- --75 Q-58 -- -- CH.sub.3 -- --76 Q-59 -- -- -- -- --77 Q-60 -- -- CH.sub.3 -- --78 Q-61 -- -- CH.sub.3 CH.sub.3 --79 Q-62 -- -- CH.sub.3 -- --80 Q-63 -- -- -- -- --81 Q-63 -- -- -- -- c82 Q-64 -- -- CH.sub.3 -- --83 Q-65 -- -- -- -- --84 Q-66 -- -- CH.sub.3 -- --85 Q-67 -- -- -- -- --86 Q-68 -- -- CH.sub.3 -- --87 Q-69 -- -- -- -- --88 Q-70 -- -- CH.sub.3 -- --89 Q-71 -- -- -- -- --90 Q-72 -- -- CH.sub.3 -- --91 Q-73 -- -- CH.sub.3 -- --92 Q-74 -- -- -- -- --93 Q-75 -- -- CH.sub.3 -- --94 Q-76 -- -- -- -- --95 Q-77 -- -- CH.sub.3 -- b96 Q-78 -- -- -- -- --97 Q-79 -- -- -- -- --98 Q-80 -- -- -- -- --99 Q-81 -- -- CH.sub.3 -- --100 Q-82 -- -- -- -- --101 Q-83 -- -- -- -- --102 Q-84 -- -- CH.sub.3 -- --103 Q-85 -- -- -- -- --104 Q-86 -- -- -- -- --105 Q-87 -- -- -- -- --______________________________________ .sup.a Q.sub.1 is substituted by a 4methyl group .sup.b Structure B of Table J is excluded with the use of the Q value designated in this entry .sup.c Substituted by α,dimethyl
______________________________________MELTING POINT TABLE (AJQ)DES- TABLE A: TABLE J: TABLE QIGNATIONS: ENTRY #: ENTRY # ENTRY # STRUCTURE STRUCTURENo. Matrix Designation MP° C.______________________________________1 4: 1-B: 7-J 185-872 5: 1-B: 7-J 194-953 1: 1-B: 72-J 184-854 4: 1-B: 72-J 139-425 5: 1-B: 72-J 184-856 1: 1-B: 70-J 192-947 2: 1-B: 70-J 177-788 4: 1-B: 70-J 183-859 6: 1-B: 70-J 202-0410 3: 1-B: 70-J 185-8611 5: 1-B: 70-J 195-9612 2: 1-B: 1-J 202-04.513 6: 1-B: 1-J 178-82.514 1: 1-B: 1-J 193-9615 5: 1-B: 1-J 182-8516 3: 1-B: 1-J 188-9417 4: 1-B: 1-J 178-8218 1: 1-E: 7-J 174-7619 2: 1-E: 7-J 163-6520 4: 1-E: 7-J 137-3921 6: 1-E: 7-J 182-8322 3: 1-E: 7-J 171-7223 5: 1-E: 7-J 169-7124 1: 1-E: 72-J 159-6125 2: 1-E: 72-J 146-5526 4: 1-E: 72-J 157- 6027 6: 1-E: 72-J 146-5028 3: 1-E: 72-J 155-6129 1: 1-E: 70-J 190-9130 2: 1-E: 70-J 169-7231 4: 1-E: 70-J 129-3132 6: 1-E: 70-J 168-7533 3: 1-E: 70-J 154-5934 5: 1-E: 70-J 170-7335 4: 1-E: 33-J 150-6036 5: 1-E: 33-J 170-72______________________________________
Formulations
Useful formulations of the compounds of Formula I can be prepared in conventional ways. They include dusts, granules, pellets, solutions, suspensions, emulsions, wettable powders, emulsifiable concentrates and the like. Many of these may be applied directly. Sprayable formulations can be extended in suitable media and used at spray volumes of from a few liters to several hundred liters per hectare. High strength compositions are primarily used as intermediates for further formulation. The formulations, broadly, contain about 0.1% to 99% by weight of active ingredient(s) and at least one of (a) about 0.1% to 20% surfactant(s) and (b) about 1% to 99.9% solid or liquid inert diluent(s). More specifically, they will contain these ingredients in the following proportions:
______________________________________ Weight Percent* Active Ingredient Diluent(s) Surfactant(s)______________________________________Wettable Powders 20-90 0-74 1-10Oil Suspensions, 3-50 40-95 0-15Emulsions, Solutions,(including EmulsifiableConcentrates)Aqueous Suspension 10-50 40-84 1-20Dusts 1-25 70-99 0-5Granules and Pellets 0.1-95 5-99.9 0-15High Strength 90-99 0-10 0-2Compositions______________________________________ *Active ingredient plus at least one of a Surfactant or a Diluent equals 100 weight percent.
Lower or higher levels of active ingredient can, of course, be present depending on the intended use and the physical properties of the compound. Higher ratios of surfactant to active ingredient are sometimes desirable, and are achieved by incorporation into the formulation or by tank mixing.
Typical solid diluents are described in Watkins, et al., "Handbook of Insecticide Dust Diluents and Carriers", 2nd Ed., Dorland Books, Caldwell, N.J., but other solids, either mined or manufactured, may be used. The more absorptive diluents are preferred for wettable powders and the denser ones for dusts. Typical liquid diluents and solvents are described in Marsden, "Solvents Guide," 2nd Ed., Interscience, New York, 1950. Solubility under 0.1% is preferred for suspension concentrates; solution concentrates are preferably stable against phase separation at 0° C. "McCutcheon's Detergents and Emulsifiers Annual", MC Publishing corp., Ridgewood, New Jersey, as well as Sisely and Wood, "Encyclopedia of Surface Active Agents", Chemical Publishing Co., Inc., New York, 1964, list surfactants and recommended uses. All formulations can contain minor amounts of additives to reduce foaming, caking, corrosion, microbiological growth, etc.
The methods of making such compositions are well known. Solutions are prepared by simply mixing the ingredients. Fine solid compositions are made by blending and, usually, grinding as in a hammer or fluid energy mill. Suspensions are prepared by wet milling (see, for example, Littler, U.S. Pat. No. 3,060,084). Granules and pellets may be made by spraying the active material upon preformed granular carriers or by agglomeration techniques. See J. E. Browning, "Agglomeration", Chemical Engineering, Dec. 4, 1967, pp. 147ff, and "Perry's Chemical Engineer's Handbook", 5th Ed., McGraw-Hill, New York, 1973, pp. 8-57ff.
For further information regarding the art of formulation, see for example:
H. M. Loux, U.S. Pat. No. 3,235,361, Feb. 15, 1966, Col. 6, line 16 through Col. 7, line 19 and Examples 10 through 41;
R. W. Luckenbaugh, U.S. Pat. No. 3,309,192, Mar. 14, 1967, Col. 5, line 43 through Col. 7, line 62 and Examples 8, 12, 15, 39, 41, 52, 53, 58, 132, 138-140, 162-164, 166, 167 and 169-182;
H. Gysin and E. Knusli, U.S. Pat. No. 2,891,855, June 23, 1959, Col. 3, line 66 through Col. 5, line 17 and Examples 1-4;
G. C. Klingman, "Weed Control as a Science", John Wiley and Sons, Inc., New York, 1961, pp. 81-96; and
J. D. Fryer and S. A. Evans, "Weed Control Handbook", 5th Ed., Blackwell Scientific Publications, Oxford, 1968, pp. 101-103.
In the following examples, all parts are by weight unless otherwise indicated.
EXAMPLE 4
______________________________________Wettable Powder______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 80%oxo-1-pyrrolidinylmethyl)benzenesulfonamidesodium alkylnaphthalenesulfonate 2%sodium ligninsulfonate 2%synthetic amorphous silica 3%kaolinite 13%______________________________________
The ingredients are blended, hammer-milled until all the solids are essentially under 50 microns, reblended, and packaged.
EXAMPLE 5
______________________________________Wettable Powder______________________________________N--[[4-methoxy-6-methyl-1,3,5-triazin-2-yl)- 50%aminocarbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)-benzenesulfonamidesodium alkylnaphthalenesulfonate 2%low viscosity methyl cellulose 2%diatomaceous earth 46%______________________________________
The ingredients are blended, coarsely hammermilled and then air-milled to produce particles essentially all below 10 microns in diameter. The product is reblended before packaging.
EXAMPLE 6
______________________________________Granule______________________________________Wettable Powder of Example 5 5%attapulgite granules 95%(U.S.S. 20-40 mesh; 0.84-0.42 mm)______________________________________
A slurry of wettable powder containing 25% solids is sprayed on the surface of attapulgite granules while tumbling in a double-cone blender. The granules are dried and packaged.
EXAMPLE 7
______________________________________Extruded Pellet______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 25%oxo-1-pyrrolidinylmethyl)benzenesulfonamideanhydrous sodium sulfate 10%crude calcium ligninsulfonate 5%sodium alkylnaphthalenesulfonate 1%calcium/magnesium bentonite 59%______________________________________
The ingredients are blended, hammer-milled and then moistened with about 12% water. The mixture is extruded as cylinders about 3 mm diameter which are cut to produce pellets about 3 mm long. These may be used directly after drying, or the dried pellets may be crushed to pass a U.S.S. No. 20 sieve (0.84 mm openings). The granules held on a U.S.S. No. 40 sieve (0.42 mm openings) may be packaged for use and the fines recycled.
EXAMPLE 8
______________________________________Oil Suspension______________________________________N--[[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)aminocar- 25%bonyl]-2-(2-oxo-1-pyrrolidinylmethyl)benzene-sulfonamidepolyoxyethylene sorbitol hexaoleate 5%highly aliphatic hydrocarbon oil 70%______________________________________
The ingredients are ground together in a sand mill until the solid particles have been reduced to under about 5 microns. The resulting thick suspension may be applied directly, but preferably after being extended with oils or emulsified in water.
EXAMPLE 9
______________________________________Wettable Powder______________________________________N--[[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)amino- 20%carbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)-benzenesulfonamidesodium alkylnaphthalenesulfonate 4%sodium ligninsulfonate 4%low viscosity methyl cellulose 3%attapulgite 69%______________________________________
The ingredients are thoroughly blended. After grinding in a hammer-mill to produce particles essentially all below 100 microns, the material is reblended and sifted through a U.S.S. No. 50 sieve (0.3 mm opening) and packaged.
EXAMPLE 10
______________________________________Low Strength Granule______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 1%oxo-1-pyrrolidinylmethyl)benzenesulfonamideN,N--dimethylformamide 9%attapulgite granules 90%(U.S.S. 20-40 sieve)______________________________________
The active ingredient is dissolved in the solvent and the solution is sprayed upon dedusted granules in a double cone blender. After spraying of the solution has been completed, the blender is allowed to run for a short period and then the granules are packaged.
EXAMPLE 11
______________________________________Aqueous Suspension______________________________________N--[[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)amino- 40%carbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)benzene-sulfonamidepolyacrylic acid thickener 0.3%dodecylphenol polyethylene glycol ether 0.5%disodium phosphate 1%monosodium phosphate 0.5%polyvinyl alcohol 1%water 56.7%______________________________________
The ingredients are blended and ground together in a sand mill to produce particles essentially all under 5 microns in size.
EXAMPLE 12
______________________________________Solution______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 5%oxo-1-pyrrolidinylmethyl)benzenesulfonamide.sodium saltwater 95%______________________________________
The salt is added directly to the water with stirring to produce the solution, which may then be packaged for use.
EXAMPLE 13
______________________________________Low Strength Granule______________________________________N--[[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)aminocar- 0.1%bonyl]-2-(2-oxo-1-pyrrolidinylmethyl)benzene-sulfonamideattapulgite granules 99.9%(U.S.S. 20-40 mesh)______________________________________
The active ingredient is dissolved in a solvent and the solution is sprayed upon dedusted granules in a double-cone blender. After spraying of the solution has been completed, the material is warmed to evaporate the solvent. The material is allowed to cool and then packaged.
EXAMPLE 14
______________________________________ Granule______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 80%oxo-1-pyrrolidinylmethyl)benezenesulfonamidewetting agent 1%crude ligninsulfonate salt (containing 10%5-20% of the natural sugars)attapulgite clay 9%______________________________________
The ingredients are blended and milled to pass through a 100 mesh screen. This material is then added to a fluid bed granular, the air flow is adjusted to gently fluidize the material, and a fine spray of water is sprayed onto the fluidized material. The fluidization and spraying are continued until granules of the desired size range are made. The spraying is stopped, but fluidization is continued, optionally with heat, until the water content is reduced to the desired level, generally less than 1%. The material is then discharged, screened to the desired size range, generally 14-100 mesh (1410-149 microns), and packaged for use.
EXAMPLE 15
______________________________________High Strength Concentrate______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 99%oxo-1-pyrrolidinylmethyl)benzenesulfonamide.silica aerogel 0.5%synthetic amorphous silica 0.5%______________________________________
The ingredients are blended and ground in a hammer-mill to produce a material essentially all passing a U.S. Ser. No. 50 screen (0.3 mm opening). The concentrate may be formulated further if necessary.
EXAMPLE 16
______________________________________Wettable powder______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 90%oxo-1-pyrrolidinylmethyl)benzenesulfonamidedioctyl sodium sulfosuccinate 0.1%synthetic fine silica 9.9%______________________________________
The ingredients are blended and ground in a hammer-mill to produce particles essentially all below 100 microns. The material is sifted through a U.S. Ser. No. 50 screen and then packaged.
EXAMPLE 17
______________________________________Wettable Powder______________________________________N--[[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)amino- 40%carbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)-benzenesulfonamidesodium ligninsulfonate 20%montmorillonite clay 40%______________________________________
The ingredients are thoroughly blended, coarsely hammer-milled and then air-milled to produce particles essentially all below 10 microns in size. The material is reblended and then packaged.
EXAMPLE 18
______________________________________Oil Suspension______________________________________N--[[(4,6-dimethoxypyrimidin-2-yl)aminocarbonyl]-2-(2- 35%oxo-1-pyrrolidinylmethyl)benzenesulfonamide.blend of polyalcohol carboxylic 6%esters and oil soluble petroleumsulfonatesxylene 59%______________________________________
The ingredients are combined and ground together in a sand mill to produce particles essentially all below 5 microns. The product can be used directly, extended with oils, or emulsified in water.
EXAMPLE 19
______________________________________Dust______________________________________N--[[(4-methoxy-6-methyl-1,3,4-triazin-2-yl)amino- 10%carbonyl]-2-(2-oxo-1-pyrrolidinylmethyl)-benzenesulfonamideattapulgite 10%Pyrophyllite 80%______________________________________
The active ingredient is blended with attapulgite and then passed through a hammer-mill to produce particles substantially all below 200 microns. The ground concentrate is then blended with powdered pyrophyllite until homogeneous.
Utility
Test results indicate that the compounds of the present invention are highly active preemergent or postemergent herbicides or plant growth regulants. Many of them have utility for broad-spectrum pre and/or post-emergence weed control in areas where complete control of all vegetation is desired, such as around fuel storage tanks, ammunition depots, industrial storage areas, parking lots, drive-in theaters, around billboards, highway and railroad structures. Some of the compounds have utility for selective weed control in crops such as wheat, second barley. Alternatively, the subject compounds are useful to modify plant growth.
The rates of application for the compounds of the invention are determined by a number of factors, including their use as plant growth modifiers or as herbicides, the crop species involved, the types of weeds to be controlled, weather and climate, formulations selected, mode of application, amount of foliage present, etc. In general terms, the subject compounds should be applied at levels of around 0.005 to 10 kg/ha, the lower raters being suggested for use on lighter soils and/or those having a low organic matter content, for plant growth modification or for situations where only short-term persistence is required.
The compounds of the invention may be used in combination with any other commercial herbicides, examples of which are those of the triazine, triazole, uracil, urea, amide, diphenylether, carbamate and bipyridylium types.
The herbicidal properties of the subject compounds were discovered in a number of greenhouse tests. The test procedures and results follow.
______________________________________COMPOUNDS______________________________________ ##STR26##COMPOUND Q X Y Z______________________________________ ##STR27## OCH.sub.3 OCH.sub.3 CH2 ##STR28## OCH.sub.3 OCH.sub.3 N3 ##STR29## CH.sub.3 CH.sub.3 CH4 ##STR30## OCH.sub.3 OCH.sub.3 CH5 ##STR31## OCH.sub.3 OCH.sub.3 N6 ##STR32## CH.sub.3 CH.sub.3 CH7 ##STR33## CH.sub.3 OCH.sub.3 CH8 ##STR34## Cl OCH.sub.3 CH9 ##STR35## CH.sub.3 OCH.sub.3 CH10 ##STR36## OCH.sub.3 OCH.sub.3 N11 ##STR37## CH.sub.3 OCH.sub.3 N12 ##STR38## OCH.sub.3 OCH.sub.3 CH______________________________________ ##STR39##COMPOUND Q X Y Z______________________________________13 ##STR40## CH.sub.3 OCH.sub.3 CH14 ##STR41## OCH.sub.3 OCH.sub.3 CH15 ##STR42## Cl OCH.sub.3 CH16 ##STR43## CH.sub.3 CH.sub.3 CH17 ##STR44## CH.sub.3 OCH.sub.3 CH18 ##STR45## OCH.sub.3 OCH.sub.3 CH19 ##STR46## Cl OCH.sub.3 CH20 ##STR47## CH.sub.3 OCH.sub.3 N21 ##STR48## CH.sub.3 OCH.sub.3 CH22 ##STR49## OCH.sub.3 OCH.sub.3 CH______________________________________
Test A
Seeds of crabgrass (Digitaria, spp.), barnyard-grass (Echinochloa crusgalli), wild oats (Avena fatua), cheatgrass (Bromus secalinus), velvetleaf (Abutilon theophrasti), morningglory (Ipomoea spp.), cocklebur (Xanthium pensylvanicum), sorghum, corn, soybean, sugarbeet, cotton, rice, wheat, and purple nutsedge (Cyperus rotundus) tubers were planted and treated preemergence with the test chemicals dissolved in a non-phytotoxic solvent. At the same time, these crop and weed species were treated with a soil/foliage application. At the time of treatment, the plants ranged in height from 2 to 18 cm. Treated plants and controls were maintained in a greenhouse for sixteen days, after which all species were compared to controls and visually rated for response to treatment. The ratings, summarized in Table A, are based on a numerical scale extending from 0=no injury, to 10=complete kill. The accompanying descriptive symbols have the following meanings:
C=chlorosis/necrosis;
B=burn;
D=defoliation;
E=emergence inhibition;
G=growth retardation;
H=formative effect;
U=unusual pigmentation;
X=axillary stimulation;
S=albinism; and
6Y=abscised buds or flowers.
TABLE A______________________________________ Cmpd. 1 Cmpd. 2 Cmpd. 3Rate (kg/ha) 0.05 0.05 0.05______________________________________POSTEMERGENCEMorningglory 10C 1C,1H 9CCocklebur 10C 1C 5C,9GVelvetleaf 9C 0 2C,6GNutsedge 3C,8G,9X 0 5GCrabgrass 4C,9G 0 5C,9GBarnyardgrass 9C 0 9CCheatgrass 9C 0 8GWild Oats 4C,8G 2C,2H 9CWheat 3G 0 9CCorn 5U,9G 8G 10CSoybean 9C 3C 9CRice 9C 5G 6C,9GSorghum 9C 4G 9CSugar Beets 9C 3C,3H 9CCotton 9C 2C,2H 5C,9GPREEMERGENCEMorningglory 9G 2H 8HCocklebur 9H 2H 9HVelvetleaf 9C 7G 7GNutsedge 8G 0 4GCrabgrass 2C,6G 2G 2GBarnyardgrass 4C,9H 2G 2C,9HCheatgrass 5C,9H 0 7HWild Oats 4C,9G 0 9CWheat 4C,8G 0 9HCorn 4C,9H 2G 4C,9HSoybean 3C,7G 0 5GRice 10E 0 10ESorghum 10E 0 10ESugar Beets 5C,9G 10ECotton 4C,9G 0 8G______________________________________ Cmpd. 4 Cmpd. 5 Cmpd. 6Rate (kg/ha) 0.05 0.05 0.05______________________________________POSTEMERGENCEMorningglory 10C 2C,6G 2C,5GCocklebur 9C 2C,3H 3C,9HVelvetleaf 10C 0 3GNutsedge 3C,9G 0 2C,4GCrabgrass 3C,9H 0Barnyardgrass 9C 3C 8H 3C,5HCheatgrass 7G 0 6GWild Oats 4C,8G 4C,8G 6GWheat 0 0 4GCorn 6C,9G 5C,9G 3C,7HSoybean 6C,9G 4C,8G 5C,9GRice 9C 4C,8G 5GSorghum 5C,9G 3C,6H 4C,8HSugar Beets 9C 4C,7G 2HCotton 9C 4C,6G 4C,8HPREEMERGENCEMorningglory 9G 3G 7HCocklebur 9H 3G 2HVelvetleaf 8G 0 3GNutsedge 9G 8G 0Crabgrass 9G 0 4GBarnyardgrass 5C,9H 2C 0Cheatgrass 2C,7G 0 7GWild Oats 3C,8G 0 0Wheat 7G 0 0Corn 3U,9H 2C,5G 0Soybean 4C,8H 2G 10ERice 10E 7G 0Sorghum 4C,9H 2C,6G 3GSugar Beets 10C 10C 8GCotton 5C,9G 0 0______________________________________ Cmpd. 7 Cmpd. 8Rate (kg/ha) 0.05 0.05______________________________________POSTEMERGENCEMorningglory 5C,9G 4C,9GCocklebur 6C,9G 5C,9GVelvetleaf 3C,8H 5GNutsedge 5G 2GCrabgrass 3G 0Barnyardgrass 3C,8H 0Cheatgrass 2C,8G 0Wild Oats 2C,5G 0Wheat 2C,5G 0Corn 3C,9G 0Soybean 9C 3C,8GRice 3C,8G 5GSorghum 2C,9G 3C,7GSugar Beets 3C,5G 2HCotton 3C,6G 5GPREEMERGENCEMorningglory 9G 3GCocklebur 9H 9GVelvetleaf 9C 0Nutsedge 3G 0Crabgrass 2G 0Barnyardgrass 2C,5G 0Cheatgrass 8G 0Wild Oats 2C,6G 0Wheat 7G 2GCorn 2C,8H 2GSoybean 3C,6H 2HRice 3C,7H 0Sorghum 3C,9H 2CSugar Beets 4C,9G 6GCotton 5G 0______________________________________ Cmpd. 9 Cmpd. 10 Cmpd. 11Rate kg/ha 0.05 0.05 0.05______________________________________POSTEMERGENCEMorningglory 10C 4C,8G 6C,9GCocklebur 10C 4C,9G 4C,9GVelvetleaf 4C,9G 4C,8H 4C,9GNutsedge 0 0 0Crabgrass 3G 0 0Giant Foxtail 4G 0 0Barnyardgrass 2C,8G 1C 0Cheatgrass 2C,8G 0 0Wild Oats 5G 0 0Wheat 4G 0 0Corn 3C,7G 1H 0Barley 2C,7G 0 0Soybean 5H 0 0Rice 7G 0 2GSorghum 2C,9G 2C,5G 4GSugar beet 3C,7G 9C 9CCotton 9C 8G 2C,9GPREEMERGENCEMorningglory 9G 5G 9CCocklebur -- 9H --Velvetleaf 10C 9C 2GNutsedge 0 0 0Crabgrass 7G 0 0Giant Foxtail 5G 0 0Barnyardgrass 2C,8G 2C 0Cheatgrass 7G 0 0Wild Oats 5G 0 0Wheat 5G 0 0Corn 2C,7G 0 0Barley 8G 0 0Soybean 2G 2G 2C,5GRice 7G 2G 0Sorghum 2C,8G 3G 4GSugar beet 8G 7G 4C,8GCotton 7G 4G 5G______________________________________ Compound 12 Cmpd. 13 Cmpd. 14Rate kg/ha 0.05 0.01 0.05 0.05______________________________________POSTEMERGENCEMorningglory 9C 2G 10C 10CCocklebur 10C 2C,9H 9C 9CVelvetleaf 10C 5C,9G 4C,8G 9CNutsedge 6G 2G 4G 4C,8GCrabgrass 0 0 0 0Giant Foxtail 2G 0 4G 4C,9GBarnyardgrass 7H 3H 8H 10CCheatgrass 7G 6G 0 7GWild Oats 0 0 3C,6G 0Wheat 5G 0 4G 0Corn 1H 0 3C,8H 9GBarley 7G 3G 0 2CSoybean 2C,8G 5H 5C,9G 9CRice 8G 3G 2C,6G 2C,9GSorghum 2C,8H 7G 3C,8H 4C,9GSugar beet 9C 5C,9G 10C 10CCotton 3C,9G 4C,8G 5C,9G 9CPREEMERGENCEMorningglory 5G 5G 8G 9GCocklebur -- 7G 9H 9HVelvetleaf 7G 6G 9G 9GNutsedge 4G 0 0 5GCrabgrass 0 0 4G --Giant Foxtail 4G 2C 2G 6GBarnyardgrass 2C,7G 2C 2G 8GCheatgrass 9H 7G 0 7GWild Oats 0 0 0 0Wheat 0 0 0 0Corn 6G 5G 3C,7H 3C,8GBarley 7G 0 0 5GSoybean 0 0 3C,7H 9HRice 6G 0 3G 6GSorghum 2C,8H 3G 4G 4C,9HSugar beet 8G 5G 10C 10CCotton 5G -- 3C,7G 9G______________________________________ Cmpd. 15 Cmpd. 16 Cmpd. 17 Cmpd. 18Rate kg/ha 0.05 0.05 0.05 0.05______________________________________POSTEMERGENCEMorningglory 5C,9G 10C 10C 10CCocklebur 5C 9H 10C 10C 10CVelvetleaf 2G 5G 4C,9G 9CNutsedge 0 2C,9G 3C,7G 5C,9GCrabgrass 0 6G 2G 3GGiant Foxtail 0 5C,9G 4C,8G 3C,8GBarnyardgrass 5H 10C 4C,9H 4C,9HCheatgrass 0 9G 7G 4C,9GWild Oats 0 3G 0 0Wheat 0 3G 3G 0Corn 4G 9C 9C 10CBarley 0 2C,5G 0 0Soybean 3C,8G 4C,9G 4C,9G 9CRice 6G 9C 5C,9G 8GSorghum 4C,9H 4C,9G 4C,9H 9HSugar beet 4C,8G 10C 10C 10CCotton 3C,7G 4C,9G 10C 10CPREEMERGENCEMorningglory 8G 9G 9G 9GCocklebur -- 9H 9H 9HVelvetleaf 7G 9G 9G 9GNutsedge 0 9G 8G 10ECrabgrass -- 6G 5G 5GGiant Foxtail 3G 3C,7G 3C,7G 3C,7GBarnyardgrass 2G 3C,9H 4C,9H 9HCheatgrass 0 8G 8G 9HWild Oats 0 5G 5G 4GWheat 0 4G 2G 0Corn 3G 9H 3C,9H 3C,9HBarley 0 2C,8G 5G 6GSoybean 0 7H 9H 9HRice 3G 4C,8H 8G 8GSorghum 0 8G 3C,8G 7GSugar beet 8G 10E 10E 10ECotton 8G 9G 9G 9G______________________________________ Cmpd. 19 Cmpd. 20 Cmpd. 21 Cmpd. 22Rate kg/ha 0.05 0.05 0.05 0.05______________________________________POSTEMERGENCEMorningglory 10C 4C,8H 10C 4C,9GCocklebur 10C 4C,9G 9C 4C,9HVelvetleaf 3C,7G 3C,7H 4C,8G 4C,8GNutsedge 4G 0 2C 2GCrabgrass 3G 0 3G 2GGiant Foxtail 3C,5G 2C,8G 2G 0Barnyardgrass 3C,8H 5C,9H 2C,5H 0Cheatgrass 3C,6G 0 0 0Wild Oats 0 0 0 0Wheat 2G 0 0 0Corn 9H 10C 8H 3HBarley 0 0 0 0Soybean 4C,9G 2C,7G 4C,9G 4C,9GRice 8G 7G 5G 4GSorghum 4C,9H 4C,9H 3C,8G 2GSugar beet 9C 4C,8H 3C,7G 2C,6GCotton 10C 3C,7G 4C,8H 3C,6GPREEMERGENCEMorningglory 8G 7H 9G 7HCocklebur 8H 7G 9H 7HVelvetleaf 9G 0 8G 7GNutsedge 9G 0 0 0Crabgrass 2G 0 3G --Giant Foxtail 2C,4G 0 3G 0Barnyardgrass 3C,7G 0 0 0Cheatgrass 5G 0 0 0Wild Oats 0 0 0 0Wheat 0 0 0 0Corn 7G 7G 5G 0Barley 0 0 0 0Soybean 0 0 3C,6H 2C,4HRice 5G 5G 2C,5G 0Sorghum 6G 0 2C,4G 2CSugar beet 4C,9G 9C 8G 8GCotton 2C,8G 4G 2C,6G 7G______________________________________
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FIELD OF THE INVENTION
The present invention pertains to combining cryogenic freezing and mechanical refrigeration to freeze foodstuffs.
BACKGROUND OF THE INVENTION
Attempts have been made in the past to combine use of a cryogenic freezing process prior to mechanical refrigeration to freeze food products. The so called hybrid systems boost overall production, reduce dehydration to some extent, but increase the freezing costs. In order to use a hybrid system attempts have been made to utilize the vaporizing cryogen in the mechanical refrigeration system to enhance the mechanical refrigerator. U.S. Pat. Nos. 4,856,285 and 4,858,445 disclose and claim devices to utilize vaporized cryogen by heat exchanging the vaporizing cryogen against the atmosphere in the mechanical refrigeration unit by means of a separate heat exchanger. Such devices require extensive equipment and the heat transfer is not as effective as could be accomplished with a direct heat exchange.
SUMMARY OF THE INVENTION
According to the present invention, an improved hybrid freezing system is achieved by mating the outlet of an immersion type cryogenic freezer to the inlet of a spiral type mechanical freezer. Cryogen vaporizing in the immersion unit is directly injected into the mechanical refrigerator, where the cryogen is in direct heat exchange with refrigerated air circulating inside the mechanical refrigerator. Vaporized cryogen injected into the spiral portion of the hybrid unit is exhausted through the exit end of the spiral freezer by means of a controlled exhaust fan. Key to the refrigeration system is the movement of identical volumes of vaporized cryogen into and out of the mechanical refrigeration unit. Hybrid systems according to the present invention provide the benefits of cryogenic freezing because initial quick freezing of the product forms a crust on the product and therefore minimizes or lowers the dehydration of the finally frozen product and the cryogen assisted mechanical refrigeration system has the benefit of lower cost to finally freeze the product completely.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of an apparatus according to the present invention.
FIG. 2 is a plot of immersion time against both heat removal per pound and percent dehydration for a hot chicken product frozen according to the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the apparatus of the present invention comprises a first section 10 which is an immersion type freezer of the type adapted to maintain a pool of liquid cryogen (e.g. nitrogen) 12 inside an insulated enclosure 14. First section or immersion freezer 10 includes a product inlet 16 adapted to permit product shown by arrows 17 to be introduced into the liquid cryogen bath 12. A continuous conveyor 18 driven by a belt drive 20 as is known in the art is positioned to move product (e.g. foodstuffs) from the bath toward a discharge 22 in section 10. Discharge 22 is adapted to discharge product onto a spiral conveyor 24 contained inside a second section 26 which is a spiral type mechanically refrigerated freezer. Mechanical spiral type refrigerators such as 26 are well known in the art and comprise a refrigerated housing 28, a product inlet 30 at a low level, and a product discharge 32 at a higher level. The product to be frozen moves from the inlet 30 around the spiral and is discharged out of the discharge opening 32. The interior of the housing 28 is cooled to freezing temperatures by means of a mechanical refrigeration system (not shown) as is well known in the art. Sections 10 and 26 are mated or married together in a gas tight relationship so that cryogen vaporizing inside of the immersion freezer 10 will flow out of the discharge 22 and into the housing 28 of mechanical refrigerator 26. Movement of the vaporized cryogen is effected by a cryogen mover 36 which can be an exhaust fan. The exhaust fan is so constructed that equal volumes of cryogen are admitted through the gas inlet 49 of freezer 26 and discharged from outlet 32 of freezer 26. Flow of vaporized cryogen is as shown by arrows 50. The exhaust fan includes a bypass system 38 which includes a temperature control valve 40 with a thermocouple connected to control valve 40 being disposed inside of the freezer 26. In order to maintain the correct volumetric flow of vaporized cryogen, injection of vaporized cryogen into the refrigerator 26 is in response to the temperature control and positioning of valve 40.
The product to be frozen is introduced into the immersion unit through aperture 16 where the product is permitted to drop into and remain in the liquid cryogen (e.g. liquid nitrogen) bath for a time sufficient to produce a frozen crust on the outside surface of the product or article to be frozen. Immersion usually persists for a period of from 1 to 20 seconds depending upon the product being frozen. The product is then discharged from the liquid nitrogen bath or pool 12 to the mechanical refrigeration unit 26 to finish the freezing process. Boil-off gas (vaporized cryogen) from the immersion freezer 10 is directly injected into the mechanical refrigeration unit 26 for contact with the food to efficiently and effectively utilize both the vaporized cryogen and the air recirculating inside the freezer. The vaporized cryogen is drawn off or exhausted from the product discharge 32 of the spiral freezing 26 utilizing the exhaust fan 36 at the exit.
The system of the present invention is limited to approximately 30% of the total product duty being handled by cryogenics so as not to override the mechanical refrigeration control system.
Set forth in Table 1 are the results of an economic analysis for freezing chicken according to the method and apparatus of the present invention.
TABLE 1__________________________________________________________________________ INCREASE EXPECTED.sup.3BTU.sup.1 IN EXPECTED DEHYDRATION.sup.2 OPERATINGREMOVAL/LB PRODUCTION DEHYDRATION SAVINGS ¢/LB SAVINGS ¢/LB__________________________________________________________________________25 14% 2.0% 2.4¢ 1.15¢45 26% 1.3% 3.8¢ 1.65¢64 36% 0.8% 4.8¢ 1.75¢__________________________________________________________________________ .sup.1 Total product BTU removal required, 170 BTU/lb. .sup.2 Based on 3.2% on current operation, expected dehydration (laboratory simulation) and $2.00/lb product value. .sup.3 (Dehydration Savings) + (Reduction in Mechanical Refrigeration Cost) - (LIN Cost to Crust Freeze)
Plotted in FIG. 2 are the results of tests of immersion time in liquid cryogen against heat removal per pound which is shown as curve A and a plot of percent dehydration against liquid cryogen immersion time in seconds which is shown as curve B for a hot chicken product.
The process and apparatus according to the present invention results in the benefit of the lower cost of mechanical refrigeration, without consideration for dehydration, to freeze then to achieve the same level of freezing using a cryogenic freezer. However, because most mechanically frozen products dehydrate one, two, four percent more than cryogenically frozen products, the integration of cryogenics into a mechanical freezer to lower dehydration such as taught by the present invention provides a method and apparatus heretofore unknown in the prior art.
Thus, according to the present invention the benefits of cryogenic freezing are realized with the lower cost of mechanical refrigeration. The benefit of cryogenic freezing comes about by reducing the amount of dehydration of the product or product moisture loss while freezing. Dehydration is strictly a time-temperature freezing rate phenomenon. By integrating the two systems, it is possible to first crust freeze the product to lock in the moisture then finish the freeze in a mechanical refrigeration unit which uses by direct heat exchange the vaporized cryogen from the cryogenic unit.
The process according to the present invention provides a 30% production increase depending upon the product being frozen. This is the heat value removed by the cryogenic system during crust freezing and off-gas supplement in the mechanical freezing unit. In addition, it is expected that with lower dehydration the mechanical unit will experience less moisture build-up in the coils, easier belt clean-up and consequently longer run times between necessary shutdown for cleaning.
Laboratory and field tests have shown that dehydration for hot products can be upwards of 4%, and 2% for cold products. With the cryomechanical system, dehydrations of 0.8% for hot products and 0.35% for cold products were measured, respectively. This results in net product weight retention which can more than pay for nitrogen costs depending on product value per pound.
Having thus described my invention what is desired to be secured by letters patent of the United States is set forth in the appended claims. | Method and apparatus for reducing dehydration during freezing of foodstuffs utilizing a combination of cryogenic freezing to lock in moisture followed by vaporized cryogen assisted mechanical freezing to through freeze other foodstuff. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for transferring plate-like objects such as semiconductor wafers.
2. Description of the Related Art
The semiconductor wafer processing apparatuses have a carrier mechanism or device for transferring or carrying wafers, which will be loaded into and unloaded from a process section, into a housing section such as the cassette. One of these wafer processing apparatuses which use this carrier mechanism is the heat processing apparatus. This heat processing apparatus is intended to oxidize, diffuse and anneal the wafer or film-form on it. Plural sheets of semiconductor wafers are transferred from the cassette into a boat, which will be loaded into a heat processing tube, in the heat processing apparatus, or these semiconductor wafers which have been unloaded from the heat processing tube are transferred from the boat into the cassette in it.
As shown in FIG. 1, the carrier device is arranged in a load/unload section of the heat processing apparatus to transfer semiconductor wafers between the cassette and the boat. It is intended to increase throughput in the course of making semiconductor devices, and it can carry the wafers all at once. The carrier device has an arm mechanism 10 rotatable, movable up and down and reciprocatable. This arm mechanism 10 has a wafer-mounted section, on which five sheets of wafers can be mounted, at the front end of an arm. It can transfer five sheets of wafers all at once between the cassette 12 and the boat 14.
On the other hand, it is sometimes needed that only one sheet of monitor or dummy wafer is transferred into the boat 14. In addition to the above-mentioned plural wafers carrying arm mechanism, therefore, a one wafer carrying arm mechanism is needed.
As shown in FIG. 3, the single and plural sheets carrying arm mechanisms 22 and 20 are arranged one upon the other in the conventional carrier device, and the single sheet carrying arm mechanism 22 is driven independently of the plural sheets one 20. Five sheets carrying arms 20A are arranged at a same pitch interval but the single sheet carrying arm 22A has no pitch interval relative to the plural sheets ones 20A. In short, the interval of the single sheet carrying arm 22A relative to the plural sheets ones 20A is larger than the pitch interval at which the plural sheets carrying arms 20A are arranged one another. This is intended to prevent both of the arms 20A and 22A from interfering with each other when they are being moved. Therefore, the space the conventional carrier device occupies is large and the device itself is also large in size.
Further, both mechanisms 20 and 22 are driven independently of the other. This makes it necessary to independently position each of them. Teaching procedure which is carried out in a drive section to position each of them becomes complicated accordingly, and positioning error thus obtained may be large. Both of the mechanisms 20 and 22 are also assembled independently of the other. This increases the number of parts used and the number of assembling steps for them. Cost for each mechanism, therefore, becomes high.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to provide a plate-like object carrier device capable of transferring or carrying plural plate-like objects together as well as a single one alone but without becoming large in size and without increasing the number of component parts used and the steps of assembling them.
According to an aspect of the present invention, there can be provided a device for transferring or carrying plate-like objects comprising: plural arms having a single arm and a group of arms, arranged at a substantially same pitch interval to horizontally support a plate-like object on each of the arms; first drive means for driving the single arm forward and backward independently of the group of arms; second drive means for driving the group of arms forward and backward at the same time except the single arm; a power supply for supply power to the first and second drive means; and control means for selecting whether to supply power from the power supply only to the first drive means or to both of the first and second drive means.
According to another aspect of the present invention, there can be provided a device for transferring or carrying plural plate-like objects together, which are arranged at a substantially same pitch interval, into or out of a section, while taking a center reference position as the reference, comprising: plural pairs of arms arranged in symmetrically relative to the center reference position to horizontally support the plate-like object on each of the arms; and pitch changing means for moving the paired arms up and down and symmetrically relative to the center reference position to change the pitch interval between the adjacent two of the plate-like objects.
The above-mentioned pitch changing means comprises the charging means has slide guide members connected to the corresponding paired arms; plural screws for supporting the slide guide members movable for every pair of arms; means for driving or rotating the screws at the same time; and means for transmitting rotation force from the drive or rotation means to each of the screws; wherein each of the screws has a screw thread on an upper half thereof, which is located above the center reference position, extending along it in a direction, and it also has another screw thread on a lower half thereof, which is located below the center reference position, extending along it in another direction reverse to the above direction, and wherein the rotation transmitting means adjusts the number of rotations transmitted to each of the screws in such a way that paired arms can be arranged symmetrically and at a same pitch interval relative to the center reference position.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view showing the whole of the conventional device;
FIG. 2 is a sectional view showing a part of the inside arrangement in the conventional device;
FIG. 3 is a side view showing the carrier arm assembly of the conventional device;
FIG. 4 is a perspective view showing the whole of the carrier device for plate-like objects according to an embodiment of the present invention;
FIG. 5 is a perspective view showing a carrier arm assembly of our device;
FIG. 6 is a sectional view showing the carrier arm assembly of our device;
FIG. 7 is a perspective view showing a drive section of our carrier arm assembly dismantled;
FIG. 8 is a perspective view showing a drive section of a carrier arm assembly of our device dismantled, our device being made according to another embodiment of the present invention in this case;
FIG. 9 is a side view showing the carrier arm assembly of our device;
FIG. 10 is a block diagram showing a control section for our device;
FIG. 11 is a sectional view showing a pitch changing mechanism of our carrier device;
FIG. 12A is a partly-sectioned view showing those portions to which carrier arms are attached;
FIG. 12B is a sectional view showing carrier arms detached;
FIG. 13A is a sectional view showing the pitch changing mechanism seen before it is operated to change the pitch;
FIG. 13B is a sectional view showing the pitch changing mechanism seen after it is operated to change the pitch;
FIG. 14A is a perspective view showing the pitch changing mechanism seen before it is operated to change the pitch;
FIG. 14B is a perspective view showing the pitch changing mechanism seen after it is operated to change the pitch; and
FIG. 15 is a sectional view showing a detector for detecting the distance of each carrier arm moved.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of the present invention will be described in detail with reference to the accompanying drawings.
As shown in FIG. 4, a wafer transfer section is arranged just under the heat process tube (not shown) in the heat process apparatus of the vertical type. A wafer boat 30 is housed in the wafer transfer section and a carrier device 40 for plate-like objects is arranged adjacent to the boat 30. The boat 30 is supported, movable up and down, by an elevator 32 so that it can be loaded into and unloaded from the heat process tube. A cassette stage 36 is also arranged in the wafer transfer section and plural cassettes 34 in each of which plural sheets of semiconductor wafers W are held are housed in the cassette stage 36. The plate-like object carrier device 40 is arranged between the boat 30 and the cassette stage 36.
The carrier device 40 is mounted on a stage which is movable up and down and rotatable, and it can be thus moved along an axis Z and rotated round it by an angle O. Each arm 50 of the carrier device 40 is supported by a drive mechanism to move forward and backward in a horizontal plane.
As shown in FIG. 5, the carrier device 40 has five rectangular arms 42, 44, 46, 48 and 50, which are arranged parallel to one another at a same pitch interval. A sheet of wafer W is mounted on each of the arms 42, 44, 46, 48 and 50. The arm 50 positioned in the center of them is driven forward and backward independently of the others. The position of the arm 50 is called center reference position.
As shown in FIG. 6, a pair of ball splined shafts 52 and 54 are housed in a box which is positioned under the carrier device 40. These paired ball splined shafts 52 and 54 extend along the longitudinal line of the arm 50 and both ends of each shaft are supported rotatable. A slide block 56 is fitted onto the ball splined shaft 52 to support the center arm 50. This slide block 56 fitted onto the ball splined shaft 52, however, can be held not rotatable in relation to the shaft 52. The slide block 56 includes a support arm 58 by which the center arm 50 is supported in the cantilever manner. It can slide on the ball splined shaft 52 and its slide is made possible by a timing belt 62 to which the drive force of a first stepping motor 60, which serves as first drive source, is transmitted.
As shown in FIG. 7, a part of the timing belt 62 is sandwiched between tops of fixing blocks 64, which are made integral to the slide block 56, and the bottom of the support arm 58, which is located above the fixing blocks 64. The timing belt 62 is thus made integral to the center arm 50. As a result, the rotating force of the stepping motor 60 is transmitted to the slide block 56 through the timing belt 62 and when the slide block 56 is driven in this manner, the center arm 50 can be moved forward or backward.
As shown in FIG. 6, another slide block 68 which supports the other four arms 42, 44, 46 and 48 through a support arm 70 is fitted onto the other ball splined shaft 54. It is held there not rotatable also in this case relative to the ball splined shaft 54. However, it can slide on the ball splined shaft 54 and its slide can be attained by a timing belt 74 to which the drive force of a second stepping motor 72, which serves as second drive source, is transmitted.
As shown in FIG. 8, a part of the timing belt 74 is sandwiched between tops of fixing blocks 76, which are made integral to the slide block 68, and the bottom of the support arm 70, which is positioned above the fixing blocks 76. The timing belt 74 can be thus made integral to the arms 42, 44, 46 and 48. As a result, the rotating force of the stepping motor 72 can be transmitted to the slide block 68 through the timing belt 74 and when the slide block 68 is driven in this manner, the arms 42, 44, 46 and 48 can be moved forward or backward.
Referring to FIG. 10, it will be described how forward and backward movements of the carrier arms are controlled.
A control section 80 houses a microcomputer and power sources in it. First and second switches 82 and 84 and various kinds of sensor 86 are connected to the input side of its microcomputer, while first and second drive sources 60 and 72 and a pitch changing drive source 106 to the output side thereof.
The first (or single-sheet-feeding) switch 82 is connected to the first stepping motor 60 via an I/O interface (not shown). The second (or plural-sheet-feeding) switch 84 is connected to the first and second stepping motors 60 and 72 via an I/O interface (not shown). Selection is manually made about which of the first and second switches 82 and 84 to be turned on and off. In addition, they can be set to automatically turn on and off according to a sequence program, that is, they can be automatically turned on and off, responsive to those positions and number of wafers in the cassette which have been detected by a counter (not shown) when these wafers are to be transferred between the cassette and the boat. In short, the control section 80 can select either of the first and second switches 82 and 84, responsive to detection signals applied from the sensors 86 or according to a predetermined recipe.
when only a sheet of wafer W is to be carried by the plate-like object carrier device 40, as shown in FIG. 9, the first switch 82 is turned on to drive only the center arm 50 forward and backward. When five sheets of wafers W are to be carried together, the second switch 84 is turned on to drive the center arm 50 and the other ones 42, 44, 46, 48 forward and backward at the same time.
The plate-like object carrier device according to another embodiment of the present invention and provided with a pitch changing mechanism 90 will be described referring to FIGS. 11 through 15.
The pitch changing mechanism 90 is housed in a box 92 attached to the support arm 70, and it has a pair of screws 94 and 96 each of which is supported, rotatable, at its both ends between the support arm 70 and the ceiling of the box 92. A forward screw thread is formed on the lower half of each of the screws 94 and 96, while a backward screw thread on the upper half of each of them. These forward and backward screw threads are formed at a same pitch.
As shown in FIG. 11, a pair of ball nuts 98 and 100 are screwed onto each of the screws 94 and 96. These ball nuts 98 and 100 are moved, departing from each other, in reverse directions as the screws 94 and 96 are rotated. While leaving the center arm 50 as it is, therefore, the arms 42, 44, 46 and 48 are moved along the axis Z to thereby change the pitch interval between them.
Sleeves 102 are fixed to the ball nuts 98 and 100 attached to the screw 94. Plates 44A and 46A to which the arms 44 and 46 are attached are attached to the sleeves 102. Similarly, sleeves 104 are fixed to the ball nuts 98 and 100 which are screwed onto the other screw 96. Plates 42A and 48A to which the arms 42 and 48 are attached are supported by the sleeves 104.
As shown in FIG. 12A, those portions of the plates 42A and 44A which are opposed to their arm-attached portions are bent, as basic portions, at right angle and this bent basic portion of the plate 42A overlaps that of the plate 44A when they are attached to the sleeves 102 and 104 by screws. Same thing can be said about the plates 46A and 48A. When basic portions of the arm-attached plates 44A and 46A are attached to the sleeves 102, those portions of the sleeves 104 to which basic portions of the plates 42A and 48A will be next attached are exposed or left free, as shown in FIG. 12B, and this makes it possible to freely attach and detach the plates 42A and 48A to and from the sleeves 104. In addition, basic portions of the arm-attached plates 42A, 44A, 46A and 48A are bent so that the interval between the adjacent two of arms 42 to 48 can be made small.
As shown in FIGS. 13A and 13B, large and small pulleys 94A and 96A are attached to bottom ends of the screws 94 and 96. A timing belt 110 is stretched, extending round the two pulleys 94A, 96A and the drive shaft of a stepping motor 106. The diameter of the large pulley 94A is two times that of the small one 96A. The pitch changing mechanism 90 is under such a state as shown in FIG. 13A before the pitch interval is changed and it is under such a state as shown in FIG. 13B after the pitch interval is changed. The adjacent two of the arms 42 to 48 (or plates 42A to 48A) can be kept same in pitch interval in these cases. The sleeves 102 and 104 are guided along guide shafts 120.
As shown in FIGS. 14A and 14B, the guide shafts 120 are of the ball splined type and they are fitted into the ball nuts 98 and 100 in the sleeves 102 and 104. When this ball splined mechanism is employed, play between component parts can be kept smaller and the arms 42 to 48 can be positioned with a higher accuracy.
When the adjacent two of the arms 42 to 48 are to be separated from each other to enlarge the pitch interval in this example, it is a must that they are placed one above the other. The screws 94 and 96, therefore, must stop their rotation at the time when the arms 42 to 48 come to their positions at which they are placed one above the other.
When it is assumed in this example that the minimum pitch interval between the adjacent two of semiconductor wafers which are to be transferred onto the carrier arms be set 4.8 mm and that the pitch interval between the adjacent two of arm-attached plates be set 4.6 mm, considering the strength of each carrier arm and its processing error relative to the size of each semiconductor wafer W transferred, therefore, up and down movements of arms are stopped in a limit range of 0.2 mm which is the difference between the pitch intervals 4.8 mm and 4.6 mm. As the result, the arm-attached plates can be placed one above the other. Therefore, the stepping motor 106 is stopped at the time when the distance of a single arm-attached plate moved is detected to be same as the above-mentioned difference of 0.2 mm.
However, it is practically difficult to detect the distance of 0.2 mm by which the arm-attached plate is moved. It is arranged, therefore, in this example that the distance of arm-attached plates 42A and 48A moved, which is larger than that of arm-attached plates 44A and 46A moved, is detected. As shown in FIG. 15, an optical sensor S1 is attached to one sleeve 104 while a light shielding member 112 to the other sleeve 104. The distance of sleeves 104 moved as the screw 96 rotates becomes two times that of sleeves 102 moved. In short, it becomes equal to {0.2×2×2} mm. This stroke (0.8 mm) is employed as a range to be detected by the optical sensor S1. This makes it easier to detect the distance as compared with the case where the smaller stroke is detected. To add more, symbol S2 in FIG. 15 represents an origin sensor and symbol S3 an end limit sensor.
When wafers W are to be transferred between the boat 30 and the cassette 34, the carrier arms are positioned in the vertical direction of the device 40, taking the position of the center arm 50 as the reference, whichever switch 82 or 84 is turned on.
When the first switch 82 is turned on, the center arm 50 is driven forward and backward. In short, pulse signals are applied to the first stepping motor 60 to rotate it. Prior to this, however, it is detected by an optical sensor or encoder (which is one of the various sensors represented by 86 in FIG. 10) whether or not the slide block 56 which serves to move the center arm 50 and which is made integral to the timing belt 62 is placed at its start position. Only when it is at its start position, the number of rotation pulses which corresponds to the distance of the center arm 50 moved forward is applied to the first stepping motor 60. The direction and number of the stepping motor 60 rotated are thus set to move the center arm 50 forward and backward.
When the second switch 84 is turned on, the second stepping motor 72 as well as the first one 60 is driven. Before they are rotated, however, it is detected also in this case whether or not the slide block 56 for the center arm 50 and the other slide block 68 which serves to move the carrier arms 42, 44, 46 and 48 forward and which is made integral to the timing belt 74 are placed at their start positions.
When it is detected that all of the arms 42 to 50 are placed at their start positions, the control section 80 applies on- and off-signals to the first and second stepping motors 60 and 72. The arms 42, 44, 46 and 48 as well as the center one 50 are thus driven forward and backward by the timing belts 62 and 74.
When the arms 42 to 50 are moved forward and backward particularly to carry plural wafers together, the pitch interval between the adjacent two of them is changed corresponding to the pitch interval between the adjacent two of the wafers carried. In short, the arms 42, 44, 46 and 48 can be moved relative to their corresponding one, taking the position of the plate 50A for the center arm 50, which is placed in the center of them, as their reference. In addition, the pitch interval between the arms 44 and 46 can be made equal to that between the arms 42 and 48 due to the rate of rotation numbers between the screws 94 and 96.
The above-described device can be made lower in height and more compact in structure because the screws 94 and 96 in it can be made short. Further, no drive section is present under the slide blocks and this space can be therefore used as a wiring section for the drive sources of the pitch changing mechanism. This is because the slide guide section employs the above-mentioned ball splines. The slide guide section is usually constructed in such a way that linear guides 132 each having a length needed to guide a slide block 130 are located beside the slide blocks 130, as shown in FIG. 2. In this case, however, the first and second drive sources cannot be located beside the slide blocks 130, and each of the drive shafts of the stepping motors must be placed along by the vertical axis of the device. Pulleys 134 to which the timing belt are attached are thus forced to come under the slide blocks 130. This makes it difficult to locate the wiring section under the slide blocks 130. When the space under the slide blocks 56 and 68 is left free for wiring, as shown in FIG. 6, the space under the slide blocks 130 can be prevented from becoming complicated as shown in FIG. 2.
According to the above-described device, each of the drive shafts of the stepping motors 60 and 72 is placed along by the horizontal axis of the device. Therefore, the timing belts can also be placed along by the horizontal axis thereof. When they are placed in this manner, slits of the box through the support arms are projected outside the box can be closed by them. Dust and particles caused by the drive sources in the box can be thus prevented from flowing to the wafer transferring section through the slits of the box.
It may be arranged that the rotation number of one screw is made equal to that of the other one to make different the distance of their one sleeve moved from that of their other sleeve moved.
The above-described plate-like object carrier device according to the present invention can be applied to each process in the semiconductor and liquid crystal manufacturing apparatuses as well as those in the heat process apparatus. It can be applied to the CVD, plasma processing and cassette and boat stocking apparatuses as well.
According to the present invention as described above, the plate-like object carrier device can be prevented from becoming large in size. Further, the number of component parts used can be made smaller and the manufacturing cost can be thus made lower. In addition, the teaching procedure due to carry plate-like objects can be made easier.
According to the present invention, the pitch interval between the adjacent two of the carrier arms can be changed, taking the position of that one, which is located in the center of them when uneven sheets of the arms are used, as their reference. This pitch changing process can be thus made easier while moving those carrier arms, which correspond to each other, over a same distance.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A plate-like object carrier device comprising plural arms arranged at a same pitch interval to horizontally support a wafer on each of the arms, a first motor for driving a single arm forward and backward and independently of a group of arms, a second motor for driving the group of arms forward and backward at the same time except the single arm, a power supply for supplying power to the first and second motors, and a controller for selecting whether to supply power only to the first motor or both of the first and second motors. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a division of U.S. patent application Ser. No. 10/774,301, filed Feb. 6, 2004, pending, which is a continuation of U.S. Pat. No. 6,691,032, issued Feb. 10, 2004, the priority filing dates of which are claimed and the disclosures of which are incorporated by reference.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as appearing in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD
[0003] The present invention relates in general to user navigational events and, in particular, to a method for executing user navigational events triggered through geolocational data describing zones of influence.
BACKGROUND
[0004] The Global Positioning System (GPS) is a satellite navigation system consisting of 24 satellites that orbit the Earth every 12 hours. GPS signals received from the satellites are processed by GPS receivers to determine location in latitude and longitude. Nonmilitary GPS receivers are capable of determining a location with a six-meter range of accuracy.
[0005] GPS receivers are passive devices that provide relative locational data only. The locational data must be combined with maps, charts and other navigational aids to bring meaning to the latitude and longitude coordinates. Thus, GPS navigation information is most useful when used in combination with preferably automated and wireless technologies.
[0006] Accordingly, many portable and wireless computational devices, such as cellular telephones, personal data assistants, pagers and wireless electronic mail (email) clients incorporate GPS receivers, to enhance and complement the locational information provided. For instance, personal data assistants having integrated GPS receivers can provide navigational information through a portable database storing points of interest. Moreover, the processing capabilities of many of these portable devices support downloadable cartridges for utilizing the GPS receiver-provided information for customized applications.
[0007] One popular use of GPS information is a modified version of a treasure hunting game, known as geocaching. During a geocaching game, users equipped with a GPS receiver navigate from point to point using latitude and longitude values obtained by correctly solving clues received throughout the hunt. Players proceed from a starting point until the cache, that is, treasure, is found. Variations of geocaching include incorporating wireless computing technology to enable interactions directly between competing players and managed gameplay, where each player is tracked and the clues are customized based on individual progress. Other uses of GPS information are known in the art.
[0008] U.S. Pat. No. 6,320,495 discloses a treasure hunting game utilizing GPS-equipped wireless computing devices. Players are given clues or directions to proceed along one of several predetermined treasure hunting routes based on their location, as determined by a GPS receiver. Each player's position, along with the treasure hunt route, is calculated by the GPS receiver and transmitted to a software program by a wireless computing device. The first player to arrive at the treasure wins the game. However, the clues or messages provided to each player must be first determined by a centralized software program and are not dynamically triggered based on user-definable conditions.
[0009] U.S. Pat. No. 5,923,100 discloses an automobile navigation system utilizing GPS geolocational data. The vehicle location and travel time are transmitted to a central database via a wireless computing device and used to plan travel times and determine optimal travel routes. As necessary, the route is revised to adjust for deviations in travel direction and time. However, user-definable events cannot be programmed into the route planning process.
[0010] Prior art non-GPS based informational systems include infrared portable narrators. These devices store a recorded script associated with points of interest within an attraction, such as an art museum or zoo. The narrators receive infrared input signals from static display positions along the route, which trigger the playback of the narration associated with the display. However, these devices are passive and user-definable events cannot be programmed into the recorded script.
[0011] Prior art non-GPS based informational systems also include wireless messaging systems, such as the Cooltown technology disclosed in http://www.internex.org/hp_world_news/hpw203/03newshtml, the disclosure of which is incorporated by reference. Mid-air messages are provided by combining GPS technology with infrared or Bluetooth-capable wireless devices. An information broadcast is triggered whenever a user enters a geographically described location. However, the Cooltown technology operates only within discrete areas and user-definable events cannot be programmed into the mid-air messaging system.
[0012] Therefore, there is a need for an approach to generating user-definable events triggered through geolocational data describing zones of influence, as well as temporal and independent conditions.
[0013] There is a further need for a framework for building user-definable events triggerable through geolocational data describing zones of influence as well as temporal and independent conditions.
[0014] There is a further need for an approach to defining locational, temporal and independent event triggers used in a combination of GPS and wireless computational technologies.
SUMMARY
[0015] The present invention provides a system and method for producing and processing zones of influence described through locational, temporal and independent conditions. Preferably, the user is equipped with a wireless computing device having a GPS receiver and timer. A plurality of zones of influence is defined through geolocational data, preferably expressed in latitude and longitude. User-definable events are associated with the zones of influence. The events are triggered as a user transitions between, within and around the zones of influence. Timed events relative to an initial starting time and independent events can also be defined. The timed and independent events are triggered as the time limits expire and independent conditions are met.
[0016] An embodiment provides a method for executing user events on a mobile user device. Data in a cartridge script loaded into a memory of a mobile user device is accessed. The data includes one or more zones of influence, which each describe a plurality of points of static geolocational data, and one or more user events, which are each associated with at least one zone of influence. A scenario is executed by triggering the user events stored on the cartridge script through movement of the mobile user device. A location is dynamically determined in response to the movement by continuous self-identification. A positional overlap between the location and the static geolocational data for one or more of the zones of influence is determined. The user event associated with the zones of influence is locally triggered based on the positional overlap.
[0017] A further embodiment provides a method for executing user navigational events triggered through geolocational data describing zones of influence. Data is stored in a cartridge script loadable into a user device. One or more zones of influence is defined into the cartridge script by describing by a plurality of points of static geolocational data. One or more user navigational events is defined into the cartridge script and each user navigational event is associated with at least one zone of influence. A trigger condition is specified for each user navigational event based on the static geolocational data for the associated zone of influence. A scenario is executed by triggering the user navigational events stored on the cartridge script through movement of the user device. A location of the user device is continuously self-identified based on dynamic geolocational data determined in response to the movement. A correlation between the dynamic geolocational data and the static geolocational data for one or more of the zones of influence is determined. The user navigational event associated with the trigger condition of the zones of influence is locally triggered based on the correlation.
[0018] A further embodiment provides a method for executing zones of influences that describe geolocational data triggered through user navigational events. Data is stored in a cartridge script loadable into a user device. One or more user navigational events is defined into the cartridge script. One or more zones of influence is defined into the cartridge script by describing by a plurality of points of static geolocational data and each zone of influence is associated with at least one user navigational event. A trigger condition is specified for each zone of influence for the associated user navigational event. A scenario is executed by triggering the zones of influence stored on the cartridge script through user events. Event satisfaction of one or more of the user navigational events is determined. Each zone of influence associated with the user navigational events is locally triggered based on the event satisfaction.
[0019] Still other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein are described embodiments of the invention by way of illustrating the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various obvious respects, all without departing from the spirit and the scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1A is a block diagram showing a system for executing user-definable events triggered through geolocational data describing zones of influence, in accordance with the present invention.
[0021] FIG. 1B is a block diagram showing a further embodiment of the system of FIG. 1A .
[0022] FIGS. 2A and 2B are template drawings showing, by way of example, arbitrary two-dimensional vector-based zones of influence.
[0023] FIGS. 3A and 3B are template drawings showing, by way of example, arbitrary two-dimensional point-radius zones of influence.
[0024] FIG. 4 is a template drawing showing, by way of example, an arbitrary three-dimensional vector-based zone of influence.
[0025] FIGS. 5A and 5B are template drawings showing, by way of example, arbitrary three-dimensional point-radius zones of influence.
[0026] FIG. 6 is a map diagram showing, by way of example, interrelated zones of influence.
[0027] FIG. 7 is a map diagram showing, by way of further example, interrelated zones of influence.
[0028] FIG. 8 is a block diagram showing the functional software components of a production system for use with the system of FIG. 1 .
[0029] FIG. 9 is a data structure diagram showing the cartridge template utilized by the toolkit of the system of FIG. 8 .
[0030] FIG. 10 is a flow diagram showing a method of executing user-definable events triggered through geolocational data describing zones of influence, in accordance with the present invention.
[0031] FIG. 11 is a flow diagram showing a routine for checking and updating user status and history for use in the method of FIG. 10 .
[0032] FIG. 12 is a flow diagram showing a routine for checking and verifying a location status for use in the method of FIG. 10 .
[0033] FIG. 13 is a flow diagram showing a routine for checking and verifying a cartridge status and history for use in the method of FIG. 10 .
[0034] FIG. 14 is a flow diagram showing a routine for checking queue conditions for use in the method of FIG. 10 .
[0035] FIG. 15 is a flow diagram showing a routine for executing queued actions for use in the method of FIG. 10 .
[0036] FIG. 16 is a flow diagram showing a routine for performing a timed event for use in the routine of FIG. 14 .
[0037] FIG. 17 is a flow diagram showing a routine for performing a queue action and update for use in the routines of FIGS. 14, 16 , 18 and 19 .
[0038] FIG. 18 is a flow diagram showing a routine for performing a user-initiated event for use in the routines of FIG. 14 .
[0039] FIG. 19 is a flow diagram showing a routine for performing a proximity event for use in the routine of FIG. 14 .
[0040] FIG. 20 is a flow diagram showing a routine for defining global cartridge settings for use in the method of FIG. 10 .
[0041] FIG. 21 is a flow diagram showing a routine for defining zones of influence for use in the routine of FIG. 20 .
[0042] FIG. 22 is a flow diagram showing a routine for defining items for use in the routine of FIG. 20 .
[0043] FIG. 23 is a flow diagram showing a routine for defining events for use in the routine of FIG. 20 .
[0044] FIG. 24 is a flow diagram showing a routine for defining non-player characters for use in the routine of FIG. 20 .
[0045] FIG. 25 is a flow diagram showing a routine for defining cartridge initialization settings for use in the routine of FIG. 20 .
[0046] FIG. 26 is a flow diagram showing a routine for defining zone information for use in the routine of FIG. 21 .
DETAILED DESCRIPTION
Glossary
[0000]
Cartridge: A cartridge is a collection of zones, items, events, and non-player characters, which create a user experience in the physical world using geolocational data.
Item: An item is a virtual or physical object that can be manipulated through cartridge events, player characters, or non-player characters.
Player A player character is a human player who interacts with
Character: the physical or virtual world independent of the system programming.
Non-Player A non-player character is a computer-generated entity
Character: with whom the player character can interact. Interaction occurs programmatically through query and response behaviors.
Events: Events are triggers which occur programmatically within a cartridge. There are four types of events:
(1) Recurring Events: Time-based events which reoccur at certain intervals, for example, a timer that announces the score every 15 minutes or a random movement of an non-player character. (2) Triggered Events: Time-based events which occur after a certain amount of time has passed, for example, a clock that chimes every hour and half-hour. Alternatively, events which occur at an exact time, for example, at 4:00 pm, a door opens, then closes again at 4:15 pm. (3) Conditional Triggered Events: Time-based events which occur when certain conditions exist at certain time intervals or exact times, for example, if a zone has been entered and the player character has x item, the door will open at 4:00 pm. (4) Non-Timed Events: Non-time-based-events which occur based on locational or independent conditions. Locational conditions are met when a player character enters, exits or is proximate to a zone of influence, player character, note player character, or object. An independent condition is met when a user-initiated, player character, or non-player character, action occurs.
[0058] The foregoing terms are used throughout this document and, unless indicated otherwise, are assigned the meanings presented above.
[0059] FIG. 1A is a block diagram showing a system 10 for executing user-definable events triggered through geolocational data describing zones of influence, in accordance with the present invention. The system 10 operates in accordance with a sequence of process steps, as further described below with reference to FIG. 10 .
[0060] A constellation of global positioning system (GPS) satellites 11 provides geolocational data to a wireless computing device (WCD) 12 . GPS satellites 11 transmit geolocational data, including latitude, longitude, altitude, and precision. The wireless computing device 12 , incorporating a GPS receiver, receives GPS signals from the GPS satellites 11 and processes the GPS signals to determine the location of the wireless computing device 12 . In addition, the wireless computing device 12 executes a cartridge (CRT) 13 to trigger user-definable events when the location of the wireless computing device correlates to geolocational data describing one or more zones of influence, as further described below beginning with reference to FIGS. 2A and 2B .
[0061] Although a wireless computing device 12 is shown, other forms and arrangements of devices could be used. At a minimum, the device must be capable of executing a cartridge 13 , of determining a location from geolocational data, minimally consisting of latitude and longitude, and of providing some form of output responsive to a triggered event. Processing devices capable of executing a cartridge 13 include a personal or laptop computer, either a wireless or standard personal data assistant, a programmable cellular telephone, a programmable pager, a wireless email client, a two-way radio, and a dedicated processing device. Locational devices capable of determining a location from geolocational data include a standalone GPS receiver attached via a conventional cable, OPS receiver components incorporated into a processing device, such as a wireless personal data assistance with internal GPS receiver, and receiver for receiving signals from a stationary GPS beacon, as described below with reference to FIG. 1B . Output devices include any of the processing devices, as well as augmented reality devices working in conjunction with or as an alternative to the processing devices to provide an output platform for presenting triggered events. Augmented reality devices include “Heads Up” Displays (HUDs), virtual reality eyewear, gloves, earphones and goggles, and any other form of display device, as is known in the art. Accordingly, the term wireless compiling device 12 will apply broadly to any arrangement, configuration or combination of processing, locational and output devices having the aforementioned capabilities and which could be used interchangeably herein, as would be recognized by one skilled in the art.
[0062] The wireless computing device 12 downloads the cartridge 13 from a centralized server 14 via an internetwork 16 , such as the Internet, or similar means for interconnecting computational devices. The centralized server 14 includes a Web server 17 and database manager 18 . The Web server 17 serves Web content to the wireless computing device 12 to facilitate the retrieval of the cartridge 13 from a cartridges database 15 coupled to the centralized server 14 . The centralized server 14 also includes a database manager 18 that accesses the cartridges database 15 to retrieve the requested cartridge 13 . A client 18 interconnected to the centralized server 14 via the internetwork 16 executes a Web browser 19 to display Web content received from the centralized server 14 . The client 18 can be used to organize the cartridges database 15 and to build new cartridges for use in a wireless computing device 12 , as further described below with reference to FIG. 8 .
[0063] A sequence of events is stored in the cartridge 13 . Events can be logically linked to one or more zones of influence, which logically define an enclosed space through which the user progresses, or can be defined as global or “world” event, independent of any zone of influence. The events are triggered based on locational, temporal, and independent conditions. In the described embodiment, a plurality of zones of influence are described using geolocational data to define a logically enclosed space. Each non-time-based and nor-global event is triggered as the wireless computing device 12 progresses through the associated zones of influence. The operator of the wireless computing device 12 , referred as a player character, receives a dialog in the form of an interactive, story like experience throughout the event sequence via the wireless computing device 12 . In a further embodiment, the player character competes against other player characters also having wireless computing devices 20 . Additionally, the actions of other non-player characters having wireless computing devices 21 can also factor into the progress of the event sequence.
[0064] Optionally, the wireless computing device 12 can also download information from a points of interest database 22 from the centralized server 14 . The points of interest database 22 includes general and specialized information, which can be retrieved via the wireless computing device 12 in an interactive session. The points of interest information includes thematic data, such as bird watching sites, sushi restaurants and sponsor locations. The wireless computing device 12 can determine and provide directions to individual points of interest through server-provided geolocational data.
[0065] The individual computer systems, including server 14 and client 18 , include general purpose, programmed digital computing devices consisting of a central processing unit (CPU), random access memory (RAM), nonvolatile secondary storage, such as a hard drive or CD ROM drive, network or wireless interfaces, and peripheral devices, including user interfacing means, such as a keyboard and display. Program code, including software programs, and data is loaded into the RAM for execution and processing by the CPU and results are generated for display, output, transmittal, or storage.
[0066] FIG. 1B is a block diagram showing a further embodiment 23 of the system 10 of FIG. 1A . Ordinarily, GPS signals can only be received out-of-doors by a GPS-capable receiver. In the further embodiment 23 , stationary GPS beacons transmit static geolocational and informational data on a substantially continuous basis to provide conventional GPS signals indoors and in areas without GPS coverage. The geolocational data identifies the locations of stationary and non-stationary objects. Each beacon includes a short-range transmitter capable of providing GPS-equivalent signals whenever a GPS receiver cannot receive regular GPS signals and is proximate to the beacon.
[0067] For instance, a vehicle 24 equipped with a GPS receiver will ordinarily only receive GPS signals from the constellation of GPS satellites 11 . However, GPS short-range beacons can be located in a building 25 , at a landmark 26 , on a marine buoy 27 , and on a traffic signal 28 , for example, and in other stationary or non-stationary objects to provide static geolocational data, each short-range beacon continually transmits geolocational data. In addition, the short-range beacons can transmit informational messages, which can be used in conjunction with an event sequence.
[0068] In the described embodiment, each short-range beacon 25 - 28 operates as a low-powered radio frequency transmitter, such as provided in accordance with IEEE 802.11b, “Bluetooth” or similar wireless protocols. The short-range beacons can be portable or mounted on a stationary object and transmit standard GPS geolocational data, including latitude, longitude, altitude, date and time, identification, and, optionally, executable program code. Other arrangements of GPS and short-range transmission components are feasible, as would be recognized by one skilled in the art.
[0069] Alternatively, each short-range beacon 25 - 28 transmits nonstandard GPS geolocational data, in accordance with a wireless protocol, such as the Short Message Service (SMS). A pseudo-GPS receiver is provided communicatively interposed between the GPS receiver circuitry and the general purpose processor. The pseudo-GPS receiver translates packets received from the short-range beacon in a non-GPS compatible format and extracts and forwards the GPS signals received from the beacon. Pseudo-GPS receivers allow backward compatibility with devices limited to receiving GPS signals only.
[0070] FIGS. 2A and 2B are template drawings showing, by way of example, arbitrary two-dimensional vector-based zones of influence. Vector-based zones of influence are definable by specifying a starting point, vector angle, and distance. Referring first to FIG. 2A , a square zone of influence 30 is logically defined by a set of four straight line vectors. Referring next to FIG. 2B , a zone of influence 31 roughly shaped as the letter ‘E’ is logically defined by a set of twelve straight line vectors. Other analogous forms of defining vector-based zones of influence, such as through polar or Cartesian coordinates, are possible, as would be recognized by one skilled in the art.
[0071] FIGS. 3A and 3B are template drawings showing, by way of example, arbitrary two-dimensional point-radius zones of influence. Point-radius zones of influence are definable by specifying one or more centers or foci and associated radii. Referring first to FIG. 3A , a circular zone of influence 32 is formed by specifying a radius projected from a center. Referring next to FIG. 3B , an elliptical zone of influence 33 is formed specifying major and minor axes projected from a center. Alternatively, the elliptical zone of influence 33 could be specified by a pair of foci (not shown). Other forms of point-radius zones of influence are possible, as would be recognized by one skilled in the art.
[0072] FIG. 4 is a template drawing showing, by way of example, an arbitrary three-dimensional vector-based zones of influence. Three-dimensional vector-based zones of influence are definable by specifying a starting point, vector angle, distance, and height. A cubical zone of influence 34 is defined by a set of 12 individual vectors formed into a cube. Other forms of three-dimensional vector-based zones of influence are possible, as would be recognized by one skilled in the art.
[0073] FIGS. 5A and 5B are template drawings showing, by way of example, arbitrary three-dimensional point-radius zones of influence. Three-dimensional point-radius zones of influence are definable by specifying one or more foci and associated radii and a height. Referring first to FIG. 5A , a cylindrical zone of influence 35 is defined by a two-dimensional circular zone of influence specified with a height. Referring next to FIG. 5B , an elliptical cylindrical zone of influence 36 is defined by an elliptical zone of influence projected with a given height. Other forms of three-dimensional radius zones of influence are possible, as would be recognized by one skilled in the art.
[0074] FIG. 6 is a map diagram 60 showing, by way of example, interrelated zones of influence 61 - 64 . Each of the zones of influence 61 - 64 is a user-definable vector storing geolocational data, which describe a logically enclosed space. The geolocational data specifies latitude, longitude, altitude, time, date, identification, security code, signal strength, and similar relevant data, as would be recognized by one skilled in the art.
[0075] A zone of influence 61 - 64 can have any shape and size limited, however, by the maximum accuracy of GPS technology. In the described embodiment, an accuracy of six meters is utilized. Individual zones of influence 61 - 64 can be discrete from each other, overlapping, nested, layered, or adjoining.
[0076] As well, any zone of influence can inherit attributes and events from other zones of influence to allow consistency across individual zones of influence. For example, a count-down tinier for an activity involving solving a puzzle could be an inherited attribute. Inheritance is available between any zone of influence and does not require a priori relationships, such as parent-child associates. Zones of influence can inherit attributes and events from another zone even when those attributes and events were also inherited. A zone of influence can inherit discrete attributes and events by specifying the identifiers for another zone of influence. Alternatively, a zone of influence can inherit attributes and events from all zones of influence if no identifiers are specified.
[0077] Unlike a grid describing geographic location, the zones of influence 61 - 64 are flexibly defined to accommodate random event sequences, such as might be formed by a story plotline or gameplay, as with geocaching. In contrast, geographically-based grids are strictly adjoining and cannot resolve into arbitrarily defined enclosed spaces or be arranged in overlapping or nested configurations.
[0078] The purpose of a zone of influence 61 - 64 is to logically define an enclosed space used to trigger user-definable events stored in a cartridge 13 on a wireless computing device 12 (shown in FIG. 1 ). A series of zones of influence 61 - 64 can be formed together to create a story, dialog, game, or other type of conversation, as expressed though the triggered user-definable events.
[0079] Each event can be triggered through locational, temporal or independent conditions. Locational conditions are met when the wireless computing device 12 enters, exits or is proximate to a zone of influence, player character, non-player character, or object. A temporal condition is met when a timer expires relative to a global, zone, non-player character, user, or object condition. An independent condition is met when a user-initiated, player character, or non-player character action occurs. User-initiated actions occur with reference to the world at large, zone of influence, user, player character, non-player character, or object.
[0080] By way of example, a player character enters a first zone of influence 61 (step 1 ). Upon entering the first zone of influence 61 , a user-definable event is triggered to play the sound of a low, muffled growl accompanied by the display on the wireless computing device 12 of the text message, “You can hear growling sounds emanating from the southwest.” The player character then enters a second zone of influence 62 (step 2 ). While within the second zone of influence 62 , growling sounds continue to play on the wireless computing device 12 and an image of a doorway is flashed to indicate to the player character that a door is nearby. Upon approaching the door, the player character enters a third zone of influence 63 (step 3 ). A new sound of louder (and more vicious) growling noises is played and a video segment showing scratches appearing on a door is displayed. Next, the player character enters a fourth zone of influence 64 (step 4 ). The wireless computing device 12 prompts the player character with the query, “Do you wish to open the door?” Upon nearing the door, a further event is triggered, causing a telephone 69 to ring and playback a prerecorded message begging the player character to not open the door. Upon exiting the fourth zone of influence 64 , the player character remains within the enclosing third zone of influence 70 (step 5 ). Depending upon the actions previously taken by the player character, sounds of a fading growl may be played on the wireless computing device 12 , accompanied by text explaining that the growling sound is fading away. However, if the door was opened, the player character will have a predetermined time during which to exit the area before a wild animal “eats” the player character. Finally, the player character exits the outermost and first zone of influence 71 (step 6 ). If the door was opened and the player character escaped within the time allotted, points are awarded. Otherwise, the player character receives no credit for completing the previous sequence.
[0081] FIG. 7 is a map diagram 80 showing, by way of further example, interrelated zones of influence 81 - 88 . As before, each of the zones of influence 81 - 88 is described by geolocational data to form a logically enclosed space. In combination with events stored in the cartridge 13 (shown in FIG. 1 ), the zones of influence 81 - 88 associate individual event sequences joined by a common theme, such as playing a game of golf.
[0082] The zones of influence 81 - 88 include the golf course zone 81 , base zone 82 , cart track zone 83 , tee zone 84 , fairway zone 85 , sand trap zone 86 , green zone 87 , and cup zone 88 . The golf course zone 81 provides the general environment in which the event sequence operates. The base zone 86 contains multiple zones, which each inherit properties from the base zone 82 . By way of example, the base zone 82 is the 18 th Hole in the golf course zone 81 . The cart track zone 83 forms a zone of influence separate from the base zone 82 . The cart track zone 83 could be used to track the flow of traffic through a golf course by creating an event whenever a specific golf cart enters the cart track zone 83 . The event would notify the clubhouse of movement. The tee zone 84 creates an event, “in play,” which notifies the clubhouse that a user is teeing off from the 18 th Hole. The event also queries the tee zone 84 to see if any other player is in play. If so, the event generates an alert indicating that another player is on the hole and instructing the player to wait until the other player has either moved out of range or completed the hole. The fairway zone 85 updates a location parameter to “on fairway” when the player enters the fairway. In addition, an event is created that presents options on golf clubs to use in relation to the pin and position of the golf ball. The sand trap zone 86 likewise generates an event presenting choices of golf clubs, such as a sand wedge, and further indicates the position of the golf ball from the pin.
[0083] Entering the green zone 87 triggers a plurality of events. First, a list of golf clubs, such as a choice of putter, can be displayed. As well, distance from the pin and a detailed map of the green can be provided to aid the player on putting. Note that some zone-aware items can trigger additional events, such as a golf ball tracking system that creates zone triggers. Finally, the cup zone 88 triggers a zone change when the golf ball enters the cup, which is queried to the user.
[0084] FIG. 8 is a block diagram showing the functional software components of a production system 90 for use with the system of FIG. 1 . Each component is a computer program, procedure or process written as source code in a conventional programming language, such as the C++ programming language, and is presented for execution by the CPU as object or byte code, as is known in the art. The various implementations of the source code and object and byte codes can be held on a computer-readable storage medium or embodied on a transmission medium in a carrier wave.
[0085] The production system 90 provides a means with which to build user-customizable cartridges 98 for use with wireless computing devices 12 (shown in FIG. 1 ). The cartridges 98 are generated by a production server 91 based on user instructions received from a client 93 . The production server 91 includes two components: a toolkit 94 and compiler 95 . The toolkit 94 is accessed via the client 93 through a standard Web browser 97 , such as the Internet Explorer or Netscape Navigator. The toolkit 94 accesses a production database 92 in which are stored cartridge templates 96 , preferably expressed in a page description language, such as the Extensible markup Language (XML), such as further described below with reference to FIG. 9 .
[0086] The toolkit 94 enables a user to define a series of events 99 that are triggered by temporal, locational and independent conditions and to define zones of influence (ZOIs) 100 described by geolocational data. Upon the completion of definition, the cartridge templates 96 are compiled by the compiler 95 into interpretable cartridges 98 for downloading and execution on a wireless computing device 12 (shown in FIG. 1 ). Although the production server 91 incorporates components XML through a standard Web browser 97 , neither the production server 91 , nor the took kit 94 and compiler 95 need be made available as Web-based applications and could be implemented as standard stand-alone or distributed applications and other variations, as would be recognized by one skilled in the art.
[0087] FIG. 9 is a data structure diagram showing the cartridge template 105 utilized by the toolkit of the system of FIG. 8 . In the described embodiment, the cartridge template 105 is written in XML, although another form of tag delineated page description language could be used, as would be recognized by one skilled in the art. The cartridge template 105 includes a plurality of tags to identify zones of influence (<zones>), objects (<objects>), and non-player characters (<npcs>). Each tag for a zone of influence can further define relationships through a related tag (<related>). In addition, the tag for each mobile device can define user-specified events (<events>). The events can be generic or device-dependent and include multimedia events, including sound, visual, tactile, olfactory, text, and multimedia effects, as well as other user-definable messages and communications, such as triggering a telephone call. By way of example, a source code listing for a cartridge implementing a generic golf course, such as described above with reference to FIG. 7 , written in the XML programming language is included in the Appendix. Other programming languages or procedural and data structuring could be employed, as would be recognized by one skilled in the art.
[0088] FIG. 10 is a flow diagram showing a method 110 of executing user-definable events triggered through geolocational data describing zones of influence, in accordance with the present invention.
[0089] The method 110 functions as a continuous control loop (blocks 114 - 119 ) executed on a wireless computing device 12 (shown in FIG. 1 ). During each iteration of the control loop, the status of various aspects of the wireless computing device 12 and cartridge 13 are examined and user-definable events are executed in an event-driven manner using a queue.
[0090] Preliminarily, a cartridge 13 is downloaded from the centralized server 14 (shown in FIG. 1A ) (block 111 ). Optionally, points of interest and other data is downloaded (block 112 ). Global cartridge settings are then defined (block 113 ). The user status and history are checked and updated (block 114 ), as further described below with reference to FIG. 11 . Next, the location status is checked and verified (block 115 ), as further described below with reference to FIG. 12 . The status of the cartridge 13 is checked and verified (block 116 ), as further described below with reference to FIG. 13 . Queue conditions are checked (block 117 ), as further described below with reference to FIG. 14 . Finally, any queued event actions are executed (block 118 ), as further described below with reference to FIG. 15 . The control loop (blocks 114 - 119 ) continues until all actions are done (block 119 ), after which the method terminates.
[0091] FIG. 11 is a flow diagram showing a routine 120 for checking and updating user status and history for use in the method of FIG. 14 . The purpose of this routine is to maintain historical user information regarding preferences, attributes and historical movements.
[0092] If the user data is new (block 121 ), the user data stored with the cartridge 13 of the wireless computing device 12 (shown in FIG. 1 ) is updated (block 122 ) to load default preferences, attributes and an initial position. Thereafter, the current user preferences and device settings (block 123 ), the current user attributes and state (block 124 ), and the historical movements (block 125 ) are looked tip. The user preferences include notifying the user upon entry into a zone of influence, enabling flash feedback, and showing text-only feedback instead of graphical feedback. The device settings control color, monochrome, sound, screen size, video capabilities, telephone capabilities, electronic mail, short messaging service (SMS), paging, and execution of client-side code, such as J2EE scripts. User state indicates whether the user is in motion, speed, score, game state, movement history (route data), last known position, direction of movement, attributes (healthy, sick, sad, happy, and so forth), inventory, spells, characters, and access to a telephone. Historical movements are tracked by location, speed, altitude, direction, and distance. Other types and combinations of user preferences, device, settings, and state are feasible, as would be recognized by one skilled in the art. The routine then returns.
[0093] FIG. 12 is a flow diagram showing a routine 130 for checking and verifying a location status for use in the method of FIG. 10 . The purpose of this routine is to provide a “reality” check on an updated user movement. Improbable user movements are rejected.
[0094] First, GPS signals are received by the wireless computing device 12 (block 131 ) and processed into geolocational data (block 132 ), preferably in terms of latitudinal and longitudinal values. The geolocational data is compared to the historical data (block 133 ) stored as historical movements in the user data. If the movement is possible (block 134 ), the user history, current time, location, bearing and distance are updated (block 135 ). Otherwise, no update is performed. In the described embodiment, a movement is possible if, based on the user data stored with the cartridge 13 in the wireless computing device 12 , the current location can be achieved in the time frame relative to the location, speed, altitude, direction and distance from the last update. The routine then returns.
[0095] FIG. 13 is a flow diagram showing a routine 140 for checking and verifying a cartridge status and history for use in the method of FIG. 10 . The purpose of this routine is to update the status of the cartridge 13 of the wireless computing device 12 (shown in FIG. 1 ).
[0096] If no cartridge is currently in progress (block 141 ), a new cartridge is loaded with a virtual world, objects and characters (block 142 ), after which the routine returns. Otherwise, if a cartridge is in progress (block 141 ), a world update is requested from the centralized server 14 (shown in FIG. 1 ) (block 143 ) and world conditions are updated within the in-progress cartridge 13 (block 144 ). Note the world conditions update could also be determined locally on cartridges in progress on a non-wireless computing device running a cartridge autonomously. The routine then returns.
[0097] Next, the status and locations of global users are requested from the centralized server 14 (block 145 ). The status and locations of objects are requested from the centralized server 14 (block 146 ). The status and locations of any non-player characters (NPCs) are requested from the centralized server 14 (block 147 ). Finally, the status and areas of coverage of the zones of influence 61 - 64 (shown in FIG. 6 ) are requested from the centralized server 14 (block 148 ). The status and location of the various users, objects, characters, and zones could be physical or virtual or a combination thereof. The routine then returns.
[0098] FIG. 14 is a flow diagram showing a routine 150 for checking queue conditions for use in the method of FIG. 10 . The purpose of this routine is to determine the condition of the queue based on a player action. The types of actions that affect queue conditions include timed events, zone of influence entries and exits, user-, player character- and non-player character-initiated actions, and proximity actions.
[0099] If the current action is a timed event (block 151 ), a timed event is processed (block 152 ), as further described below with reference to FIG. 16 . If the action is the entry into a zone of influence 61 - 64 (shown in FIG. 6 ) by the user (block 153 ), a queue action and update is performed (block 154 ), as further described below with reference to FIG. 17 . Similarly, if the user has exited the zone of influence 31 - 34 (block 155 ), a queue action and update is performed (block 156 ), as further described below with reference to FIG. 17 . If the action is a user-initiated action (block 157 ), a user-initiated event is performed (block 158 ), as further described below with reference to FIG. 18 . If the action is a player-character- or non-player-character-initiated action (block 159 ), a queue action and update is performed (block 160 ), as further described below with reference to FIG. 17 . Finally, if the action is a proximity action (block 161 ), a proximity event is performed (block 162 ), as further described below with reference to FIG. 19 . The routine then returns.
[0100] FIG. 15 is a flow diagram showing a routine 170 for executing queued actions for use in the method of FIG. 10 . The purpose of this routine is to retrieve and execute actions placed in the event queue of the cartridge 13 in the wireless computing device 12 (shown in FIG. 1 ).
[0101] First, the user interface is updated based on user preferences (block 171 ). Next, an event is removed from the queue (block 172 ). If the event is a client-side event (block 173 ), the client-side event is performed (block 174 ) on the wireless computing device 12 . Playing a media clip or sound is an example of a client-side event. Other types of client-side events are possible, as would be recognized by one skilled in the art. Otherwise, if the event is an external event (block 175 ), an event trigger is sent (block 176 ) to the external device, such as a telephone or similar instrument. Note the event trigger could also be sent to the centralized server for a team (shown in FIG. 1 ) to generate other triggers, such as unlocking a door. Finally, if the event queue is not empty (block 177 ), processing continues (block 172 - 176 ) until the queue is empty (block 177 ), after which the routine returns.
[0102] FIG. 16 is a flow diagram showing a routine 180 for performing a timed event for use in the routine of FIG. 13 . The purpose of this routine is to execute a timed event relative to an internal timer maintained by the cartridge 13 in the wireless computing device 12 (shown in FIG. 1 ).
[0103] First, if the timed event is a timed global condition (block 181 ), a queue action and update is performed (block 182 ), as further described below with reference to FIG. 16 . Similarly, if the event is a timed zone condition (block 183 ), timed non-player character condition (block 185 ), timed user condition (block 187 ), or timed object condition (block 189 ), a queue action update is likewise performed (blocks 184 , 186 , 188 , and 190 , respectively), as further described below with reference to FIG. 17 . The routine then returns.
[0104] FIG. 17 is a flow diagram for performing a queue action 205 and update for use in the routines of FIGS. 13, 14 , 15 , and 169 . The purpose of this routine is to place event actions into the queue of the cartridge 13 in the wireless computing device 12 (shown in FIG. 1 ).
[0105] First, the action is requested from the cartridge 13 (block 206 ) and prioritized (block 207 ). In the described embodiment, actions are sorted and enqueued to prioritize the actions. Next, any media is loaded (block 208 ), for instance, a sound file is retrieved to play a sound effect. Finally, the user status and history are checked and updated (block 209 ), as further described above with reference to FIG. 13 . The routine then returns.
[0106] FIG. 18 is a flow diagram showing a routine 210 for performing a user-initiated event for use in the routine of FIG. 14 . The purpose of this routine is to identify and enqueue a user-initiated event.
[0107] If the user-initiated event interacts with the world (block 211 ), a queue action and update is performed (block 212 ), as further described above with reference to FIG. 16 . Similarly, if the user-initiated event interacts with a zone of influence 61 - 64 (shown in FIG. 6 ) (block 213 ), with the user (block 215 ), with a player character or non-player character (block 217 ), or with an object, (block 219 ), a queue action and update is performed (blocks 214 , 216 , 218 , and 220 , respectively), as further described above with reference to FIG. 16 . The routine then returns.
[0108] FIG. 19 is a flow diagram showing a routine 230 for performing a proximity event for use in the routine of FIG. 14 . The purpose of this routine is to identify and execute a proximity event.
[0109] First, if the proximity event is relative to a zone of influence 31 - 34 (shown in FIG. 2 ) (block 231 ), a queue action and update is performed (block 232 ), as further described above with reference to FIG. 16 . Similarly, if the proximity event is relative to a player character or non-player character (block 233 ), or an object (block 235 ), a queue action and update is performed (blocks 234 and 236 , respectively), as further described above with reference to FIG. 16 . The routine then returns.
[0110] While the invention has been particularly shown and described as referenced to the embodiments thereof, those skilled in the art will understand that the foregoing and other changes in form and detail may be made therein without departing from the spirit and scope of the invention.
[0111] FIG. 20 is a flow diagram showing a routine 240 for defining global cartridge settings for use in the method of FIG. 8 . The purpose of this routine is to specify a collection of zones of influence, items, events, and non-character players, which collectively provide a user experience in the physical world using geolocational data.
[0112] First, zones of influence are defined (block 241 ), as further described below with reference to FIG. 21 . Items are defined (block 242 ), as further described below with reference to FIG. 22 . Events are defined (block 243 ), as further described below with reference to FIG. 23 . Non-player characters (NPCs) are defined (block 244 ), as further described below with reference to FIG. 24 . Cartridge initialization settings are defined (block 245 ), as further described below with reference to FIG. 25 . Finally, the cartridge 13 (shown in FIG. 1A ) is compiled (block 246 ) into program code interpretable by the wireless computing device 12 . The routine then returns.
[0113] FIG. 21 is a flow diagram showing the routine 250 for defining zones of influence for use in the routine of FIG. 20 . The purpose of this routine is to specify zone geolocational data and to associate events with zones.
[0114] First, the dimensions of each zone of influence are defined (block 251 ), as further described below with reference to FIG. 26 . The zone attributes are then defined (block 252 ). The attributes include initialization and state settings and relationships to other zones of influence. For instance, if the present zone of influence inherits from a parent zone, the attributes for the parent zone of influence are copied. Next, any events which occur conditionally with respect to the zone of influence are defined (block 253 ).
[0115] In addition, events defining interactions between zones of influence are defined (block 254 ). Interaction events carry over between successive zones of influence to provide a continuous storyline. Finally, the initialization settings for the zone of influence are defined (block 255 ), after which the routine returns.
[0116] FIG. 22 is a flow diagram showing the routine 260 for defining items of influence for use in the routine of FIG. 20 . The purpose of this routine is to specify virtual or physical objects, which can be manipulated through the various events associated with the zones of influence.
[0117] First, attributes for each item are defined (block 261 ). Item attributes include both logical and physical characteristics, such as color, size and description. The interaction between the items and events are then defined (block 262 ). Similarly, events which are conditioned on an item are defined (block 264 ). Finally, item initialization settings are defined (block 264 ), after which the routine returns.
[0118] FIG. 23 is a flow diagram showing the routine 270 for defining events for use in the routine of FIG. 20 . The purpose of this routine is to specify time-based triggers, which occur programmatically within a cartridge.
[0119] First, trigger attributes are defined (block 281 ). The trigger attributes include properties specific to the type of trigger defined, such as tinier values or exact times. Next, trigger conditions are defined (block 272 ), such as conditions which exist at certain time intervals or exact times. Similarly, timed and conditionally timed events are defined (block 273 ). Finally, event initialization's settings, such as for recurring events, are defined (block 274 ). The routine returns.
[0120] FIG. 24 is a flow diagram showing the routine 280 for defining non-player characters for use in the routine of FIG. 20 . The purpose of this routine is to create a fictional nor-participative character with whom a player character can interact through query and response behaviors.
[0121] First, the attributes of the non-player characters are defined (block 281 ). These attributes are similar to those defined for a player character with the addition of cartridge-specific characteristics. Interactions between the non-player characters and events are then defined (block 282 ). Similarly, events conditioned on the non-player characters are defined (block 283 ). Finally, non-player character initialization settings are defined (block 284 ), after which the routine returns.
[0122] FIG. 25 is a flow diagram showing the routine 290 for defining cartridge initialization settings for use in the routine of FIG. 20 . The purpose of this routine is to specify the initial values for the various characteristics for a cartridge storing a sequence of events for a set of zones of influence.
[0123] First, the base level attributes for the cartridge upon initialization are defined (block 291 ). The zones of influence, items, non-player characters, and global events present at initialization are defined (block 292 ). Lastly, the player character attributes at initialization for the current player are defined (block 293 ). The routine then returns.
[0124] FIG. 26 is a flow diagram showing the routine 300 for defining zone information for use in the routine of FIG. 21 . The purpose of this routine is to specify the geolocational data for a zone of influence.
[0125] First, a zone of influence type is defined (block 301 ). As described above with reference to FIGS. 2 A-B, 3 A-B, 4 , and 5 A-B, zones of influence can be two- or three-dimensional and be defined by vector or radius values, or combinations thereof. Next, vector data specifying the zone of influence dimensions are defined (block 302 ). Finally, the hierarchy for the zone, that is, level, is defined (block 303 ), if applicable. The routine then returns.
[0126] While the invention has been particularly shown and described as referenced to the embodiments thereof, those skilled in the art will understand that the foregoing and other changes in form and detail may be made therein without departing from the spirit and scope of the invention.
APPENDIX <cartridge version =“0.1b” company=“Groundspeak” name=“Generic Golf Course”> (...Define Global zone properties) <zones> <zone id=200 layer=“+3”> <name>Hole 18: Green (Radial Zone Example)</name> <description>You're on the Green!</description> <shape=“radial” dimension=2 measurement=“km”> .015</shape> <vectors datum= “WGS84”> <point id=1 lat=47.655 lon=−122.001 altitutde=300> </vectors> <on_enter> <trigger_event desc=“Entering Hole 18 Green”>64</trigger_event> <pc_set attribute=“position” recurring=true> Entered the Green</pc set> <set_score recurring=false>+20</set_score> </on_enter> <on_exit> <trigger_event desc=“Leaving Hole 18 Green”>123</trigger_event> <pc_set attribute= “position” recurring=true>Left the Green</pc_set> </on_exit> <proximity measurement=“m” distance=5 desc=“Close to the Green”> <trigger_event >222</trigger event> </proximity> </zone> <zone id=200 layer=“+3”> <name>Hole 18: Sand Trap (Vector Zone Example)</name> <description>You are in the sand trap. Good luck!</description> <shape=“vector” dimension=2 /> <vectors datum= “WGS84”> <point id=1 lat=47.XXX lon=−122.XXX/> <point id=2 lat=47.XXX lon=−122.XXX/> ... </point id=450 lat=47.XXX lon=−122.XXX/> </vectors> <on_enter> <trigger_event desc=“Entering Hole 18 Sand Trap”>164</trigger_event> <pc_set_attribute=“position” recurring=true>In the Sand Trap</pc_set> <set_score recurring=true>−5</set score> </on_enter> <on_exit> <trigger_event desc=“Leaving Hole 18 Green>123</trigger_event> <pc_set_attribute=“position” recurring=true>Outside Sand Trap</pc_set> </on_exit> <proximity measurement=“m” distance=5 desc=“Danger! Near Sand Trap”> <trigger_event>232</trigger event> </proximity> </zone> <items> <item id=12> <short_name>a Golf Ball<short_name> >long_name>a brand new golf ball</long_name> <description>It looks like your typical golf ball</description> <action_command=“crush”> <destroy_item id=12/> </action> </item> </items> <npcs> <npc id=32> <short_name>Charles the Caddy<short_name> <action command=“recommend”> ...trigger some action </action> <topics> <topic name=“Golf”> <topic /> </topic> <topics> </npc> </npcs> <events> <event id=64 type=“execute/recurringltime”> <conditions> </triggers> </conditions> <triggers> <set_attributes /> <play_media/> </triggers > </event> </events> <initialization> <create_zone id=200/> <create_item id=12 lat=47.675 lon=−122.123/> <create_npc id=32 lat=47.678 lon=−122.234/> <set_score>0</set_score> </initialization> </cartridge> | A method for executing user navigational events triggered through geolocational data describing zones of influence is provided. Data is stored in a cartridge script loadable into a user device. Zones of influence are defined by describing by points of static geolocational data. User navigational events are defined and each user event is associated with a zone of influence. A trigger condition is specified for each user event based on the static data for the associated zone of influence. A scenario is executed by triggering the user events stored on the cartridge script through movement of the user device. A location of the user device is continuously self-identified based on dynamic geolocational data determined in response to the movement. A correlation between the dynamic data and the static data for the zones of influence is determined. The user event associated with a trigger condition is locally triggered based on the correlation. | 6 |
RELATED APPLICATIONS
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FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
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APPENDICES
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FIELD
Related fields include wearable electronics, and more particularly the formation of temporary ad-hoc communication networks including wearable electronics.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a conceptual map of an example of an ad-hoc network.
FIG. 2 is a block diagram of an example of an ad-hoc network.
The main components are sensors (input transducers), indicators (output transducers), and an intelligent agent that may include hardware, software, or both in a processor or in a group of distributed processors. The intelligent agent analyzes the sensor inputs, classifies them according to urgency and need for outside data, decides which indicators need to respond to the sensor inputs and how the signals are to be routed.
“Sensors” is used here is a generic term for all the input transducers transmitting signals to one or more processors. Sensors include cameras and microphones as well as biometric and environmental sensors. On-body sensors 202 include wearables (clothing 212 and mounted directly to the body with adhesive 232 ), hand-held or carried in backpacks or pockets while operating (accessories 222 ). Off-body sensors 204 may include anything not worn or carried by a user while operating. Off-body sensors may include sensors mounted on a vehicle 214 , on equipment are tools not carried during operation 224 , or in some embodiments the sensors worn or carried by another user 234 .
In some embodiments, the incoming information from all the sensors is synchronized in step 242 and recorded to storage in step 244 . The recordings may be transmitted in real-time to a server, or they may be stored for later upload.
The incoming information for all the sensors also goes to the intelligent agent 252 , and may be synchronized or not depending on the embodiment. In the intelligent agent 252 , a signal recognition engine 254 compares the incoming signals with examples of predicted signals stored in an event/response database 258 . If a match is found, intelligent agent 252 infers that the corresponding event has happened. Some embodiments may cross-check numerous sensors to prevent “false alarm” inferences. To formulate a response to the inferred event, the intelligent agent may use data from teammate/contact database 256 , which may use the location and type of inferred event, sometimes along with the identity of the user originate in the sensor signals, to decide who needs to be notified of the inferred event; partners, supervisors, medics, etc.
A procedural template database 262 may be included as a reference for any strict, complex, or frequently changed procedures that users must follow even in a chaotic environment, such as clean forensic practices, chain-of-custody handling of evidence, or emergency first aid for specialized situations. Some embodiments of the intelligent agent 252 may make use of other internal databases 264 ; for example, if the users are SCUBA divers, there may be an internal database 264 to calculate how much longer each diver may stay submerged and what kind of decompression stop, if any, is needed. In some embodiments, the intelligent agent may dry information from external or remote databases 272 , such as facial and voice recognition databases and criminal record databases.
If the signal recognition engine 254 infers an event that needs an immediate response, the prescribed command from event/response database 258 is sent directly over the local ad-hoc network to the prescribed indicator. The indicators may be visual, such as LEDs or the screens of smart watches or heads-up displays; audible, from variable tones to recorded instructions (e.g., from procedural template database 262 ); or tactile, such as haptic transducers. Like the sensors, there may be a group of on-body indicators 206 on clothing 216 , accessories 226 , or attached to the body by adhesive 236 . There may also be a group of off-body indicators 208 mounted on or in a vehicle 218 , tools are equipment 228 , or someone else's body 238 . In some embodiments, the intelligent agent may use location sensors to determine whether any of the users are close enough to make use of an off-body indicator.
FIG. 3 is a flowchart of data handling by a processor connected to an ad-hoc network.
FIGS. 4A-B illustrate an example of a holster interlock sensor for an ad-hoc network of armed professionals.
FIGS. 5A-K illustrate examples of wearable articles incorporating sensors or indicators.
FIGS. 6A-D illustrate an example of an ad-hoc network for police work.
FIG. 7 is a flowchart of an example of a procedural-guidance function.
DETAILED DESCRIPTION
A team of workers performing a hazardous, unpredictable task can mitigate some of the risk by leveraging “safety in numbers,” coming to the aid of any teammate that finds himself or herself in trouble. Being able to help hinges on knowing what and where the trouble is as soon as it starts. This can be difficult if the teammates are too far apart to see or hear each other and normal communications (e.g., walkie-talkies, earbuds, cell phones, speaking and listening hardware built into protective gear) are not working. The area may be too noisy, or it may lack a repeater or other necessary infrastructure. The trouble may be of a kind that prevents the victim from communicating clearly: being overcome by toxic fumes, falling from a crumbling cliff-edge, or being ambushed by enemy combatants. Therefore, a need exists for a way to monitor teammates' situations in real time without needing to converse over a conventional channel. Such a solution could be applied to war, anti-terrorist action, police and security work, firefighting, toxic-waste cleanup, disaster relief, search and rescue, and similar activities.
An ad-hoc network including wearable electronics worn on users' bodies, and optionally including other components mounted on vehicles or temporarily set up at the task site, alerts other on-site (and optionally off-site) users when any user appears to need backup. For example, one or more wearable accelerometers may detect when the wearer falls or begins running. Wearable heart rate (HR) or galvanic skin response (GSR) sensors may detect surprise, strong emotion, or the onset of exhaustion. Wearable temperature and humidity sensors may warn when exposure to the environment becomes dangerous. Weapon holster interlocks may inform other users when any user draws a weapon. Microphones can produce audio data for voice stress analysis and voice recognition of users and other people that the users encounter, or sounds characteristic of environmental hazards such as flash floods or rockfall. Cameras may collect data for facial recognition or monitor activity in users' blind spots. If input from multiple sensors is aggregated, synchronized using time-stamps, and recorded, a multi-perspective record of events can be produced.
FIG. 1 is a conceptual map of an example of an ad-hoc network. Police officers 102 and 104 are looking for missing hiker 122 . At the trailhead, they park their vehicle 106 and set off on foot. Each of the officers 102 and 104 has a wearable electronics with capabilities including transmission T and reception R. Transmission T and reception R may use any suitable communication protocol.
Vehicle 106 as capabilities that also include transmission T and reception R; either or both officers 102 and 104 may communicate with the vehicle at any time. This expands the officers' capabilities while keeping their wearables simple, rugged, and lightweight with low power consumption, extending battery life and increasing the usefulness of portable chargers such as solar and hand-cranked chargers. For example, vehicle 106 may be able to relay messages from officers 102 and 104 to their dispatcher or to other police or park rangers in the area. The vehicle 106 may contain processors and on-board databases or links to databases in cloud 110 .
Optionally, a communication hub may be brought to the site, or an existing on-site communication hub may be redeployed as part of the a-hoc network. For example, a portable signal booster 108 may be carried in and set up if some feature of the terrain, such as the crest of a hill, attenuates communication between the officers 102 , 104 and/or the vehicle. In rescue or emergency communication situations where target 122 wants to be found, portable signal booster 108 may enable officers 102 , 104 to reach the mobile phone 124 of target 122 , or scan for a locator chip in mobile phone 124 , where previously the signals were too weak because the nearest cellular towers were too far away. Portable signal booster 108 may also enable the officers' wearables to communicate with servers in cloud 110 directly.
Officers 102 and 104 may split up to cover more area, knowing that if they encounter threats such as unfriendly animal 114 or human fugitive 116 , their partner will be notified instantly. In some embodiments, the officers need not be able to give accurate directions or even to speak, because their wearable transmitters may react to the readings of stress-level sensors and motion sensors by transmitting a distress signal after such triggers as a rapid increase in heart rate, a rapid increase in perspiration, or beginning to run, jump, or fall. Their wearable receivers' output may include a distance to the source of the distress signal, a direction from which the stress signal is coming, and the strength of the distressed person's reaction.
Embodiments of processors in the vehicle 106 , the portable signal booster 108 , and in some embodiments integrated with the wearables of officers 102 , 104 , may distinguish urgent messages from non-urgent received messages, or messages that require the use of a database from those that do not, and route them differently as appropriate. Distress signals and other urgent messages may be immediately circulated through the local ad-hoc network formed between the officers' wearables and optionally including one or more on-site vehicles and one or more deployed portable signal boosters. Such messages may simultaneously be sent to a dispatcher or to other officers in the area. Non-urgent messages may be sent to one or more cloud servers for retransmission with or without further processing. Optionally, the processor may record all the incoming signals from the officers' wearable and other equipment to thoroughly document the operation. Such recordings may be archived on the fly or after the officers' return.
As well as in search-and-rescue operations, the usefulness of these ad-hoc networks with wearables is readily adaptable to firefighting, criminal apprehension, warfare, disaster relief, mountain or cave exploration, undersea diving, in-habitat study of dangerous animals, and other activities where teams of users may face unpredictable hazards while not remaining visible to each other, where conventional communication may be difficult, or we're hazards may emerge too quickly to rely on conventional communications.
FIG. 2 is a block diagram of an example of an ad-hoc network. The main components are sensors (input transducers), indicators (output transducers), and an intelligent agent that may include hardware, software, or both in a processor or in a group of distributed processors. The intelligent agent analyzes the sensor inputs, classifies them according to urgency and need for outside data, decides which indicators need to respond to the sensor inputs and how the signals are to be routed.
“Sensors” is used here is a generic term for all the input transducers transmitting signals to one or more processors. Sensors include cameras and microphones as well as biometric and environmental sensors. On-body sensors 202 include wearables (clothing 212 and mounted directly to the body with adhesive 232 ), hand-held or carried in backpacks or pockets while operating (accessories 222 ). Off-body sensors 204 may include anything not worn or carried by a user while operating. Off-body sensors may include sensors mounted on a vehicle 214 , on equipment are tools not carried during operation 224 , or in some embodiments the sensors worn or carried by another user 234 .
In some embodiments, the incoming information from all the sensors is synchronized in step 242 and recorded to storage in step 244 . The recordings may be transmitted in real-time to a server, or they may be stored for later upload.
The incoming information for all the sensors also goes to the intelligent agent 252 , and may be synchronized or not depending on the embodiment. In the intelligent agent 252 , a signal recognition engine 254 compares the incoming signals with examples of predicted signals stored in an event/response database 258 . If a match is found, intelligent agent 252 infers that the corresponding event has happened. Some embodiments may cross-check numerous sensors to prevent “false alarm” inferences. To formulate a response to the inferred event, the intelligent agent may use data from teammate/contact database 256 , which may use the location and type of inferred event, sometimes along with the identity of the user originate in the sensor signals, to decide who needs to be notified of the inferred event; partners, supervisors, medics, etc.
A procedural template database 262 may be included as a reference for any strict, complex, or frequently changed procedures that users must follow even in a chaotic environment, such as clean forensic practices, chain-of-custody handling of evidence, or emergency first aid for specialized situations. Some embodiments of the intelligent agent 252 may make use of other internal databases 264 ; for example, if the users are SCUBA divers, there may be an internal database 264 to calculate how much longer each diver may stay submerged and what kind of decompression stop, if any, is needed. In some embodiments, the intelligent agent may dry information from external or remote databases 272 , such as facial and voice recognition databases and criminal record databases.
If the signal recognition engine 254 infers an event that needs an immediate response, the prescribed command from event/response database 258 is sent directly over the local ad-hoc network to the prescribed indicator. The indicators may be visual, such as LEDs or the screens of smart watches or heads-up displays; audible, from variable tones to recorded instructions (e.g., from procedural template database 262 ); or tactile, such as haptic transducers. Like the sensors, there may be a group of on-body indicators 206 on clothing 216 , accessories 226 , or attached to the body by adhesive 236 . There may also be a group of off-body indicators 208 mounted on or in a vehicle 218 , tools are equipment 228 , or someone else's body 238 . In some embodiments, the intelligent agent may use location sensors to determine whether any of the users are close enough to make use of an off-body indicator.
FIG. 3 is a flowchart of data handling by a processor connected to an ad-hoc network. The “on” trigger 302 that starts the system may be manual and user-operated, or maybe triggered by some action that indicates that the user is joining an ad-hoc network. For example, a police vehicle could have an infrared path across the doorway, similar to the obstacle detector that keeps an automatic door from closing if something is in the path. Whenever the police officer left the vehicle, e.g., for a traffic stop, crossing the infrared beam would automatically turn on the officer's wearable system and the vehicle system as step 304 . Alternatively, a proximity sensor in the vehicle could turn on the systems for step 304 when the officer's body moves out of a certain range.
Some embodiments with automatic “on” triggers 302 may provide for user override 306 , which triggers sensor deactivation 308 . For example, if a police officer leaves the vehicle to work on reports at the station or take a lunch break, it is highly unlikely that the ad-hoc network will be needed; nor will 2 hours of recorded typing be worth the data storage space it occupies.
If the sensors are activated and there is no user override, the user's wearable electronics connect to other local devices, any local processors, and optionally to a remote processor in step 310 . The processors commence monitoring the received sensor signals in step 312 . The signals are compared to entries in the local event/reaction database 314 and if a match is found at decision 316 , the urgency level is evaluated at decision 318 . For example, even if the sensors a single microphone, the intelligent agent may analyze the amount of voice stress and infer a degree of urgency from the result. The lowest urgency events may simply be stored to processor later time in step 328 . The highest urgency events will immediately activate a local indicator through the ad-hoc network, “jumping the queue” to precede or even interrupt less-urgent signals. Events of medium urgency (including high-urgency events that have already been broadcast over the ad-hoc network, and requests that involve querying one or more off-site databases) are relayed to a remote processor, e.g., a cloud-based processor, for processing: consulting the database, contacting dispatchers or other nearby officers, or other tasks that present no risks by being sent to the remote processor.
Not all signals that come two decisions 316 will match events in the event/response database. Some signals may be data transmitted from a remote processor in step 320 , including answers to medium-urgency queries. Those signals are relayed to the local indicators in the ad-hoc network whenever the system is not occupied by higher-urgency signals. If the signal does not match inferred event and is not data coming from a remote processor, the intelligent agents ignores it and continues to monitor the sensor signals, in effect looking back to step 312 . At any time, there may be an “off” trigger at decision 330 deactivating the system to save power when the ad-hoc network is not needed. Like the “on” trigger, the “off” trigger may be manual or automatic.
FIGS. 4A-B illustrate an example of a holster interlock sensor for an ad-hoc network of armed professionals. When a soldier, police officer, or other security specialist draws a weapon during an operation, it almost always signifies an emergency need for backup. If removing a weapon from a holster automatically sends a high-urgency signal over an ad-hoc network, the user's allies in the area will be alerted immediately, even if the user is out of their sight or the environment is too noisy to hear what the user is saying. In some embodiments, removing the weapon from a holster may activate a wearable camera (e.g., mounted on a cap or near the neckline of a body-armor vest) to record what the user is seeing and/or a microphone to record what the user hears and says. This an example of sensors temporarily acting as indicators when they are turned on in response to signals from other sensors.
In FIG. 4A , handgun 402 is secured in holster 404 . There may be a proximity sensor 414 in holster 404 , an accelerometer 412 on handgun 402 , or both to provide redundancy and reduce the incidence of false alarms. In FIG. 4B , when handgun 402 is removed from holster 404 , accelerometer 412 senses the motion and sends a first signal 422 over the ad-hoc network. In addition, proximity sensor 414 in holster 404 stops sensing handgun 402 nearby and sends a second signal 424 over the ad-hoc network.
Although a handgun is the illustrated example, similar sensors could be mounted to nightsticks, stun guns, Tasers™, pepper-spray canisters, or other hand-held weapons.
FIGS. 5A-K illustrate examples of wearable articles incorporating sensors or indicators. Some may have both sensors 502 and indicators 504 , or multiple sensor or indicator units. For example, an article that encircles some part of the body such as a watchband, hatband, glove, collar, shoe, or belt may hold a ring of haptic transducers indicating a direction to travel by activating the transducer facing that direction.
In FIG. 5A , sensors 502 and/or indicators 504 may be mounted on the band, bezel, or strap of smart-watch 506 . In FIG. 5B , sensors 502 and/or indicators 504 may be mounted on the brim or crown of cap 516 . In FIG. 5C , sensors 502 and/or indicators 504 may be mounted on the outside or inside of glove 526 . In FIG. 5D , sensors 502 and/or indicators 504 may be mounted on the outside or inside of body-armor 536 .
In FIG. 5E , sensors 502 and/or indicators 504 may be mounted on the outside or inside of work shirt 546 . In FIG. 5F , sensors 502 and/or indicators 504 may be mounted on the upper of work boot 556 . In FIG. 5G , sensors 502 and/or indicators 504 may be mounted on the strap or buckle of belt 566 . In FIG. 5H , sensors 502 and/or indicators 504 may be mounted on the pendant, cord, or clasp of lanyard 576 .
In FIG. 5I , sensors 502 and/or indicators 504 may be mounted on the outside or inside of service-animal collar 586 . In FIG. 5J , sensors 502 and/or indicators 504 may be mounted on the inward- or outward-facing services of a removable clip 596 . 1 and 596 . 2 . In FIG. 5K , sensors 502 and/or indicators 504 may be mounted on a removable adhesive patch 598 to be worn temporarily on the surface of the skin. The adhesive embodiment may be convenient for sensors such as galvanic skin response (GSR) that need to maintain contact with the skin on a user in vigorous or nearly constant motion.
FIGS. 6A-D illustrate an example of an ad-hoc network for police work. In FIG. 6A , police officer 602 and partner 604 are patrolling in a vehicle 606 with an automatic on-trigger 608 for the officers' wearable electronics. In FIG. 6B , the officers have detained a suspect vehicle 626 carrying a driver 624 and a passenger 622 . Officer 602 has exited from vehicle 606 , automatically activating her wearable location sensor 618 .
In FIG. 6C , officer 602 comes to the driver's window of suspect vehicle 626 to speak to the driver. In officer 602 's blind spot, passenger 622 leaves vehicle 626 at a run. Although officer 602 may not have seen it, a camera on police vehicle 606 had an excellent view. The intelligent agent reading the camera signal recognizes the event of the passenger leaving a detained vehicle and immediately send signal 610 over the ad-hoc network to or more of officer 602 's wearable indicators. For example, a warning LED under the brim of the officer's cap may illuminate; a haptic transducer on the officer's belt facing the direction of the fleeing passenger may buzz; or a heads-up display built into the officers' eyewear may give more detailed information.
In FIG. 6D , the timely-alerted officer 602 chases the suspect passenger 622 . The ad-hoc network stretches to wherever officer 602 goes. Her location sensor 618 allows her partner or other backup to join the chase from another direction, and biometric sensors 628 monitor her levels of stress and exertion as urgency indicators.
FIG. 7 is a flowchart of an example of a procedural-guidance function. Procedural steps can be difficult to remember if the procedure is new, or new to the person executing it; if the procedure is complex, seldom used, or has recently changed. Nevertheless, much can be put at risk by skipping a step of a procedure or doing it wrong. Evidence, or entire cases, may be thrown out of court. A patient may die or be permanently injured. A piece of military machinery may malfunction in battle. Therefore, a need exists to more reliably ensure that procedures are done correctly.
Ad-hoc networks including wearable sensors and/or indicators that enable prompts for the various stages of a procedure as is being performed. At step 702 , a sensor detects a procedure trigger. For example, a microphone may receive a police officer's voice saying the words “You're under arrest.” The intelligent agent infers the event of a suspect being arrested. In step 704 , it searches the procedure database (or other data-store) 703 for arrest procedures and retrieves the latest (for example including Miranda warnings). Periodically, step 705 updates the stored procedures. In step 706 , the steps of the procedure are visually displayed (or may be audibly recited) to the user executing the procedure. In some embodiments, the sensors look or listen for cues that a step has been performed (for example, by analyzing a filled-out form through a camera. Optionally, the execution of the procedure may be recorded to storage in step 708 .
The preceding Description and accompanying Drawings describe examples of embodiments in some detail to aid understanding. However, the scope of the claims may also include equivalents, permutations, and combinations that are not explicitly described herein. | One or more sensors gather data, one or more processors analyze the data, and one or more indicators notify a user if the data represent an event that requires a response. One or more of the sensors and/or the indicators is a wearable device for wireless communication. Optionally, other components may be vehicle-mounted or deployed on-site. The components form an ad-hoc network enabling users to keep track of each other in challenging environments where traditional communication may be impossible, unreliable, or inadvisable. The sensors, processors, and indicators may be linked and activated manually or they may be linked and activated automatically when they come within a threshold proximity or when a user does a triggering action, such as exiting a vehicle. The processors distinguish extremely urgent events requiring an immediate response from less-urgent events that can wait longer for response, routing and timing the responses accordingly. | 7 |
BACKGROUND OF THE INVENTION
[0001] a) Field of the Invention
[0002] The present invention relates to a double-layer directed sweat cloth and more particularly to a sweat cloth structure which is able to quickly expel sweat and is provided with a dry-wet separation effect, especially that sweat which is forcefully drawn in a lining is distributed directionally to a hydrophobic dissipation layer for evaporation, such that sweat can be expelled quickly and that an explicit dry-wet separation mechanism is provided between the lining and the dissipation layer, wherein sweat is expelled primarily through simultaneous drainage with plural routes, thereby being expelled quickly.
[0003] b) Description of the Prior Art
[0004] Since the beginning of human history, a requirement of comfortableness in wearing clothes has stimulated progressiveness of textile industries. Recently, there is an improved outcome to a sweat cloth, wherein a primary ingredient of the cloth is based upon a polyester fiber due to that the polyester fiber is hydrophobic and is able to absorb water through a special processing.
[0005] A fundamental concept of the sweat cloth is that the sweat cloth is provided with a lining of hygroscopic layer and an external sweat dissipation layer between which is interwoven into a single cloth. The object is that the hygroscopic layer can be affinity to skin to draw and deliver sweat coming from a human body to the external dissipation layer. A drawing layer must be provided with capillarity and if braided wires are polyester fibers then the drawing layer can be formed with a capillary or porous adsorption effect through a chemical or physical treatment, so as to achieve a water drawing function or to achieve a capillary drawing capability through a blended fabric of natural cotton fibers. However, the blended fabric of natural cotton fibers scales off easily by a mechanical force of washing. As a result, recently, the lining layer employs a polyester fiber of an anisotropic cross section to serve as a capillary water absorption function, thereby achieving an object of expelling sweat. On the other hand, the external layer uses the braided wires which are made by twirling the polyester fiber to weave into an interlaced structure, a special hydrophobicity of which is utilized to achieve the object of quickly evaporating and expelling sweat as a water film formed by sweat spreading that sweat can be evaporated in a large area.
[0006] The overall object is to provide a sweat cloth, allowing sweat, which comes out after a user wears the cloth to take an exercise, to be drawn to be carried outward, such that skin can be dry and further keep warm, thereby maintaining health. The achievement of the object can even prevent germs from growing due to wetness and warmth and form air permeability as there is no water in interwoven gaps of the cloth.
[0007] The Japanese TEIJIN Limited Company has proposed plural kinds of cloth fiber technologies and also claimed the sweat cloth and fiber. That patent discloses a water guiding design between an inner and an outer layer of cloth and a water guiding design in an interlining. The company has proposed plural kinds of patent technologies of cloth and fiber and fulfilled market demands.
[0008] In addition, an Asian company has disclosed a cloth which is provided with ingredients of different proportions, forming an inner and an outer layer. The cloth also provides sweat removing for sporting, according to a function of water distribution, wherein part of braided wires use two wires to interweave with a different den, but sections of the braided wires which draw sweat and wind toward a surface layer cannot be assisted by other elements and as drawing braided wires are attached to yarns at an external layer, a feedback must occur when the yarns at the surface layer are fully loaded or due to a function of gaps, allowing the drawing braided wires to regain moisture, thereby losing an object of sweat removing.
[0009] A conventional knitted sweat cloth is generally shown in FIG. 3 , wherein a surface and an interior of a cloth 8 is formed with a first and a second surface 81 , 82 , the second surface 82 includes braided wires which are braided into plural hoops 820 in a full stitch and bottom wires of the first surface 81 are interwoven with capillary water absorbing braided wires 810 which are distributed horizontally in a shape of yarns. As sweat which is drawn by the braided wires 810 can be only submitted at dot-shaped tiny sections at overlapping portions 80 , it is difficult to satisfy a demand of evaporation of the second surface 82 .
SUMMARY OF THE INVENTION
[0010] The primary object of the present invention is to provide a sweat cloth with a dry-wet separation operation, wherein among interwoven hoops of a dissipation layer, part include drawing hoops and complex braided hoops which are directly extended and configured from a lining layer, allowing sweat which is drawn in the lining layer can be drained and transported in a high speed to the interwoven hoops of the dissipation layer, forming water films immediately that sweat can be quickly evaporated, according to a draining operation of drawing yarns and complex braided wires which provide a capillary function with a same strand and a single core, as well as provide a simultaneous drawing structure of plural routes.
[0011] A second object of the present invention is to provide a double-layer directed sweat cloth, wherein a core portion of the drawing yarn in the lining layer is an arched section, an interior of which is formed with a hollow portion to serve as a basis of a spacing of dry-wet separation.
[0012] A third object of the present invention is to provide a double-layer directed sweat cloth, wherein between the neighboring arched sections in a series is spaced with a groove which serves as a dry-wet separation in a beginning when skin sweats; whereas, when sweat is accumulated into grains (sweat beads), sweat can be quickly drained through plural interwoven routes at a bottom of the groove.
[0013] To enable a further understanding of the said objectives and the technological methods of the invention herein, the brief description of the drawings below is followed by the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows a schematic view of a braided wire of the present invention.
[0015] FIG. 2 shows a schematic of a finished cloth of the present invention.
[0016] FIG. 3 shows a structural diagram of a conventional cloth.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention discloses a double-layer directed sweat cloth, especially a sweat cloth which forces sweat drawn in a lining to be quickly distributed to a hydrophobic dissipation layer directionally for evaporation and prevents sweat after distribution from reversely staining skin to maintain dryness of a lining layer and result in dry-wet separation in time.
[0018] To achieve the aforementioned object, among interweaving of the dissipation layer 100 and the lining layer 10 , the lining layer 10 is directly extended with drawing hoops 21 which are positioned in interwoven hoops 41 of the dissipation layer 100 . The lining layer 10 is formed inward (a bottom surface) with arched sections 20 which are affinitive to skin, and sweat which is drawn by the arched sections 20 can be distributed directly to the belonging drawing hoops 21 , which are close to the interwoven hoops 41 of the dissipation layer 100 , according to a capillary function in a same strand and a single core. Next, by a guiding function of neighboring gaps between the drawing hoops 21 and the interwoven hoops 41 , an adhesion property of water liquid and an effect of pressure balance, sweat which is entrapped by the drawing hoops 21 can be effectively diffused and spreading to surfaces of the interwoven hoops 41 to form water films; thus, an evaporation area is enlarged, allowing water molecules of the water films to be more active to jump and scatter for evaporation.
[0019] On the other hand, grooves 7 of the lining layer 10 do not operate explicitly in a beginning when skin sweats, with sweat only being expelled by drawing yarns 2 . However, when skin sweats a lot, sweat is accumulated into sweat beads 5 which must be expelled out quickly; whereas, one of routes for expelling out the sweat beads 5 is at the arched sections 20 of the drawing yarns 2 and the other one is at the grooves 7 .
[0020] Referring to FIG. 1 and FIG. 2 at a same time, a sweat cloth 1 disclosed by the present invention is provided with the dissipation layer 100 and the lining layer 10 , wherein the lining layer 10 is clung to and interwoven at an inner surface (a bottom of the cloth) of the dissipation layer 100 ; this inner surface is affinitive to skin where the cloth is worn on.
[0021] The said dissipation layer 100 is braided into interwoven hoops 41 by plural columns of interwoven wires 4 in a full stitch, interweaving into a base of the cloth.
[0022] Complex braided wires 3 are also braided into complex braided hoops 31 which are similar to the interwoven hoops 41 of the interwoven wires 4 , with a difference that the complex braided wires 3 are knitted intermittently in a slip stitche, such as using an intermittent ratio of slipping two stitches and knitting two stitches or as many as an intermittent slip-stitch knitting with ten stitches or a various ratio of a number of slip stitches and a number of knitted stitches, like 2:3 or 3:5; a result is that plural kinds of textures of different widths can be knitted to alter patterns of textures.
[0023] The aforementioned description is that the ratio of slip stitches is chosen for the complex braided wires 3 with an intermittent program to braid complexly with the interwoven wires 4 in the intermittent way, with a position of the complex braiding at a needle position of L 1 .
[0024] Through the aforementioned procedure, the needle position of L 1 is simultaneously braided with the interwoven hoop 41 of the interwoven wire 4 and the complex braided hoop 31 of the complex braided wire 3 , where the interwoven hoop 41 is interwoven with the complex braided hoop 31 . At this moment, a needle position of L 2 of an alternate slip-stitch only exists with an independent interwoven hoop 41 of the interwoven wire 4 .
[0025] Regarding to weaving the drawing yarns 2 of the lining layer 10 with the dissipation layer 100 , the drawing yarns 2 are used to pick up a stitch at the needle position of L 2 of the aforementioned slip-stitch, allowing the independent interwoven hoop 41 of the interwoven wire 4 to be combined with the drawing hoop 21 of the drawing yarn 2 , with a shape of the drawing hoop 21 similar to that of the complex braided hoop 31 of the complex braided wire 3 .
[0026] In principle, the needle positions of the drawing hoop 21 and the complex braided hoop 31 are staggered; that is, the drawing hoop 21 and the complex braided hoop 31 of the complex braided wire 3 are staggered at a different location. In other braiding requirement of the cloth, the drawing hoop 21 and the complex braided hoop 31 are allowed to be weaved at the same needle position.
[0027] The lining layer 10 is braided with the dissipation layer 100 by the drawing yarns 2 through the aforementioned knitting method. Toward an inner side (a bottom of the cloth) is preserved with the intermittent arched sections 20 which are formed directly from sections of the drawing yarns 2 . In addition, through serial knitting, the arched sections 20 are serially arranged into the grooves 7 at a left and right side and a depth of the grooves 7 is dependent on a height that the arched sections 20 arch. A hollow portion 6 is formed by using a space between the arched section 20 and the groove 7 , allowing an interlining layer to be formed on a skin surface after a user wears on the cloth, thereby effectively preventing sweat of the dissipation layer 100 from reversely staining the skin surface where the cloth is worn on.
[0028] On the other hand, regarding to a dry-wet separation operation of sweat removing, it is primarily that the drawing yarns 2 provided in the lining layer 10 are normally provided with the capillary function. Using a same and a single strand and based on the arched sections 20 , the drawing yarns 2 are continuously extended toward the dissipation layer 100 to be braided with the drawing hoops 21 at the interwoven hoops 41 , with a shape of the drawing hoop 21 roughly same as the interwoven hoop 41 . Therefore, sweat which is drawn at the arched sections 20 will be directly distributed to the drawing hoops 21 along a route of a same axis and a single core by a principle of capillary pressure difference; during the transportation, there is no need to jump over any gap, like along a single core route of a body of the arched section 20 , and sweat can be smoothly transported to the drawing hoops 21 .
[0029] A side of the drawing hoop 21 at the dissipation layer 100 is exposed outward, a shape of the drawing hoop 21 is about same as or smaller than that of the interwoven hoop 41 and the drawing hoop 21 is close to the interwoven hoop 41 , between them is formed with a coalesced capillary. Sweat which is drained into will be spreading and distributed on a wiring surface of the interwoven hoop 41 by adhesion of the sweat itself and an effect of pressure balance, forming a diffusive distribution in a water film shape. The interwoven hoop 41 is hydrophobic and according to an evaporation principle of water liquid, under a lower temperature and that water molecules are not frozen, as long as that the water molecules are not subjected to a strong pressure, they still have an active, jumping and scattering capability. Therefore, after sweat on the surface of the interwoven hoop 41 forms the water film, an internal pressure of sweat will become smaller and energy of the water molecules will be able to fight against that pressure to scatter and evaporate, thereby quickly dissipating sweat.
[0030] Besides, as described above, regarding to the primary work load of the grooves 7 , in the beginning when skin sweats, the drawing yarns 2 will take the burden and when skin sweats a lot, in addition to that the drawing yarns 2 will still be responsible for expelling sweat, a larger quantity of sweat is submitted to the grooves 7 ; whereas, in the beginning stage when skin sweats, as the grooves 7 do not contact with skin and thus are suspended, the grooves 7 do not take burden in absorbing water temporarily.
[0031] The operation of expelling sweat in a large quantity by the grooves 7 occur when skin sweats a lot. As sweat will be attached on a skin surface due to a cohesion force and adhesion ability of water liquid and will be accumulated as grain-shaped sweat beads 5 . The sweat beads 5 which are located at the arched sections 20 of the drawing yarns 2 will be directly drained to flow to the dissipation layer 100 by the drawing yarns 2 ; whereas, for the sweat beads 5 which are located at the grooves 7 , as the sweat beads 5 have a grain size and when the grain size becomes larger and is able to meet a contact distance to a bottom of the grooves 7 , an upper surface curve of the sweat beads 5 will touch the bottom, which is formed by interweaving bottom wires 30 extended from the complex braided wires 3 with bottom loops 22 extended from the drawing yarns 2 , of the grooves 7 , and the sweat beads 5 will touch the bottom and will be collapsed quickly to be drained toward the dissipation layer 100 , through the pressure and the capillary function.
[0032] The base structure of the bottom is the bottom wires 30 which are extended from the complex braided wires 3 and the bottom loops 22 which are extended from the drawing yarns 2 . A left and right end of the bottom are extended respectively toward the dissipation layer 100 with the complex braided hoops 31 and the drawing hoops 21 which are provided with a similar shape as that of the interwoven hoops 41 of the interwoven wires 4 and are close together. Therefore, sweat which is drawn by the complex braided hoops 31 and the drawing hoops 21 can be quickly delivered to the interwoven hoops 41 for dissipation by water spreading and the capillary phenomenon.
[0033] The said bottom wires 30 are in a straight line shape, flat located at an intersection between the lining layer 10 and the dissipation layer 100 due to slip-stitch in spacing. In addition, the bottom wires 30 belong to the lining layer 10 and two sides are extended with the complex braided hoops 31 which are complexly braided at the same positions as the interwoven hoops 41 . The said bottom loops 22 are formed by knitting the drawing yarns 2 ; that is, the bottom loops 22 are formed by extending downward the interwoven hoops 41 , with a bottom contact point of the bottom loops 22 being intersected with the flat bottom wires 30 .
[0034] The operation of massively and quickly expelling the sweat beads 5 is that when the sweat beads 5 are accumulated, as described above, such that the grain size is large enough to touch the bottom of the grooves 7 , especially that the sweat beads 5 are exactly at the intersected positions between the bottom loops 22 and the bottom wires 30 , along with the capillary function of the wirings and a gap effect among interweaving of the wirings; then there will be four draining routes in total from the left and right ends of the bottom wires 30 and two sides of the bottom loops 22 up in a curved direction and with convenience of directly delivering along the wiring of a single core and a same strand by the capillary function, that the sweat beads 5 per unit volume can be quickly collapsed to shunt and drain to each extended complex braided hoop 31 and the drawing hoop 21 . The aforementioned diffusion and delivering operation is repeated to expel sweat which is evaporated quickly at the interwoven hoops 41 of the dissipation layer 100 .
[0035] In the aforementioned evaporation process, if the water film on the surface of the interwoven hoop 41 is evaporated off, then sweat which is entrapped by the complex braided hoops 31 and the drawing hoops 21 will acquire a different pressure position to be diffused in balance again, enabling the water film which is once more distributed on the surface of the interwoven hoops 41 to be ready for the repeated evaporation cycle or the sequential operation.
[0036] If the aforementioned operation is added by a relative speed of body movement with respect to air or blowing of natural wind, then a streamline of outside air will enter into an inner ring of the drawing hoop 21 and the interwoven hoop 41 to form turbulence and a shock force which are beneficial to partly evaporate sweat in advance. As a result, a semi-loop shape of the interwoven hoop 41 and the drawing hoop 21 is necessary to explicitly aid the evaporation.
[0037] The aforementioned dissipation layer 100 is provided with a good evaporation efficiency and under a condition that sweat is carried easily, air will flow throughout the sweat cloth 1 easily, enabling the sweat cloth 1 to be provided with a smooth breathing and air permeable function.
[0038] FIG. 1 shows a structure of braided yarns of a cloth of the present invention, which is ended up as the cloth in FIG. 2 after interweaving plural columns of the yarns. In general, the cloth is provided with an inner and an exterior surface and in the present invention, the inner surface is defined as the lining layer 10 ; whereas, the exterior surface is defined as the dissipation layer 100 . The lining layer 10 utilizes the drawing yarns 2 and complex braided wires 3 which form directly the drawing hoops 21 and the complex braided hoops 31 during the braiding process, and are braided at same locations in the interwoven hoops 41 that are braided by the interwoven wires 4 of the external dissipation layer 100 , allowing the drawing hoops 21 and the complex braided hoops 31 to face respectively the interwoven hoops 41 and to be knitted at each needle position, such that sweat which is drawn by the lining layer 10 can be directly transported to the drawing hoops 21 and the complex braided hoops 31 , along the same axis of the single core strand of the drawing yarns 2 and the complex braided wires 3 , following the direct route and through the capillary function. As a result, sweat can be drained in a high speed, along with an interaction of the drawing hoops 21 and the complex braided hoops 31 with the interwoven hoops 41 , that sweat can be evaporated quickly.
[0039] The lining layer 10 and the dissipation layer 100 of the present invention are that the lining layer 10 includes the arched sections 20 and the bottom of the grooves 7 , with the bottom being formed by intersecting the bottom loops 22 with the bottom wires 30 ; the dissipation layer 100 includes the interwoven hoops 41 of the interwoven wires 4 , the drawing hoops 21 and the complex braided hoops 31 . In addition, the lining layer 10 is provided with the hollow portion 6 and sweat which is drawn can be transported outward quickly to the dissipation layer 100 along the direct route; whereas, the dissipation layer 100 allows sweat to be evaporated by the outside air flow or a vibration effect of thermo-electromagnetic waves, and thus, the dissipation layer 100 can keep dry quickly due to the rapid transportation of sweat.
[0040] In terms of sweat evaporation efficiency, in principle, the larger the diffusion area, the more easily sweat is evaporated. To enhance the evaporation efficiency of the water film formed by sweat, a number of dens or wire diameter of the interwoven wires 4 can be increased to forcefully increase a surface area, allowing sweat per unit volume to have a larger area to be distributed into thinner water films, as water molecules inside the thinner water films can have stronger activity to jump and evaporate.
[0041] Besides, by changing a number of dens of the braided wires, a various degree of capillary can be formed, as well. In the present invention, numbers of strands of the interwoven wires 4 or the complex braided wires 3 relative to the drawing yarns 2 are implemented to be non-proportionally matched. For example, if a length and a weight of the interwoven wire 4 and the drawing yarn 2 are equal, then 144 strands of the interwoven wire 4 will be used, whereas 36 strands of the drawing yarn 2 are used. Therefore, the capillary effect of the interwoven wire 4 will be larger than that of the drawing yarn 2 , which is easy to disperse the hydraulic pressure, relatively allowing the water liquid in the drawing yarns 2 to quickly seek for places of a lower pressure difference for delivering. In addition, the capillary effect is stronger and a larger space to store water is relatively provided, allowing sweat of the drawing yarns 2 to be transferred in a high speed and in a large quantity. Therefore, sweat which is drawn by the drawing yarns 2 will quickly flow outward to maintain dryness.
[0042] The basis of concept of the present invention is to directly use the drawing hoops 21 and the complex braided hoops 31 which are formed by extending part of sections of the drawing yarns 2 and the complex braided wires 3 in the lining layer 10 , to be braided in the interwoven hoops 41 provided by the dissipation layer 100 , allowing sweat which is drawn by the lining layer 10 to be directly transported to the dissipation layer 100 along the core of wirings and to be quickly delivered to the interwoven hoops 41 of the dissipation layer 100 , by the adhesion and spreading abilities of sweat, thereby achieving an object of quickly diffusing and evaporating sweat. Furthermore, by using the hollow portions 6 inside the arched sections 20 of the drawing yarns 2 and the hollow spaces formed in the grooves 7 between the neighboring arched sections 20 , the dry-wet separation support is formed between the lining layer 10 and the dissipation layer 100 in dissipating sweat, allowing the lining layer 10 to maintain dryness to skin where the cloth is worn on and sweat of the dissipation layer 100 to be dissipated as much as it can be without flowing back; which is actually the innovative braided structure of the sweat cloth 1 .
[0043] It is of course to be understood that the embodiments described herein is merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be effected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims. | A double-layer directed sweat cloth, especially a quick hygroscopic sweat cloth, is disclosed. Sweat drawn by a lining is given a directional route for transporting and delivering quickly to an external dissipation layer for evaporation and sweat transferred is prevented from staining reversely a skin surface, forming a dry-wet separation effect to keep a lining layer dry. In the lining layer, part of core sections of yarns which absorb sweat are at same positions in the dissipation layer, allowing water liquid affinitive to the lining to directly acquire a directional route that sweat is quickly transported and carried outward to keep skin dry, by a co-core capillary effect to transport sweat directly and collapsing sweat beads at far ends. Moreover, as drawing yarns are woven hollowly, a hollow portion is formed in the lining to provide a dry-wet separation mechanism, maintaining dryness to skin where the cloth is worn on. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a cover for an ironing board or pressing machine including a skid-resistant material which provides frictional force between the cover and the articles to-be-ironed, thereby preventing the articles from sliding on the ironing surface.
During the ironing process, whether domestic, commercial or industrial, considerable difficulty may be encountered when more than half of the article being ironed extends over the edge of the ironing board. Since the conventional board cover is typically composed of a relatively slick woven textile, the force of gravity tends to pull the article off the board onto the floor. To prevent the garment from falling, the ironer must keep one hand on the article as a restraint to fix its position on the board. Ironing becomes awkward, time consuming and subject to repeated dropping mishaps.
After one or more ironing strokes, the ironer may temporarily place the iron, sole plate down, on the ironing surface aside the article being ironed, usually near the heel or untapered end of the ironing board. The iron may rest in this location while the ironer shifts, folds, hangs or replaces the article ironed. Any contact or bump to the ironing board may cause the iron to slide off the board, inasmuch as the sole plate of the iron is ultra smooth and polished, and the conventional ironing board cover is a woven textile material with minimal or no surface traction.
Generally, ironing board covers are made from coated cotton or other textile materials, or partially or entirely of man-made fibers. The typical ironing surface is slippery, affording little or no friction between the cover and the clothes being ironed.
U.S. Pat. No. 3,049,826 pertains to an ironing board cover formed from an asbestos-impregnated woven textile.
U.S. Pat. No. 3,148,467 discloses a cover of glass cloth, cotton, cotton with a silicone covering, or cotton with a plastic coating.
U.S. Pat. No. 3,414,995 discloses an ironing board cover having a central ironing panel of silicone rubber-impregnated woven glass fabric. Such a composition is insufficient to impart the necessary frictional force between the articles being ironed and the ironing board surface to prevent sliding of the articles.
U.S. Pat. No. 3,733,724 discloses an ironing board pad having a cover comprising a stretchable heat-resistant knit material.
U.S. Pat. No. 3,911,603 discloses a fabric ironing board cover having a plurality of closely-spaced apertures. The apertures have the effect of roughening the ironing surface.
U.S. Pat. No. 4,043,062 discloses an ironing pad for table-top use. A skid resistant coating is included on the underside of the pad, but not on the ironing surface. U.S. Pat. No. 4,360,984 discloses a similar table-top ironing pad having a cotton cover coated with a synthetic resin, but the resin is intended to improve heat resistance and minimize, rather than maximize, friction between the ironed aritcles and the pad.
These prior art ironing board covers are ineffective in preventing slippage of articles being ironed from the ironing board surface under the action of gravity. What is needed is a non-skid cover which is stable at ironing temperatures, easy to manufacture, and which provides a high degree of frictional contact with articles being ironed.
SUMMARY OF THE INVENTION
A cover for an ironing board or pressing machine is provided. The cover is composed of a fabric, at least a portion of which has a non-skid surface stable at ironing temperatures.
The non-skid surface may extend substantially over the entire surface of the cover, or may be restricted to the periphery of the ironing surface. The non-skid surface may be discontinuous. It may extend over the edge of the ironing surface to encompass the side skirts of the cover. It is most advantageously formed by a coating of an acrylic polymer. The preferred coating is formed from a composition of about 50-95% of an aqueous acrylic emulsion, about 0.5-3.0% thickener, about 0.5-2% thickener activator, about 0.5-5% humectant, and water.
It is therefore an object of the invention to provide an inexpensive but effective cover for an ironing board or pressing machine having a non-skid surface.
It is an object of the invention to provide an ironing surface which prevents sliding of articles being ironed during the ironing operation.
It is an object of this invention to provide for essentially one-handed ironing.
It is a further object of the invention to provide an ironing surface with non-skid characteristics such that shear fabrics may be ironed without distortion resulting from sliding or stretching during ironing.
Finally, it is an object of the invention to provide a process for forming a non-skid surface on a fabric ironing board cover.
Other objects and advantages will appear hereinafter.
DETAILED DESCRIPTION OF THE INVENTION
Unless specifically indicated otherwise, all percentages expressed herein are volume percents. The ironing board cover of the present invention is composed of a layer of fabric which has the general outline of a typical ironing board, but its edges or "side skirts" extend beyond the edges of the ironing board surface. The fabric may be a woven, knitted or non-woven textile material which will resist the heat and pressure of the ironing process. Such fabrics are well-known in the art and are readily available commercially. The preferred fabric material is cotton or a blend thereof.
It is known to coat cotton ironing board covers with metallic or slick plastic coatings. These surfaces, without some form of non-skid coating, are ineffective in preventing slippage of articles being ironed. Although synthetic or natural rubber may be used for a non-skid surface, they are less desirable because of the tendency to yellow and brown as well as becoming brittle and unstable.
Any of several known polymeric materials having non-skid properties may be affixed to the ironing side of the fabric in accordance with the present invention. Appropriate non-skid polymer coatings may be applied to the fabric in solution form. The solvents can be aqueous or non-aqueous. Likewise, the polymer may be in emulsion form. Preferred materials include acrylic polymer emulsions or mixtures thereof, particularly self-reactive acrylics such as "RHOPLEX K-14", available from Rohm & Haas Co., Philadelphia, Pa. Acrylic polymer coatings have the advantage of imparting increased abrasion resistance to the fabric.
The non-skid surface may be imparted to the fabric by a variety of well-known methods. Appropriate polymer coatings can be applied by knife coating, roller coating, flat bed screen printing, rotary screen printing or unit printing. The coating may also be applied by dipping the fabric in a bath of the coating material. Curing of the polymer, if necessary, takes place at elevated temperature.
The materials may be imparted to the fabric by other means such as weaving fibers of polymeric non-skid material into the fabric, sewing portions of non-skid material to the fabric, or attaching non-skid sheet materials by fusion, lamination or other means known to those skilled in the art.
In one embodiment of the invention, the non-skid coating extends over the entire ironing surface of the fabric. Preferably, the non-skid coating is restricted to the periphery of the ironing surface, most advantageously in a regular or irregular border extending outward up to two and one-half inches from the edge of the ironing surface. The border may be continuous or interrupted. Where the ironing board cover is provided with a silk-screened border design, the non-skid materials may be mixed with the coloring materials for the design. The result is a non-skid artistic border design on a background of cotton fabric.
The non-skid coating may advantageously be continued over the edge of the ironing surface downward onto the side skirts of the cover. I have found that coating the border and side skirts of the cover with non-skid material is particularly effective in preventing sliding of the articles being ironed from the ironing surface.
The ironing board cover of the present invention may contain a padding layer having the same shape as the fabric cover. The padding is preferably formed from a polymeric material such as foam polyurethane. The padding may be attached by a thermoplastic adhesive as described in my U.S. Pat. No. 3,911,603 to form a wrinkle-proof laminate. The edges of the fabric may contain binding or welting through which a drawstring or elastic band is run so that the cover may be secured onto the ironing board.
The ironing board cover may contain one or more layers of heat reflective materials such as pure aluminum flakes or inert material insulating materials, which may be dispersed in acrylic resin binders bonded between the fabric layer and the padding. Such an arrangement has the advantage of increasing the effectiveness of ironing since heat loss through the fabric and padding layers is reduced. Alternatively, the fabric material may itself be coated with a metallic heat reflective material as described in U.S. Pat. No. 3,049,826, or in my U.S. Pat. No. 4,485,400. The heat reflective material should be applied so as not to interfere with the desired non-skid properties.
In one embodiment of the invention, a non-skid surface is applied in the form of a coating composition containing one or more acrylic polymers in an aqueous emulsion. The composition further includes binding and thickening agents compatible with the acrylic emulsion. Additional acrylic polymers may function as these binding or thickening agents. "POLYCRIL G-9", an acrylic polymer from Polymer Industries is useful as a binding agent, while "ASE-60" from Rohm & Haas, another acrylic polymer, may be used as a thickener. The acrylic emulsion comprises about 50-95% of the composition.
The acrylic coating composition may further contain antifoaming agents, particularly of the mineral oil or vegetable oil type. The anti-foamer may include a surfactant to distribute the oil. Antifoamer #50601, available from the Inmont Division of United Technologies, is an example of a suitable antifoamer. It contains a 70-80% base of mineral oil with additional surfactants.
If heat reflection is desired, the composition may additionally contain a heat-reflective metal, particularly aluminum, in the form of a leafing paste. When a metal paste is added to the composition, an emulsifying agent such as ethylene oxide should be included.
Other ingredients include thickening activators and humectants.
A coating composition for application by rotary screen printing thus contains about 50-95% of an aqueous acrylic emulsion, about 0.5-3% thickener, about 0.5-2% ammonia to activate the thickener and stabilize the composition against mechanical shear during the printing process, about 0.5-5% of a suitable humectant, about 0.1-2% antifoamer, the balance being water. Urea, propylene glycol, glycerine and mixtures thereof may be used as humectants. The humectant most preferred comprises a mixture of 0.5-2% urea and 1-3% propylene glycol, relative to the total composition. The humectant prevents drying of the composition on the rotary screen during printing. If heat-reflection is desired, the composition additionally contains about 1-3% aluminum paste and about 0.1-1.0% ethylene oxide. The coating composition is exemplified as follows:
EXAMPLE 1
1408 oz. non-skid acrylic polymer emulsion (RHOPLEX K-14, Rohm & Haas)
896 oz. binder (POLYCRIL G-9, Polymer Indus.)
20 oz. thickener (ACRYSOL ASE-60, Rohm & Haas)
20 oz. ammonia
20 oz. urea
30 oz. propylene glycol
40 oz. aluminum leafing paste (#2462, Alcan Co.)
8 oz. ethylene oxide
15 oz. anti-foaming agent (#50601, Inmont)
up to 20 gal. water
The components were mixed at 3600 RPM at room temperature for about seven minutes then applied to a bolt of 100% cotton by a rotary screen printer. The coated fabric was immediately dried in a gas dryer operating at 350° F. at a feed rate of 22 yards per minute. Both temperature and feed rate may be varied to suit the requirements of the particular composition.
I have found that twenty gallons of the composition according to Example 1 is sufficient to finish about 400 yards of fabric to a thickness adequate to provide the anti-skid characteristics which I seek. Glycerine may be substituted for propylene glycol in Example 1.
While the coating composition may be applied to coat the entire surface of the ironing board cover, the non-skid coating may advantageously be restricted to a border area extending around the periphery of the ironing surface. Where it is desired to produce an ironing board cover with an artistic border design, the non-skid composition is mixed with coloring materials and applied by rotary screen printer or other printing means to form a non-skid border design. Additional thickening agents are used to make a print paste. Compositions for this purpose, sufficient to finish 550 yards of fabric with an artistic floral border design, were prepared as follows:
EXAMPLE 2
704 oz. RHOPLEX K-14
256 oz. POLYCRIL G-9
10 oz. ASE-60
10 oz. ammonia
10 oz. urea
15 oz. propylene glycol
21.5 oz. pigments
4 oz. Hif Carrier (#59242, Inmont)
up to 10 gal. water
EXAMPLE 3
832 oz. RHOPLEX K-14
256 oz. POLYCRIL G-9
14 oz. ASE-60
14 oz. ammonia
14 oz. urea
20 oz. propylene glycol
21.5 oz. pigments
4 oz. Hif Carrier (#59242, Inmont)
up to 10 gal. water
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | A cover for an ironing board or pressing machine is provided with non-skid characteristics to prevent articles being ironed from sliding under the influence of gravity. The non-skid surface, which extends at least over a portion of the ironing surface, is preferably formed from an acrylic polymer stable at normal ironing temperatures. The coating may be applied as a composition containing the following ingredients by volume: about 50-95% of an aqueous acrylic emulsion, about 0.5-3% thickener, about 0.5-2% of a thickener activator, about 0.5-5% humectant, and water. | 3 |
PRIORITY APPLICATION
[0001] This application is a divisional application of U.S. application Ser. No. 11/972,209, filed Jan. 10, 2008, now issued as U.S. Pat. No. ______, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] Embodiments of this invention relate to, for example, asymmetric signaling over a parallel data bus, which can improve data reception reliability.
BACKGROUND
[0003] Circuit designers of multi-Gigabit systems face a number of challenges as advances in technology mandate increased performance in high-speed components and systems. At a basic level, data transmission between components within a single semiconductor device, or between two devices on a printed circuit board, may be represented by the system 10 shown in FIG. 1A . (Accordingly, as used herein, a “device” can refer to a discrete device, such as a microprocessor or memory controller, or a component of a device, such as an integrated circuit or a functional block, for example). In FIG. 1A , data is transferred (e.g., forwarded, returned, transmitted, sent, and/or received) between a first device 12 and a second device 14 along (e.g., across, carried by, over, on, through and/or via) channels 16 (e.g., copper traces on a printed circuit board or “on-chip” in a semiconductor device). A standard interconnect approach is shown, in which each channel 16 carries a particular bit (D 0 , D 1 , etc.) in the parallel stream of data being transmitted. (This is sometimes known in the industry as a “single-ended” approach). Because either device 12 or 14 may act as the transmitter or receiver of data at any point in time, each channel 16 in each device contains both a transmitter (tx) and a receiver (rx), each operating in accordance with a clock signal, Clk. This clock signal, Clk, can comprise a forwarded clock which, as its name suggests, is forwarded on its own channel 16 from the transmitting device to the receiving device so as to synchronize with the transmitted data. Alternatively, the clock, if not transmitted on its own channel, may be derived at the receiving device via clock data recovery (CDR) techniques, which are well known in the art and well understood by those of skill in the art. A differential clock could also be used in which true clock and complement clock are sent over two channels, which can be useful to minimize clock jitter, as is well known.
[0004] A typical receiver circuit used in conjunction with the standard interconnect approach of FIG. 1A is shown in FIG. 1B . The receiver circuit comprises an amplifier stage 20 whose output is coupled to a latch 22 , which as illustrated comprises cross-coupled NAND gates. The input to the amplifier stage 20 comprises the data as received (DataIn), which is compared to a reference voltage (Vref), which is typically a midpoint voltage of one-half of the receiving device's power supply (i.e., ½Vdd). When enabled by the clock, Clk, the amplifier stage resolves and amplifies the difference between the received data, DataIn, and the reference voltage, Vref, as is well known.
[0005] Another approach used to transmit data via a parallel bus is a differential interconnect approach, which is illustrated in FIG. 2A . In this approach, a given bit (D 0 , D 1 , etc.) is always transmitted along with its complement (D 0 #, D 1 #, etc.). As a result, a pair of channels 16 must be dedicated to each bit, one channel carrying true data, and the other, its complement. To accommodate this architecture, a transmitter circuit and receiver circuit are shared between each pair of channels, as shown. The receiver circuit used in the differential interconnect approach is shown in FIG. 2B , and is essentially the same as that illustrated in FIG. 1B , except that the complementary data state (DataIn#) is used in lieu of the reference voltage, Vref.
[0006] The differential interconnect approach of FIG. 2 has the effect of making data resolution more reliable when compared to the standard interconnect approach of FIG. 1 . Such increased reliability results from at least three effects. First, because the receiver circuitry ( FIG. 2B ) uses complementary inputs, the voltage margin of the amplifier stage 20 is increased, which leads to faster, more reliable resolution of the data state by the receiver circuitry. Second, because true data is always transmitted along with its complementary data, cross talk-by which one channel perturbs data on an adjacent channel 16 in the bus-is minimized. Third, a non-differential signal is more susceptible to simultaneous switching output (SSO) noise generated at both the transmitters and receivers. Furthermore, in addition to the increased SSO rejection capability of differential interconnects, the very nature of the typical differential driver minimizes the generation of SSO.
[0007] However, increased sensing reliability in the differential interconnect approach comes at an obvious price, namely the doubling of the number of channels 16 needed to complete the parallel bus. To offset this, and keep the number of channels 16 constant, the clock, Clk, used in the differential interconnect approach is generally faster than would be used in the standard interconnect approach. Indeed, if the clock used is twice as fast, it will be appreciated that the number of bits transmitted per channel 16 , i.e., the data capacity, is equivalent between the two approaches. Fortunately, increased sensing capability in the differential interconnect approach allows for higher clock speed to be used effectively, and clock speed even higher than double speed could be used.
[0008] As well as providing for both standard and differential interconnect approaches, the prior art also provides for data to be received with “multiphase, fractional-rate receivers,” such as is shown in FIGS. 3A , 3 B, and 4 . FIG. 3A , for example, shows multiphase, fractional-rate receivers used in the standard interconnect approach. Suppose four sequential bits of data (e.g., Da, Db, Dc, Dd) are transmitted across a given channel (e.g., 16 3 ) on both the rising and falling edge of a clock, Clk, in what would be known as a Double Data Rate (DDR) application. Each of these four bits is captured at its own receiver (rx) by one of a plurality of phase-shifted, fractional-rate clocks. Because four bits are to be sensed in this example, four clocks of four distinct phases, Clk(a), Clk(b), Clk(c), and Clk(d) are used to sense data Da, Db, Dc, and Dd at each of the receivers.
[0009] As shown in FIG. 3B , the phase-shifted, fractional-rate clocks Clk(x) are typically generated from the master clock, Clk, using known techniques. Each generated phase-shifted, fractional-rate clock, Clk(x), is a fraction of the frequency of the master clock, e.g., a quarter-rate or half-rate clock. Data capture at the receivers can occur on both the rising and falling edges of each clock, or on either the rising edge or falling edges of each clock. For example, and assuming that four receivers are used to sample the four bits, either a quarter-rate clock which samples on rising and falling edges ( 18 a ) or a half-rate clock which samples on the rising edges only ( 18 b ) can be used. However, the number of fractional-rate receivers can be varied to the same effect. Thus, eight quarter-rate clocks combined with eight fractional-rate receivers could be used to sample the data only on rising edges ( 18 c ), or two half-rate clocks used with two fractional-rate receivers could be used to sample the data on rising and falling edges ( 18 d ).
[0010] Multiphase, fractional-rate clocks at the receiver are useful in situations where data can be transmitted at a rate faster than the receiver can resolve the data state. For example, when a quarter-rate clock is used, the receiver essentially has four times longer to properly resolve the data state, which is beneficial because it can take significant time for the amplifier stage 20 in the receiver ( FIG. 1B , 2 B) to amplify and resolve the data state. Fractional-rate clocks at the receiver can also be used in differential interconnect approaches, such as is illustrated in FIG. 4 . As the operation of FIG. 4 should be apparent by extension from the foregoing explanations, it is not further discussed.
[0011] While any of the above approaches can be used in the transmission of data through a parallel bus, the use of any one approach may not be optimal, a point discussed further below. This disclosure presents a more optimal solution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A and 1B illustrate a standard interconnection approach for transmitting signals between two devices along a parallel bus.
[0013] FIGS. 2A and 2B illustrate a differential interconnection approach for transmitting signals between two devices along a parallel bus.
[0014] FIG. 3A , 3 B, and 4 illustrate the standard and differential interconnection approaches extended to include the use of multiphase, fractional-rate receivers.
[0015] FIG. 5 illustrates a situation in which the disclosed asymmetric interconnection approach is particularly useful, such as when the devices involved are capable of different bandwidths.
[0016] FIGS. 6A and 6B illustrate an embodiment of the asymmetric interconnection approach of the invention in which data is transmitted in standard fashion in one direction and in differential fashion in another direction.
[0017] FIG. 7 illustrates an alternative embodiment of the asymmetric interconnection approach in which the number of fractional-rate receivers has been varied.
[0018] FIG. 8 illustrates an alternative embodiment in which asymmetric communications occur across two unidirectional busses.
DETAILED DESCRIPTION
[0019] Consider a standard interconnect approach ( FIG. 1A ) in which data reception reliability at 5 Gigabits per second (Gb/s) is proving problematic. In a
[0020] DDR application, in which data is triggered on rising and falling edges, this would comprise a clock speed of 2.5 GHz. One may wish to substitute the differential interconnect approach ( FIG. 2A ) to try and increase reliability as described earlier. However, as also described earlier, data capacity can only be preserved using the differential interconnect approach if a higher clock speed (i.e., at least double) is used.
[0021] Unfortunately, the use of a higher clock speed is not always possible. For example, consider FIG. 5 , which depicts two devices 12 and 14 connected by channels 16 in a parallel bus, as illustrated earlier. Due to differences in the design and processing of the devices 12 and 14 , the circuitry used in those devices may tolerate different maximum operating speeds. For example, assume that device 12 comprises a microprocessor or a memory controller, and assume that device 14 comprises a Synchronous Dynamic Random Access Memory (SDRAM). Because the processes used in the formation of the SDRAM 14 may be optimized to promote cell array operation (e.g., data retention), the transistors used to form the transition and reception circuitry may be non-optimal for high-speed applications. As a result, the maximum frequency of such circuitry, f(max), may be 4 GHz, for example. If so, a differential interconnect approach using a double-speed clock cannot be used, because this would require a 5 GHz clock, a value exceeding the maximum frequency, f(max)=4 GHz, of which the device 14 is capable. This limitation on clock speed can be unfortunate, especially when the process used to form the microprocessor or memory controller (hereinafter, “controller”) 12 is generally optimized for higher operating speeds. For example, f(max) for the controller 12 might equal 7 GHz. If so, the controller 12 could participate in a 5 GHz differential interconnect approach, while the SDRAM 14 could not. Accordingly, the system depicted in FIG. 5 would be restricted to the standard interconnect approach, even though the controller 12 is capable of operating at higher frequencies.
[0022] To solve this problem, asymmetric signaling over the parallel bus of channels 16 can be used. For example, the channels 16 in the parallel bus can operate as standard interconnects for data travelling in one direction through the bus, and operate as differential interconnects for data travelling in the other direction through the bus. So that data capacity of the bus remains the same in both directions, the data rate during differential transmission can be twice that of the data rate during standard transmissions.
[0023] One embodiment of this approach is shown in FIG. 6A . Shown are two channels 16 0 and 16 1 which, as just noted, can either carry standard or differential data, and which otherwise comprise just two of the channels in a bus comprised of a plurality of channels. Continuing with the above example, controller 12 is assumed to have a maximum operating frequency of 7 GHz, while SDRAM 12 is assumed to have a maximum operating frequency of 4 GHz. As illustrated, data transmission from the controller 12 to the SDRAM 14 occurs differentially at 10 Gb/s, while transmission from the SDRAM 14 to the controller 12 occurs non-differentially at 5 Gb/s. This is illustrated further in the timing diagram of FIG. 6B . As shown at top, transmission from the SDRAM 14 occurs in accordance with a standard interconnect approach, in which only true data is sent on the channels 16 0 and 16 1 . By contrast, at bottom, which depicts transmission from the controller 12 , true data and its complements are sent in parallel and at twice the rate. Although channel 16 1 is shown as being dedicated to the complementary data, such data could also appear on channel 16 0 , or on both channels in an interleaved fashion. In any event, the data capacity in both directions remains the same across the channels 16 that comprise the bus. Once again, the clock, Clk, can be forwarded, generated by CDR, or differential as noted earlier.
[0024] Example transmission and reception circuitry for achieving the timings of FIG. 6B is illustrated in FIG. 6A . As shown, the flow of data from the SDRAM 14 to the controller 12 employs standard interconnect approach hardware, with a transmitter (tx) and receiver (rx) being dedicated to each channel. Because as assumed data is to be transmitted at a rate of 5 Gb/s, clocks of 2.5 GHz are used in both the SDRAM's transmitters and the controller's receivers. However, multiphase, fractional-rate receivers could also be used in the controller 12 as well, which could drop the frequency of the clocks used as discussed previously with respect to FIG. 3B .
[0025] By contrast, the flow of data from the controller 12 to the SDRAM 14 employs a differential interconnect approach. Transmission starts by presentation of complementary data at a multiplexer 25 . The multiplexer 25 is clocked by a 5 GHz clock, to pass either odd or even differential data to the differential transmitter, tx, in the controller 12 . When the multiplexer clock is high, D 0 tx and D 0 tx # are sent to the transmitter, followed by D 1 tx and D 1 tx # when low, followed by D 2 tx and D 2 tx # when high again, etc. The effect is that true and complementary data are sent on each channel 16 0 and 16 1 at a rate of 10 Gb/s.
[0026] Stated another way, and assuming N channels are present, N data bits are transferred in parallel along the N channels from the SDRAM 14 to the controller 12 at 5 Gb/s, while N/2 data bits and their complements are transferred from the controller 12 to the SDRAM 14 at 10 Gb/s.
[0027] Reception of this data at the SDRAM is made using differential multiphase, fractional-rate receivers, such as was discussed with respect to FIGS. 3A , 3 B, and 4 earlier. As before, four receivers are used, each clocked by phase-shifted, fractional-rate clocks, Clk(x). To appropriately sample the incoming data at 10 Gb/s, and assuming that sampling at the receivers occurs on rising and falling edges of the clock, a clock of frequency 1.25 GHz is used (see, e.g., 18 a of FIG. 3B ). However, if the clocks only sample data on their rising edges, clocks of 2.5 GHz could be used ( 18 b of FIG. 3B ). Although not shown in FIG. 6A , if eight receivers are used, eight clocks, each at 1.25 GHz, but sampling on only rising or falling edges ( 18 c of FIG. 3B ), could be used. Or, if two receivers are used, two clocks, each at 2.5 GHz, but sampling on both rising or falling edges ( 18 d of FIG. 3B ), could be used. These are just some examples of the various clocks and multiphase, fractional-rate receiver arrangements that could be used. Furthermore, and regardless of the sampling approach chosen, if a differential clock is used, the need to specifically generate a 180-degree phase shifted clock is unnecessary because it is already present, which can simplify clock generation.
[0028] The depicted example of FIG. 6A assumes a DDR approach in which data is sampled on the rising and falling edges of the master clock, Clk. However, it should be understood that the asymmetric interconnect approach of the invention is equally applicable to non-DDR approaches in which data is sampled on either the rising or falling edges of the master clock. In other words, the invention is not limited to DDR, DDR 2 , DDR 3 , etc. implementations.
[0029] FIG. 7 shows alternative circuitry for implementing the asymmetric interconnect approach of the invention, and in this example only two fractional-rate receivers are used in the SDRAM 14 . So implemented, the two receiver clocks, Clk(a) and Clk(b), can operate at 2.5 GHz to sample the 10 Gb/s coming from each of the channels 16 0 and 16 1 , assuming that sampling occurs on both the rising and falling edges of the clocks (see 18 d, FIG. 3B ). While sampling could theoretically also occur using only the rising edges of the clocks as was discussed with reference to FIG. 6A , this would require 5 GHz clocks in the depicted example, which exceeds the maximum operating frequency (f(max)=4 GHz) assumed for the SDRAM 14 . The point illustrated by this example is that while many different clocking schemes can be used at the multiphase, fractional-rate receiver in accordance with the invention, care should be taken to ensure that no clock is faster than that permissible for the SDRAM 14 .
[0030] Regardless of the specific implementation chosen, the asymmetric interconnect approach should enhance the reliability of data transfer. As noted earlier, non-differential data transferred down standard interconnects can be susceptible to noise and crosstalk, and can suffer from poorer voltage margins at the receiver. In the embodiment discussed above, such standard reception occurs at the controller 12 , which, by virtue of its higher quality transistors, is better able to handle and accurately resolve the transferred data; by contrast, the SDRAM 14 enjoys more reliable differential reception, which helps it to overcome the non-optimal nature of its reception circuitry. Moreover, these benefits can be established without exceeding the maximum operating frequencies, f(max) of either of the devices 12 or 14 . Transmission from the SDRAM 14 to the controller occurs at 2.5 GHz, which does not exceed the maximum permissible frequency for either device. Transmission from the controller 12 occurs at a higher speed of 5 GHz, which is acceptable for that device, but sensing occurs at either 1.25 GHz or 2.5 GHz at the SDRAM 14 , as assisted by the use of multiphase, fractional-rate receivers, which again is acceptable.
[0031] Although the disclosed asymmetric interconnect technique has been illustrated in the context of a system comprising a controller 12 and an SDRAM 14 , it will be understood, by one skilled in the art, that the invention can be used with, and can benefit the communications between, any two integrated circuits or functional blocks, and is particularly useful in the situation where the two circuits have differing bandwidths, as has been illustrated.
[0032] Embodiments of the invention can also be employed in busses employing uni-directional signaling. In the embodiments shown to this point, each of the channels 16 in the bus have been bi-directional, i.e., they carry data from the controller 12 to the SDRAM 14 and vice versa. However, some high performance systems may employ unidirectional busses 50 and 51 between the two devices in the system, with each bus 50 , 51 carrying data in only one direction, as shown in FIG. 8 . As shown, bus 50 carries data from the controller to the SDRAM 14 , while bus 51 carries data from the SDRAM 14 to the controller 12 . In accordance with one or more embodiments of the invention, the data along the two busses are handled asymmetrically, with bus 50 carrying differential data, and bus 51 carrying non-differential data. Through this arrangement, each channel is coupled to only at least one receiver, or at least one transmitter on each device, but not both, and so data reception and transmission are decoupled at each of the devices 12 , 14 . When communications of the busses are implemented asymmetrically, the same benefits highlighted with respect to FIG. 6A should be achievable. Additionally, uni-directional signaling is advantageous in that each uni-directional channel is only loaded with a single transmitter and receiver at the respective ends of the channel as already mentioned, which reduces circuit-based parasitic loading of the channel and improves speed.
[0033] Further, note that it is not strictly required that the invention be used with integrated circuits coupled by interconnect channels, such as by a PCB. Instead, the invention can be used in communications between any two circuits which may be discrete or integrated on a common piece of semiconductor.
[0034] It should also be recognized that a “bit” of information need not be strictly binary in nature (i.e., only a logic ‘1’ or logic ‘0’), but could also comprise other values (e.g., logic ‘½’) or types of digits as well.
[0035] It should be understood that the disclosed techniques can be implemented in many different ways to the same useful ends as described herein. In short, it should be understood that the inventive concepts disclosed herein are capable of many modifications. To the extent such modifications fall within the scope of the appended claims and their equivalents, they are intended to be covered by this patent. | Methods and apparatus to transfer data between a first device and a second device, is disclosed. An apparatus according to various embodiments may comprise a first device and a second device. The first device may comprise at least one first non-differential transmitter coupled to a first channel, at least one second non-differential transmitter coupled to a second channel, and at least one differential receiver to receive a data bit and its complement on the first and second channels in parallel. The second device may comprise at least one first non-differential receiver coupled to the first channel, at least one second non-differential receiver coupled to the second channel, and at least one differential transmitter to transmit a data bit and its complement on the first and second channels in parallel. | 6 |
TECHNICAL FIELD
[0001] This patent application relates to a solderable contact for an electrical component, which is used to solder the component to form an electrical connection. This patent application also describes a solderable contact for a component which has an aluminum-comprising metallization. Because aluminum cannot be soldered directly, an additional solderable coating is required on the aluminum metallization.
BACKGROUND
[0002] Solderable contacts are used, for example, for SMD components (surface mounted components) or for components mounted in a flip-chip arrangement. In the flip-chip arrangement, a chip having component structures on its surface is soldered using bumps made of solder on a carrier substrate. This has the advantage that the expense for contacting is low, that, apart from the space required for the chip on the carrier substrate, no additional surface is required for the contacting, and that the component structures are protected by the arrangement between the chip and the carrier substrate.
[0003] SAW components, which can be used, for example, as filters in cell phones, are subject, as are cell phones, to an ever-increasing demand for miniaturization. With the help of a flip-chip arrangement, SAW components can be encapsulated in a simple way by CSS plus technology developed by the applicant, in such a way that the chip size in practice determines the component size directly, and thus the CSSP package (chip sized SAW package) is produced. A possible example of such a CSS plus packaging is provided, for example, from WO03/058812.
[0004] As a result of the increasing miniaturization, it is necessary to save as much space as possible on the chip surface and to reduce the surface area of all the component structures on the surface. This has the consequence that, for example, the solderable contacts as well, and the under bump metallizations (UBM) have to become smaller. In modern components for the 9 GHz range, the UBMs have, for example, only a diameter of approximately 90 μm. However, it has been found that with these small bump diameters, the mechanical stability of the soldering sites suffers, and there is an increased risk that the soldering sites will tear loose, and thus that the component will be damaged.
SUMMARY
[0005] Described herein is a way to improve the mechanical strength of miniaturized soldering sites.
[0006] In a series of tear-off tests, the inventors have found that the problem of the deficient mechanical strength of the soldering sites does not reside in the bump itself, instead it is caused by the metallization used for the solderable contact. Tear-offs can occur particularly at the boundary surface between the UBM metallization and the underlying pad metallization.
[0007] With the solderable contact described herein, the mechanical strength of the blimp connection can be improved. This is achieved by structuring the pad metallization under the UBM metallization in such a way that the UBM metallization can lie partially on the surface of the substrate. This has the advantage that the mechanical strength is achieved both by the connection of the UBM metallization and the substrate surface, and, also, by the connection of the UBM metallization and the pad metallization. An additional advantage is that by structuring the pad metallization, the surface area on the interface is increased, which also increases the adhesion to the pad/UBM boundary surface. Moreover, mutual bracing of the structures occurs, which also increases the rigidity.
[0008] An improvement is achieved if, below the UBM metallization, a part of the pad metallization is removed, so that the UBM can lie directly on the substrate surface. However, it is advantageous if the structuring of the pad metallization is carried out in such a way that a repeatedly alternating structure is obtained, by which the interface with the UBM can be increased further.
[0009] An advantageous structuring of the pad metallization can occur in the form of a pattern having several parallel strips, between which the surface of the substrate is uncovered, or in which the superposed UBM metallization can come in contact with the chip surface. The parallel strips can be connected to each other via connection strips which run transversely to the latter surface, to improve the electrical parameters for the soldered contact.
[0010] The UBM metallization can have a multilayered structure, which has on the surface at least a layer which is wettable with solder, and, in the interior, a diffusion barrier layer. Gold is suited for the layer that is wettable with solder. It is also possible to use nickel for this layer. The diffusion barrier layer is usually a noble metal, such as one with high density, like platinum.
[0011] Another improvement of the strength in the soldering contact is achieved by using, as the lowest layer of the UBM metallization, an adhesion-promoting layer, which improves the adhesion of the UBM metallization on the substrate surface. For SAW components manufactured from lithium tantalate chips, the use of adhesion-promoting layers made of titanium is known. A solderable contact with a titanium-comprising adhesion-promoting layer directly above the structured pad metallization improves the mechanical strength of the solderable contact further.
[0012] A pad metallization can comprise, between the adhesion-promoting layer and the wettable surface, one or more additional layers, which can be generated for stress compensation particularly during or after thermal stressing of the component, and particularly of the bump connection on the solderable contact. Mechanical-thermal stresses can be compensated by such layers.
[0013] The pad metallization is structured exclusively under the UBM metallization and continuously metallized in the remaining parts. Although the desired miniaturization also requires reducing the size of the surface area occupied by the pad metallization, it [i.e. the area of the pad metallization] is usually still greater than the UBM metallization, particularly if the pad metallization is configured in a rectangular shape, while the UBM metallization, in contrast, is round or oval, corresponding to the desired bump cross section. The pad metallization then has a round or oval structured area, on which the UBM metallization lies.
[0014] The pad metallization itself can be configured in a known conventional design. A standard metallization has, for example, a layer of aluminum or an aluminum-containing alloy, and can be configured as a single layer. In the multilayered embodiment, the pad metallization can also contain additional layers, in addition to such a layer, and particularly layers which are harder than aluminum, particularly copper layers. A structure for a pad metallization may have, for example, an aluminum/copper/aluminum layer sequence. In addition, it is, of course, also possible for adhesion-promoting layers, particularly those made of titanium, to be provided under the pad metallization.
[0015] Embodiments will be explained in detail below with reference to associated figures. The figures are intended only for illustration and therefore they are merely schematic and not true to scale. Identical parts, or parts with the same function, bear the same reference numerals.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a solderable contact on a substrate,
[0017] FIG. 2 shows a structured pad metallization in the top view,
[0018] FIG. 3 shows different process steps in the manufacture of a solderable contact,
[0019] FIG. 4 shows a layered structure for a UBM metallization in a schematic cross section, and
[0020] FIG. 5 shows an additional layered structure for a UBM metallization.
DETAILED DESCRIPTION
[0021] FIG. 1 shows a solderable contact on a substrate in a schematic cross section ( FIG. 1 a ) or in top view ( FIG. 1 b ). The solderable contact, which is applied on the substrate SU, such as a semiconductor substrate or a piezoelectric substrate, comprises a pad metallization PM which is applied directly on the substrate, and a UBM metallization UBM which is applied on the pad metallization. The pad metallization PM has a structured area SB, which is structured with elevations EH and recesses AN, with the surface of the substrate SU uncovered in the recesses AN. The pad metallization is a conventional metallization, as also used for the manufacture of electrically conductive structures on the surface of components, and as produced particularly together with these electrically conductive structures, which may be the same structure. The UBM metallization is applied at least in the structured area SB, and comes in contact in the recesses AN with the surface of the substrate SU. It is also possible for the UBM metallization to have a smaller surface area, or a larger surface area than the structured area SB.
[0022] FIG. 1 b shows the solderable contact in a top view. The pad metallization is a flat metallization, which can be connected via a supply line ZL, shown only in sections, to electrically conductive structures of a component. It is also possible for the electrical contacting of the pad metallization PM with active component structures to occur from below through the substrate, so that the electrical connection of the pad metallization occurs, for example, by plated through-hole through the substrate, or at least through an upper substrate layer. The UBM metallization covers the structured area SB completely in the depicted embodiment.
[0023] FIG. 2 shows possible structures of the pad metallization PM in the top view, where, in FIG. 2 a a smaller number of structures is represented, and, in FIG. 2 b a higher metallization density is represented, i.e., a higher portion of the surface within the structured area SB is covered by pad metallization. In both cases, the structuring of the pad metallization includes a row of parallel strip-shaped recesses AN, which are separated from each other by a corresponding striped pattern SM of metallization (elevations). A connection strip VS, which connects the striped pattern SM, runs diagonally to the striped pattern, where the connecting strip VS, as show, can have a slightly greater width than the striped pattern SM. The striped pattern here is connected by all its external ends to the remaining pad metallization PM in an electrically conductive connection, so that as a result the electrical series resistance of the soldered contact is kept low.
[0024] The surface portion of the pad metallization in the structured area SB is a function of the desired electrical values and the electrical contact required for that purpose, from the striped pattern SM, the connection strips VS, and the UBM metallization located above the latter, but not shown in the figure. If a larger portion of metal surface is required, then either the density of the striped pattern SM or the number of the individual strips is increased, as represented, for example, in FIG. 2 b.
[0025] However, any structuring in the structured area SB is possible. The represented structuring types, however, have the advantage that they can be structured in a simple manner with a stepper, for example, by structuring a lift-off lacquer and by carrying out a lift-off technique. A resulting additional advantage is that the straight structures chosen for the striped pattern SM can be structured by a lift-off technique. Above such structures, the lift-off layer with the area of the metallization located above it can be lifted. The metallization thickness and the type of the pattern are chosen as a function of the diameter of the UBM, where, as the UBM decreases, a higher metallization portion can be advantageous. However, for reasons pertaining to a simpler type of structuring, this cannot be achieved by additional strips in the striped pattern. Instead it is achieved by broader strips. Above the connection strips VS, a better electrical contact is established between all the strips of the striped pattern, which reduces the electrical resistance, and leads to a better electrical contact between the pad metallization and the UBM.
[0026] FIG. 3 shows the manufacture of a solderable contact in schematic cross sections.
[0027] First, a layer of a lift-off lacquer is applied onto to the surface of a substrate SU, over the entire surface, and structured to form a first lift-off mask AM 1 . The structuring is carried out in such a way that, in the areas intended for the metallization, the surface of the substrate SU is uncovered.
[0028] Next, a layer PMS for the pad metallization is applied over the first lift-off mask AM 1 , over the entire surface. The pad metallization can also comprise several layers, and therefore be applied in several successive steps. The individual layers may be applied by vapor deposition. FIG. 3 b shows the arrangement.
[0029] FIG. 3 c shows the finished pad metallization PM, which is produced by the lift-off of the first lift-off mask AM 1 together with the portions of the metal layer PMS applied on top of it, for the pad metallization. In the central area, the pad metallization PM has a structuring comprising elevations EH and recesses AN.
[0030] Next, a second lift-off mask AM 2 is produced by the application to the entire surface, and by the structuring, of a peel layer. In the area of the UBM metallization, the lift-off layer is removed. FIG. 3 d shows the arrangement.
[0031] FIG. 3 e shows the arrangement after the application to the entire surface of a UBMS layer for the UBM metallization.
[0032] FIG. 3 f : next, the lift-off peel mask AM 2 together with the portion of the metal layer UBMS lying over it, for the UBM metallization, is peeled off, whereby the finished solderable contact is produced.
[0033] The UBM metallization as well is constructed from several layers. FIG. 4 shows a possible layer structure for the UBM metallization UBM. As the lowermost layer, which adheres well to the substrate SU, an adhesion-promoting layer HS 1 may be used. The uppermost layer of the UBM metallization is a layer BS which can be wetted by solder, while a diffusion barrier layer DB, arranged therebetween, prevents undesired diffusion of metals in or under the contact, and particularly into the substrate SU. Diffusion can occur out of the wettable layer BS or out of an alloy of the solder and the material of the wetting layer BS, which alloy is produced by the soldering process.
[0034] For a UBM metallization that is to be applied to piezoelectric material and particularly to substrates made of lithium tantalate, a suitable layer structure, which is mentioned only as an example, includes a first adhesion-promoting layer HS 1 comprised of 100 nm titanium, a diffusion barrier layer DB comprised of 200 nm platinum, and a wetting layer BS comprised of 100 nm gold. For other substrates, other materials can also be chosen for the adhesion-promoting layer. Other heavy metals are suitable for the diffusion barrier. For the wetting layer BS, gold may be used as the solution, however, it can be replaced by nickel, if the UBM is processed rapidly or soldered rapidly.
[0035] FIG. 5 shows an additional exemplary embodiment for a UBM metallization, which includes a second adhesion-promoting layer HS 2 , a stress compensation layer SK, a first adhesion-promoting layer HS 1 , as well as the diffusion barrier layer DB and the wetting layer BS. The stress compensation layer SK can serve to receive and compensate for a large portion of the stresses that occur during the production of a soldering site on the UBM, and particularly during the soldering of the component to, for example, a carrier. This is achieved by an appropriately high layer density and by appropriate selection of the metal for the stress compensation layer via its E modulus and its thermal expansion coefficients. A UBM metallization that is suitable for a UBM on lithium tantalate substrates comprises, for example, 30 nm titanium as second adhesion-promoting layer HS 2 , 400 nm aluminum as stress compensation layer SK, 100 nm titanium as first adhesion-promoting layer at HS 1 , 200 nm platinum as diffusion barrier layer DB, as well as 100 nm gold as wetting layer BS.
[0036] The solderable contact described herein is suited for components whose electrically conductive component structures are arranged on the surface of a substrate, and produced and structured together with the pads. The solderable contact is therefore advantageous for components that operate with acoustic waves, particularly for components that operate with surface acoustic waves, SAW components, or FBAR resonators that operate with bulk waves. However, with the indicated solderable contact, as well as with all other substrate materials, an improved adhesion of the contact to the substrate is achieved, as is an improved composite material made from the pad metallization and the UBM metallization, which leads to an improved soldering site by which the solderable contact is connected electrically and mechanically to an external environment. As a result, the reliability of the corresponding component and thus its useful lifetime are also increased.
[0037] The claims are not limited to the indicated examples. In particular, with regard to the materials used, the structures indicated, and the corresponding layer thicknesses, many variations are possible within the scope of the claims, not all of which, however, are described in detail here. | A solderable contact for use with an electrical component includes a pad metallization on a substrate, and an under bump metallization over at least part of the pad metallization. The under bump metallization is in an area for receiving solder. The pad metallization is structured to reveal parts of the substrate surface. The under bump metallization is in direct contact with the parts of the substrate. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit U.S. Provisional Application No. 61/777,941, filed Mar. 12, 2013, the content of which is incorporated herein by reference in its entirety and for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] This invention was made with government support under Grant No. 1U01NS074501-1 awarded by NIH/NINDS. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] Since all of the major Aβ peptide variants, including the pathogenic Aβ 42 as known in the art, are ultimately generated by gamma-secretase-mediated proteolysis of APP-C99 (i.e., the beta-secretase-mediated cleavage product of the amyloid protein precursor |APP|), one approach to therapeutic intervention (e.g., intervention in Alzheimer's Disease, AD) relates to lowering total Aβ peptide production by inhibiting the catalytic activity of gamma-secretase. However, gamma-secretase catalyzes the proteolysis of a large number of membrane proteins including the Notch receptor which yields the Notch intracellular domain (NICD), a peptide necessary for proper cellular differentiation and development. Nonetheless, many inhibitors of gamma-secretase activity, generally referred to as gamma-secretase inhibitors (GSIs), have been discovered, and some are being developed clinically. See e.g., Coric, V. et al., 2012 , Arch Neurol. 69:1430-1440.
[0004] Without wishing to be bound by theory, it is believed that GSIs have the liability of adverse events resulting from (at least in part) the inhibition of Notch proteolysis. See e.g., Wakabayashi T. & De Strooper, B., 2008, Physiology 23:194-204; Fleisher A. S., et al., 2008 , Arch Neurol. 65:1031-1038. In addition, gamma-secretase is now known to hydrolyze a rather large number of type I membrane proteins (Wakabayashi & De Strooper, 2008, Id.), implying participation in critical membrane protein degradation and signaling pathway(s). Therefore, inhibiting this enzymatic complex, which has been described as the “proteosome of the membrane” (Kopan, R. & Ilagan, M. X., 2004, Nat. Rev. Mal Cell. Biol. 5:486-488), may in fact be detrimental to an aged AD population with an already compromised neuronal catabolism. Thus, as is the case for other age-related degenerative disorders (e.g., cardiovascular disease), successful disease modifying therapeutic approaches will require long term administration, beginning early in the disease process and with either very tolerable or without side effects.
[0005] Recently, an approach utilized NSAID-like substrate-targeted GSMs (i.e., tarenflurbil) which have been shown to selectively inhibit Aβ 42 (at least in vitro); however, their poor potency combined with their inability to cross the blood brain barrier resulted in a lack of efficacy in the clinic. See e.g., Kukar, T. L., et al., 2008, Nature 453:925-929; Green, R. C., et al. 2009, J. Amer. Med. Asso. 302:2557-2564; see also Cheng, S., et al., 2007, U.S. Pat. No. 7,244,939; Kounnas, M. Z. et al., 2010 , Neuron 67:769-780. Assays useful in characterizing the GSMs and GSIs have been described previously. See e.g., Cheng, S., et al., 2007, Id.; Kounnas, M. Z. et al., 2010, Id.) Certain GSMs have been shown to be potent and efficacious in vivo for lowering the levels of Aβ 42 and Aβ 40 in both the plasma and brain of APP transgenic mice and chronic efficacy studies revealed dramatically attenuated AD-like pathology in the Tg2576 APP transgenic mouse model.
[0006] The poor aqueous solubilities of the earlier GSMs have hindered the necessary preclinical development required for an investigational new drug (IND) application. Thus, there remains a need in the art for safe and effective GSM's. The present application provides solutions to these problems.
BRIEF SUMMARY OF THE INVENTION
[0007] Provided herein, inter alia, are compounds (also referred to herein as soluble gamma-secretase modulators or SGSMs) that display a safer mechanistic approach since they do not actually inhibit gamma-secretase activity or prevent it from proteolyzing numerous other substrates. Also provided, inter alia, are SGSMs that offer an improved facility to achieve beneficial levels in the brain of a subject. In embodiments, the compounds disclosed herein display enhanced aqueous solubilities and contain improved pharmacokinetic and pharmacodynamic properties.
[0008] In a first aspect, there is provided a compound having the formula:
[0000]
[0009] For each of Formulae (I)-(IV), z1 is 0, 1 or 2. X 1 is C(R 3 ) or N. R 1 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CN, —CHO, —OR 1A , —NR 1A R 1B , —COOR 1A , —C(O)NR 1A R 1B , —NO 2 , —SR 1A , —S(O) n1 R 1A , —S(O) n1 NR 1A R 1B , —NHNR 1A R 1B , —ONR 1A R 1B , —NHC(O)NHNR 1A R 1B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 2 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 2A , —NR 2A R 2B , —COOR 2A , —C(O)NR 2A R 2B , —NO 2 , —SR 2A , —S(O) n2 R 2A , —S(O) n2 OR 2A , —S(O) n2 NR 2A R 2B , —NHNR 2A R 2B , —ONR 2A R 2B , —NHC(O)NHNR 2A R 2B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 3 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 NR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 4 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 4A , —NR 4A R 4B , —COOR 4A , —C(O)NR 4A R 4B , —NO 2 , —SR 4A , —S(O) n4 R 4A , —S(O) n4 OR 4A , —S(O) n4 NR 4A R 4B , —NHNR 4A R 4B , —ONR 4A R 4B , —NHC(O)NHNR 4A R 4B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 5 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 5A , —NR 5A R 5B , —COOR 5A , —C(O)NR 5A R 5B , —NO 2 , —SR 5A , —S(O) n5 R 5A , —S(O) n5 OR 5A , —S(O) n5 NR 5A R 5B , —NHNR 5A R 5B , —ONR 5A R 5B , —NHC(O)NHNR 5A R 5B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl, wherein R 4 and R 5 are optionally joined together to form a substituted or unsubstituted heterocycloalkyl, or substituted or unsubstituted heteroaryl. R 6 is —CF 3 , substituted or unsubstituted cyclopropyl, or substituted or unsubstituted cyclobutyl. R 7 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 7A , —NR 7A R 7B , —COOR 7A , —C(O)NR 7A R 7B , —NO 2 , —SR 7A , —S(O) n7 R 7A , —S(O) n7 OR 7A , —S(O) n7 NR 7A R 7B , —NHNR 7A R 7B , —ONR 7A R 7B , —NHC(O)NHNR 7A R 7B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A and R 7B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. The variables n1, n2, n3, n4, n5 and n7 are independently 1 or 2.
[0010] In another aspect, there is provided a pharmaceutical composition including a compound disclosed herein and a pharmaceutically acceptable carrier.
[0011] In another aspect, there is provided a use of a compound disclosed herein for inhibiting production of Aβ 42 or Aβ 40 by a protease which proteolyzes an amyloid precursor protein (APP) or fragment thereof.
[0012] In another aspect, there is provided use of a compound disclosed herein for treating a disease or neurological disorder associated with elevated levels of specific fibrillogenic Aβ peptides by inhibiting production of Aβ 42 or Aβ 40 .
DETAILED DESCRIPTION OF THE INVENTION
I. Definitions
[0013] The abbreviations used herein have their conventional meaning within the chemical and biological arts. The chemical structures and formulae set forth herein are constructed according to the standard rules of chemical valency known in the chemical arts.
[0014] Where substituent groups are specified by their conventional chemical formulae, written from left to right, they equally encompass the chemically identical substituents that would result from writing the structure from right to left, e.g., —CH 2 O— is equivalent to —OCH 2 —.
[0015] The term “alkyl,” by itself or as part of another substituent, means, unless otherwise stated, a straight (i.e., unbranched) or branched chain, or combination thereof, which may be fully saturated, mono- or polyunsaturated and can include di- and multivalent radicals, having the number of carbon atoms designated (i.e., C 1 -C 10 means one to ten carbons). Alkyl is an uncyclized chain. Examples of saturated hydrocarbon radicals include, but are not limited to, groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, isobutyl, sec-butyl, (cyclohexyl)methyl, homologs and isomers of, for example, n-pentyl, n-hexyl, n-heptyl, n-octyl, and the like. An unsaturated alkyl group is one having one or more double bonds or triple bonds. Examples of unsaturated alkyl groups include, but are not limited to, vinyl, 2-propenyl, crotyl, 2-isopentenyl, 2-(butadienyl), 2,4-pentadienyl, 3-(1,4-pentadienyl), ethynyl, 1- and 3-propynyl, 3-butynyl, and the higher homologs and isomers. An alkoxy is an alkyl attached to the remainder of the molecule via an oxygen linker (—O—).
[0016] The term “alkylene,” by itself or as part of another substituent, means, unless otherwise stated, a divalent radical derived from an alkyl, as exemplified, but not limited by, —CH 2 CH 2 CH 2 CH 2 —. Typically, an alkyl (or alkylene) group will have from 1 to 24 carbon atoms, with those groups having 10 or fewer carbon atoms being preferred in the present invention. A “lower alkyl” or “lower alkylene” is a shorter chain alkyl or alkylene group, generally having eight or fewer carbon atoms.
[0017] The term “heteroalkyl,” by itself or in combination with another term, means, unless otherwise stated, a stable straight or branched chain, or combinations thereof, consisting of at least one carbon atom and at least one heteroatom selected from the group consisting of O, N, P, Si, and S, and wherein the nitrogen and sulfur atoms may optionally be oxidized, and the nitrogen heteroatom may optionally be quaternized. The heteroatom(s) O, N, P, S, and Si may be placed at any interior position of the heteroalkyl group or at the position at which the alkyl group is attached to the remainder of the molecule. Heteroalkyl is an uncyclized chain. Examples include, but are not limited to: —CH 2 —CH 2 —O—CH 3 , —CH 2 —CH 2 —NH—CH 3 , —CH 2 —CH 2 —N(CH 3 )—CH 3 , —CH 2 —S—CH 2 —CH 3 , —CH 2 —CH 2 , —S(O)—CH 3 , —CH 2 —CH 2 —S(O) 2 —CH 3 , —Si(CH 3 ) 3 , —CH 2 —CH═N—OCH 3 , —CH═CH—N(CH 3 )—CH 3 , —O—CH 3 , —O—CH 2 —CH 3 , and —CN. Up to two heteroatoms may be consecutive, such as, for example, —CH 2 —NH—OCH 3 .
[0018] Similarly, the term “heteroalkylene,” by itself or as part of another substituent, means, unless otherwise stated, a divalent radical derived from heteroalkyl, as exemplified, but not limited by, —CH 2 —CH 2 —S—CH 2 —CH 2 — and —CH 2 —S—CH 2 —CH 2 —NH—CH 2 —. For heteroalkylene groups, heteroatoms can also occupy either or both of the chain termini (e.g., alkyleneoxy, alkylenedioxy, alkyleneamino, alkylenediamino, and the like). Still further, for alkylene and heteroalkylene linking groups, no orientation of the linking group is implied by the direction in which the formula of the linking group is written. For example, the formula —C(O) 2 R′— represents both —C(O) 2 R′— and —R′C(O) 2 —. As described above, heteroalkyl groups, as used herein, include those groups that are attached to the remainder of the molecule through a heteroatom, such as —C(O)R′, —C(O)NR′, —NR′R″, —OR′, —SR′, and/or —SO 2 R′. Where “heteroalkyl” is recited, followed by recitations of specific heteroalkyl groups, such as —NR′R″ or the like, it will be understood that the terms heteroalkyl and —NR′R″ are not redundant or mutually exclusive. Rather, the specific heteroalkyl groups are recited to add clarity. Thus, the term “heteroalkyl” should not be interpreted herein as excluding specific heteroalkyl groups, such as —NRR″ or the like.
[0019] The terms “cycloalkyl” and “heterocycloalkyl,” by themselves or in combination with other terms, mean, unless otherwise stated, cyclic versions of “alkyl” and “heteroalkyl,” respectively. Cycloalkyl and heterocycloalkyl are not aromatic. Additionally, for heterocycloalkyl, a heteroatom can occupy the position at which the heterocycle is attached to the remainder of the molecule. Examples of cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, 1-cyclohexenyl, 3-cyclohexenyl, cycloheptyl, and the like. Examples of heterocycloalkyl include, but are not limited to, 1-(1,2,5,6-tetrahydropyridyl), 1-piperidinyl, 2-piperidinyl, 3-piperidinyl, 4-morpholinyl, 3-morpholinyl, tetrahydrofuran-2-yl, tetrahydrofuran-3-yl, tetrahydrothien-2-yl, tetrahydrothien-3-yl, 1-piperazinyl, 2-piperazinyl, and the like. A “cycloalkylene” and a “heterocycloalkylene,” alone or as part of another substituent, means a divalent radical derived from a cycloalkyl and heterocycloalkyl, respectively.
[0020] The terms “halo” or “halogen,” by themselves or as part of another substituent, mean, unless otherwise stated, a fluorine, chlorine, bromine, or iodine atom. Additionally, terms such as “haloalkyl” are meant to include monohaloalkyl and polyhaloalkyl. For example, the term “halo(C 1 -C 4 )alkyl” includes, but is not limited to, fluoromethyl, difluoromethyl, trifluoromethyl, 2,2,2-trifluoroethyl, 4-chlorobutyl, 3-bromopropyl, and the like.
[0021] The term “acyl” means, unless otherwise stated, —C(O)R where R is a substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0022] The term “aryl” means, unless otherwise stated, a polyunsaturated, aromatic, hydrocarbon substituent, which can be a single ring or multiple rings (preferably from 1 to 3 rings) that are fused together (i.e., a fused ring aryl) or linked covalently. A fused ring aryl refers to multiple rings fused together wherein at least one of the fused rings is an aryl ring. The term “heteroaryl” refers to aryl groups (or rings) that contain at least one heteroatom such as N, O, or S, wherein the nitrogen and sulfur atoms are optionally oxidized, and the nitrogen atom(s) are optionally quaternized. Thus, the term “heteroaryl” includes fused ring heteroaryl groups (i.e., multiple rings fused together wherein at least one of the fused rings is a heteroaromatic ring). A 5,6-fused ring heteroarylene refers to two rings fused together, wherein one ring has 5 members and the other ring has 6 members, and wherein at least one ring is a heteroaryl ring. Likewise, a 6,6-fused ring heteroarylene refers to two rings fused together, wherein one ring has 6 members and the other ring has 6 members, and wherein at least one ring is a heteroaryl ring. And a 6,5-fused ring heteroarylene refers to two rings fused together, wherein one ring has 6 members and the other ring has 5 members, and wherein at least one ring is a heteroaryl ring. A heteroaryl group can be attached to the remainder of the molecule through a carbon or heteroatom. Non-limiting examples of aryl and heteroaryl groups include phenyl, 1-naphthyl, 2-naphthyl, 4-biphenyl, 1-pyrrolyl, 2-pyrrolyl, 3-pyrrolyl, 3-pyrazolyl, 2-imidazolyl, 4-imidazolyl, pyrazinyl, 2-oxazolyl, 4-oxazolyl, 2-phenyl-4-oxazolyl, 5-oxazolyl, 3-isoxazolyl, 4-isoxazolyl, 5-isoxazolyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, 2-furyl, 3-furyl, 2-thienyl, 3-thienyl, 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidyl, 4-pyrimidyl, 5-benzothiazolyl, purinyl, 2-benzimidazolyl, 5-indolyl, 1-isoquinolyl, 5-isoquinolyl, 2-quinoxalinyl, 5-quinoxalinyl, 3-quinolyl, and 6-quinolyl. Substituents for each of the above noted aryl and heteroaryl ring systems are selected from the group of acceptable substituents described below. An “arylene” and a “heteroarylene,” alone or as part of another substituent, mean a divalent radical derived from an aryl and heteroaryl, respectively. Non-limiting examples of aryl and heteroaryl groups include pyridinyl, pyrimidinyl, thiophenyl, thienyl, furanyl, indolyl, benzoxadiazolyl, benzodioxolyl, benzodioxanyl, thianaphthanyl, pyrrolopyridinyl, indazolyl, quinolinyl, quinoxalinyl, pyridopyrazinyl, quinazolinonyl, benzoisoxazolyl, imidazopyridinyl, benzofuranyl, benzothienyl, benzothiophenyl, phenyl, naphthyl, biphenyl, pyrrolyl, pyrazolyl, imidazolyl, pyrazinyl, oxazolyl, isoxazolyl, thiazolyl, furylthienyl, pyridyl, pyrimidyl, benzothiazolyl, purinyl, benzimidazolyl, isoquinolyl, thiadiazolyl, oxadiazolyl, pyrrolyl, diazolyl, triazolyl, tetrazolyl, benzothiadiazolyl, isothiazolyl, pyrazolopyrimidinyl, pyrrolopyrimidinyl, benzotriazolyl, benzoxazolyl, or quinolyl. The examples above may be substituted or unsubstituted and divalent radicals of each heteroaryl example above are non-limiting examples of heteroarylene.
[0023] A fused ring heterocyloalkyl-aryl is an aryl fused to a heterocycloalkyl. A fused ring heterocycloalkyl-heteroaryl is a heteroaryl fused to a heterocycloalkyl. A fused ring heterocycloalkyl-cycloalkyl is a heterocycloalkyl fused to a cycloalkyl. A fused ring heterocycloalkyl-heterocycloalkyl is a heterocycloalkyl fused to another heterocycloalkyl. Fused ring heterocycloalkyl-aryl, fused ring heterocycloalkyl-heteroaryl, fused ring heterocycloalkyl-cycloalkyl, or fused ring heterocycloalkyl-heterocycloalkyl may each independently be unsubstituted or substituted with one or more of the substituents described herein.
[0024] For brevity, the term “aryl” when used in combination with other terms (e.g., aryloxy, arylthioxy, arylalkyl) includes both aryl and heteroaryl rings as defined above. Thus, the term “arylalkyl” is meant to include those radicals in which an aryl group is attached to an alkyl group (e.g., benzyl, phenethyl, pyridylmethyl, and the like) including those alkyl groups in which a carbon atom (e.g., a methylene group) has been replaced by, for example, an oxygen atom (e.g., phenoxymethyl, 2-pyridyloxymethyl, 3-(1-naphthyloxy)propyl, and the like).
[0025] The term “oxo,” as used herein, means an oxygen that is double bonded to a carbon atom.
[0026] The term “alkylsulfonyl,” as used herein, means a moiety having the formula —S(O 2 )—R′, where R 1 is an alkyl group as defined above. R′ may have a specified number of carbons (e.g., “C 1 -C 4 alkylsulfony.”).
[0027] Each of the above terms (e.g., “alkyl,” “heteroalkyl,” “aryl,” and “heteroaryl”) includes both substituted and unsubstituted forms of the indicated radical. Preferred substituents for each type of radical are provided below.
[0028] Substituents for the alkyl and heteroalkyl radicals (including those groups often referred to as alkylene, alkenyl, heteroalkylene, heteroalkenyl, alkynyl, cycloalkyl, heterocycloalkyl, cycloalkenyl, and heterocycloalkenyl) can be one or more of a variety of groups selected from, but not limited to, —OR′, ═O, ═NR′, ═N—OR′, —NR′R″, —SR′, -halogen, —SiR′R″R′″, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR″R′″, —NR″C(O) 2 R′, —NR—C(NR′R″R′″)═NR″″, —NR—C(NR′R″)═NR′″, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —NR′NR″R′″, —ONR′R″, —NR′C═(O)NR″NR″NR′″R″″, —CN, —NO 2 , in a number ranging from zero to (2m′+1), where m′ is the total number of carbon atoms in such radical. R, R′, R″, R′″, and R″″ each preferably independently refer to hydrogen, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl (e.g., aryl substituted with 1-3 halogens), substituted or unsubstituted heteroaryl, substituted or unsubstituted alkyl, alkoxy, or thioalkoxy groups, or arylalkyl groups. When a compound of the invention includes more than one R group, for example, each of the R groups is independently selected as are each R′, R″, R′″, and R″″ group when more than one of these groups is present. When R′ and R″ are attached to the same nitrogen atom, they can be combined with the nitrogen atom to form a 4-, 5-, 6-, or 7-membered ring. For example, —NR′R″ includes, but is not limited to, 1-pyrrolidinyl and 4-morpholinyl. From the above discussion of substituents, one of skill in the art will understand that the term “alkyl” is meant to include groups including carbon atoms bound to groups other than hydrogen groups, such as haloalkyl (e.g., —CF 3 and —CH 2 CF 3 ) and acyl (e.g., —C(O)CH 3 , —C(O)CF 3 , —C(O)CH 2 OCH 3 , and the like).
[0029] Similar to the substituents described for the alkyl radical, substituents for the aryl and heteroaryl groups are varied and are selected from, for example: —OR′, —NR′R″, —SR′, -halogen, —SiR′R″R′″, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR′R′″, —NR″C(O) 2 R′, —NR—C(NR′R″R′″)═NR″″, —NR—C(NR′R″)═NR″, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —CN, —NO 2 , —R′, —N 3 , —CH(Ph) 2 , fluoro(C 1 -C 4 )alkoxy, and fluoro(C 1 -C 4 )alkyl, in a number ranging from zero to the total number of open valences on the aromatic ring system; and where R′, R″, R′″, and R″″ are preferably independently selected from hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, and substituted or unsubstituted heteroaryl. When a compound of the invention includes more than one R group, for example, each of the R groups is independently selected as are each R′, R″, R′″, and R″″ groups when more than one of these groups is present.
[0030] Two or more substituents may optionally be joined to form aryl, heteroaryl, cycloalkyl, or heterocycloalkyl groups. Such so-called ring-forming substituents are typically, though not necessarily, found attached to a cyclic base structure. In embodiments, the ring-forming substituents are attached to adjacent members of the base structure. For example, two ring-forming substituents attached to adjacent members of a cyclic base structure create a fused ring structure. In another embodiment, the ring-forming substituents are attached to a single member of the base structure. For example, two ring-forming substituents attached to a single member of a cyclic base structure create a spirocyclic structure. In yet another embodiment, the ring-forming substituents are attached to non-adjacent members of the base structure.
[0031] Two of the substituents on adjacent atoms of the aryl or heteroaryl ring may optionally form a ring of the formula -T-C(O)—(CRR′) q —U—, wherein T and U are independently —NR—, —O—, —CRR′—, or a single bond, and q is an integer of from 0 to 3. Alternatively, two of the substituents on adjacent atoms of the aryl or heteroaryl ring may optionally be replaced with a substituent of the formula -A-(CH 2 ) r —B—, wherein A and B are independently —CRR′—, —O—, —NR—, —S—, —S(O)—, —S(O) 2 —, —S(O) 2 NR′—, or a single bond, and r is an integer of from 1 to 4. One of the single bands of the new ring so formed may optionally be replaced with a double bond. Alternatively, two of the substituents on adjacent atoms of the aryl or heteroaryl ring may optionally be replaced with a substituent of the formula —(CRR′) s —X′— (C″R′″) d —, where s and d are independently integers of from 0 to 3, and X 1 is —O—, —NR′—, —S—, —S(O)—, —S(O) 2 —, or —S(O) 2 NR′—. The substituents R, R′, R″, and R′″ are preferably independently selected from hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, and substituted or unsubstituted heteroaryl.
[0032] As used herein, the terms “heteroatom” or “ring heteroatom” are meant to include oxygen (O), nitrogen (N), sulfur (S), phosphorus (P), and silicon (Si).
[0033] A “substituent group,” as used herein, means a group selected from the following moieties:
(A) —OH, —SH, —CN, —CF 3 , —NO 2 , oxo, halogen, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, unsubstituted heteroaryl, and (B) alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, and heteroaryl, substituted with at least one substituent selected from:
(i) oxo, —OH, —NH 2 , —SH, —CN, —CF 3 , —NO 2 , halogen, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, unsubstituted heteroaryl, and (ii) alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, and heteroaryl, substituted with at least one substituent selected from:
(a) oxo, —OH, —NH 2 , —SH, —CN, —NO 2 , halogen, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, unsubstituted heteroaryl, and (b) alkyl, heteroalkyl, cycloalkyl, heterocycloalkyl, aryl, or heteroaryl, substituted with at least one substituent selected from: oxo, —OH, —NH 2 , —SH, —CN, —CF 3 , —NO 2 , halogen, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, and unsubstituted heteroaryl.
[0041] A “size-limited substituent” or “size-limited substituent group,” as used herein, means a group selected from all of the substituents described above for a “substituent group,” wherein each substituted or unsubstituted alkyl is a substituted or unsubstituted C 1 -C 20 alkyl, each substituted or unsubstituted heteroalkyl is a substituted or unsubstituted 2 to 20 membered heteroalkyl, each substituted or unsubstituted cycloalkyl is a substituted or unsubstituted C 4 -C 8 cycloalkyl, each substituted or unsubstituted heterocycloalkyl is a substituted or unsubstituted 3 to 8 membered heterocycloalkyl, each substituted or unsubstituted aryl is a substituted or unsubstituted C 6 -C 10 aryl, and each substituted or unsubstituted heteroaryl is a substituted or unsubstituted 5 to 10 membered heteroaryl.
[0042] A “lower substituent” or “lower substituent group,” as used herein, means a group selected from all of the substituents described above for a “substituent group,” wherein each substituted or unsubstituted alkyl is a substituted or unsubstituted C 1 -C 8 alkyl, each substituted or unsubstituted heteroalkyl is a substituted or unsubstituted 2 to 8 membered heteroalkyl, each substituted or unsubstituted cycloalkyl is a substituted or unsubstituted C 3 -C 7 cycloalkyl, each substituted or unsubstituted heterocycloalkyl is a substituted or unsubstituted 3 to 8 membered heterocycloalkyl, each substituted or unsubstituted aryl is a substituted or unsubstituted C 6 -C 10 aryl, and each substituted or unsubstituted heteroaryl is a substituted or unsubstituted 5 to 9 membered heteroaryl.
[0043] In embodiments, each substituted group described in the compounds herein is substituted with at least one substituent group. More specifically, in some embodiments, each substituted alkyl, substituted heteroalkyl, substituted cycloalkyl, substituted heterocycloalkyl, substituted aryl, substituted heteroaryl, substituted alkylene, substituted heteroalkylene, substituted cycloalkylene, substituted heterocycloalkylene, substituted arylene, and/or substituted heteroarylene described in the compounds herein are substituted with at least one substituent group. In embodiments, at least one or all of these groups are substituted with at least one size-limited substituent group. In embodiments, at least one or all of these groups are substituted with at least one lower substituent group.
[0044] In embodiments of the compounds herein, each substituted or unsubstituted alkyl is a substituted or unsubstituted C 1 -C 20 alkyl, each substituted or unsubstituted heteroalkyl is a substituted or unsubstituted 2 to 20 membered heteroalkyl, each substituted or unsubstituted cycloalkyl is a substituted or unsubstituted C 2 -C 8 cycloalkyl, each substituted or unsubstituted heterocycloalkyl is a substituted or unsubstituted 3 to 8 membered heterocycloalkyl, each substituted or unsubstituted aryl is a substituted or unsubstituted C 6 -C 10 aryl, and/or each substituted or unsubstituted heteroaryl is a substituted or unsubstituted 5 to 10 membered heteroaryl. In embodiments of the compounds herein, each substituted or unsubstituted alkylene is a substituted or unsubstituted C 1 -C 20 alkylene, each substituted or unsubstituted heteroalkylene is a substituted or unsubstituted 2 to 20 membered heteroalkylene, each substituted or unsubstituted cycloalkylene is a substituted or unsubstituted C 3 -C 8 cycloalkylene, each substituted or unsubstituted heterocycloalkylene is a substituted or unsubstituted 3 to 8 membered heterocycloalkylene, each substituted or unsubstituted arylene is a substituted or unsubstituted C 5 -C 10 arylene, and/or each substituted or unsubstituted heteroarylene is a substituted or unsubstituted 5 to 10 membered heteroarylene.
[0045] In embodiments, each substituted or unsubstituted alkyl is a substituted or unsubstituted C 1 -C 8 alkyl, each substituted or unsubstituted heteroalkyl is a substituted or unsubstituted 2 to 8 membered heteroalkyl, each substituted or unsubstituted cycloalkyl is a substituted or unsubstituted C 3 -C 7 cycloalkyl, each substituted or unsubstituted heterocycloalkyl is a substituted or unsubstituted 3 to 7 membered heterocycloalkyl, each substituted or unsubstituted aryl is a substituted or unsubstituted C 6 -C 10 aryl, and/or each substituted or unsubstituted heteroaryl is a substituted or unsubstituted 5 to 9 membered heteroaryl. In embodiments, each substituted or unsubstituted alkylene is a substituted or unsubstituted C 1 -C 8 alkylene, each substituted or unsubstituted heteroalkylene is a substituted or unsubstituted 2 to 8 membered heteroalkylene, each substituted or unsubstituted cycloalkylene is a substituted or unsubstituted C 3 -C 7 cycloalkylene, each substituted or unsubstituted heterocycloalkylene is a substituted or unsubstituted 3 to 7 membered heterocycloalkylene, each substituted or unsubstituted arylene is a substituted or unsubstituted C 6 -C 10 arylene, and/or each substituted or unsubstituted heteroarylene is a substituted or unsubstituted 5 to 9 membered heteroarylene. In embodiments, the compound is a chemical species set forth in the Examples section, figures, or tables below.
[0046] Provided herein are agents (e.g., compounds disclosed herein) in a prodrug form. Prodrugs of the compounds described herein are those compounds that readily undergo chemical changes under select physiological conditions to provide the final agents (e.g., compounds disclosed herein). Additionally, prodrugs can be converted to agents by chemical or biochemical methods in an ex vivo environment. Prodrugs described herein include compounds that readily undergo chemical changes under select physiological conditions to provide agents to a biological system (e.g. in a subject, in an infected cell, in a cancer cell, in the extracellular space near an infected cell, in the extracellular space near a cancer cell from the moieties attached to the prodrug moiety and included in the prodrug (e.g. compound disclosed herein).
[0047] The symbol denotes the point of attachment of a chemical moiety to the remainder of a molecule or chemical formula.
[0048] The terms “a” or “an,” as used in herein means one or more. In addition, the phrase “substituted with a[n],” as used herein, means the specified group may be substituted with one or more of any or all of the named substituents. For example, where a group, such as an alkyl or heteroaryl group, is “substituted with an unsubstituted C 1 -C 20 alkyl, or unsubstituted 2 to 20 membered heteroalkyl,” the group may contain one or more unsubstituted alkyls, and/or one or more unsubstituted 2 to 20 membered heteroalkyls. Moreover, where a moiety is substituted with an R substituent, the group may be referred to as “R-substituted.” Where a moiety is R-substituted, the moiety is substituted with at least one R substituent and each R substituent is optionally different.
[0049] Descriptions of compounds of the present invention are limited by principles of chemical bonding known to those skilled in the art. Accordingly, where a group may be substituted by one or more of a number of substituents, such substitutions are selected so as to comply with principles of chemical bonding and to give compounds which are not inherently unstable and/or would be known to one of ordinary skill in the art as likely to be unstable under ambient conditions, such as aqueous, neutral, and several known physiological conditions. For example, a heterocycloalkyl or heteroaryl is attached to the remainder of the molecule via a ring heteroatom in compliance with principles of chemical bonding known to those skilled in the art thereby avoiding inherently unstable compounds.
[0050] The term “drug” is used in accordance with its common meaning and refers to a substance which has a physiological effect (e.g. beneficial effect, is useful for treating a subject) when introduced into or to a subject (e.g. in or on the body of a subject or patient). A drug moiety is a radical of a drug.
[0051] As used herein, the term “salt” refers to acid or base salts of the compounds used in the methods of the present invention. Illustrative examples of acceptable salts are mineral acid (hydrochloric acid, hydrobromic acid, phosphoric acid, and the like) salts, organic acid (acetic acid, propionic acid, glutamic acid, citric acid and the like) salts, quaternary ammonium (methyl iodide, ethyl iodide, and the like) salts.
[0052] As used herein, the term “isomers” refers to compounds having the same number and kind of atoms, and hence the same molecular weight, but differing in respect to the structural arrangement or configuration of the atoms.
[0053] The term “tautomer,” as used herein, refers to one of two or more structural isomers which exist in equilibrium and which are readily converted from one isomeric form to another.
[0054] It will be apparent to one skilled in the art that certain compounds of this invention may exist in tautomeric forms, all such tautomeric forms of the compounds being within the scope of the invention.
[0055] Unless otherwise stated, structures depicted herein are also meant to include all stereochemical forms of the structure; i.e., the R and S configurations for each asymmetric center. Therefore, single stereochemical isomers as well as enantiomeric and diastereomeric mixtures of the present compounds are within the scope of the invention.
[0056] Unless otherwise stated, structures depicted herein are also meant to include compounds which differ only in the presence of one or more isotopically enriched atoms. For example, compounds having the present structures except for the replacement of a hydrogen by a deuterium or tritium, or the replacement of a carbon by 13 C- or 14 C-enriched carbon are within the scope of this invention.
[0057] The terms “fibrillogenic,” “fibrillogenic Aβ peptide” and the like refer, in the usual and customary sense, to a change in conformation of normally circulating soluble Aβ peptides into amyloid fibrils in the form of senile plaques, as known in the art. Thus, there are provided compounds and methods for modulating (e.g., reducing) levels of fibrillogenic Aβ peptides, e.g., Aβ 40 and Aβ 42 , and concomitantly modulating (e.g., increasing) the levels of shorter less fibrillogenic Aβ peptides (e.g. Aβ 38 and Aβ 37 ) from the APP-CTFs.
[0058] The term “modulate” or “modulating” with respect to Aβ level, refers to a detectable increase or decrease in the amount (or level) of at least one species of the Aβ peptide (such as Aβ 43 , Aβ 42 , Aβ 40 , Aβ 39 , Aβ 38 , Aβ 37 , Aβ 34 , etc., as known in the art); a detectable increase or decrease in the relative amount (or level) of different species of Aβ peptides (such as the ratio of Aβ 42 to Aβ 40 ); a detectable increase or decrease in the amount, or relative amount, of Aβ in a particular form (such as monomeric, oligomeric, or fibrillar form; in solution or aggregated in a plaque; in a particular conformation; etc.); and/or a detectable increase or decrease in the amount, or relative amount, of a particular Aβ species in a particular location (such as an intracellular, membrane-associated or extracellular location, or in a particular tissue or body fluid). In preferred embodiments, modulation is detectable as a decrease in the level of Aβ 42 or Aβ 40 , or an increase in the level of Aβ 37 or Aβ 38 . Modulation of Aβ levels can be evidenced, for example, by an increase or decrease of at least 5%, such as at least 10%, 20%, 30%, 40%, 50%, 75%, 90% or more, of the amount, or relative amount, of an Aβ species, or of a particular form of Aβ, relative to a reference level. Modulation can be an increase or decrease that is a statistically significant difference relative to the reference level.
[0059] The term “contacting” refers to bringing into association, either directly or indirectly, two or more substances. Contacting may occur in vivo, ex vivo or in vitro. A source of APP, amyloid precursor fragment thereof and/or Aβ or source of gamma-secretase activity, that is a human or other animal can be contacted with a compound, for example, by therapeutic or prophylactic administration of the compound. A source of APP, amyloid precursor fragment thereof and/or Aβ that is a tissue, tissue extract or cell can be contacted with a compound, for example, by introduction of the compound into the culture medium. A source of APP, amyloid precursor fragment thereof and/or Aβ that is a fluid, such as extracellular medium, can be contacted with a compound, for example, by admixing the compound with the fluid.
[0060] The terms “pharmaceutically acceptable excipient” and “pharmaceutically acceptable carrier” refer, in the usual and customary sense, to a substance that aids the administration of an active agent to and absorption by a subject and can be included in the compositions of the present invention without causing a significant adverse toxicological effect on the patient. Non-limiting examples of pharmaceutically acceptable excipients include water, dimethyl sulfoxide (DMSO), NaCl, normal saline solutions, lactated Ringer's, normal sucrose, normal glucose, binders, fillers, disintegrants, lubricants, coatings, sweeteners, flavors, salt solutions (such as Ringer's solution), alcohols, oils, gelatins, carbohydrates such as lactose, amylose or starch, fatty acid esters, hydroxymethylcellulose, polyvinyl pyrrolidine, polyethylene glycol, and colors, and the like. Such preparations can be sterilized and, if desired, mixed with auxiliary agents such as lubricants, preservatives, stabilizers, wetting agents, emulsifiers, salts for influencing osmotic pressure, buffers, coloring, and/or aromatic substances and the like that do not deleteriously react with the compounds of the invention. One of skill in the art will recognize that other pharmaceutical excipients are useful in the present invention.
[0061] The term “pharmaceutically acceptable salts” is meant to include salts of the active compounds that are prepared with relatively nontoxic acids or bases, depending on the particular substituents found on the compounds described herein. When compounds of the present invention contain relatively acidic functionalities, base addition salts can be obtained by contacting the neutral form of such compounds with a sufficient amount of the desired base, either neat or in a suitable inert solvent. Examples of pharmaceutically acceptable base addition salts include sodium, potassium, calcium, ammonium, organic amino, or magnesium salt, or a similar salt. When compounds of the present invention contain relatively basic functionalities, acid addition salts can be obtained by contacting the neutral form of such compounds with a sufficient amount of the desired acid, either neat or in a suitable inert solvent. Examples of pharmaceutically acceptable acid addition salts include those derived from inorganic acids like hydrochloric, hydrobromic, nitric, carbonic, monohydrogencarbonic, phosphoric, monohydrogenphosphoric, dihydrogenphosphoric, sulfuric, monohydrogensulfuric, hydriodic, or phosphorous acids and the like, as well as the salts derived from relatively nontoxic organic acids like acetic, propionic, isobutyric, maleic, malonic, benzoic, succinic, suberic, fumaric, lactic, mandelic, phthalic, benzenesulfonic, p-tolylsulfonic, citric, tartaric, oxalic, methanesulfonic, and the like. Also included are salts of amino acids such as arginate and the like, and salts of organic acids like glucuronic or galactunoric acids and the like (see, for example, Berge et al., “Pharmaceutical Salts”, Journal of Pharmaceutical Science, 1977, 66:1-19). Certain specific compounds of the present invention contain both basic and acidic functionalities that allow the compounds to be converted into either base or acid addition salts.
[0062] Thus, the compounds of the present invention may exist as salts, such as with pharmaceutically acceptable acids. The present invention includes such salts. Examples of such salts include hydrochlorides, hydrobromides, sulfates, methanesulfonates, nitrates, maleates, acetates, citrates, fumarates, tartrates (e.g., (+)-tartrates, (−)-tartrates, or mixtures thereof including racemic mixtures), succinates, benzoates, and salts with amino acids such as glutamic acid. These salts may be prepared by methods known to those skilled in the art.
[0063] The neutral forms of the compounds are preferably regenerated by contacting the salt with a base or acid and isolating the parent compound in the conventional manner. The parent form of the compound differs from the various salt forms in certain physical properties, such as solubility in polar solvents.
[0064] Certain compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms are equivalent to unsolvated forms and are encompassed within the scope of the present invention. Certain compounds of the present invention may exist in multiple crystalline or amorphous forms. In general, all physical forms are equivalent for the uses contemplated by the present invention and are intended to be within the scope of the present invention.
[0065] Certain compounds of the present invention possess asymmetric carbon atoms (optical or chiral centers) or double bonds; the enantiomers, racemates, diastereomers, tautomers, geometric isomers, stereoisomeric forms that may be defined, in terms of absolute stereochemistry, as (R)- or (S)- or, as (D)- or (L)- for amino acids, and individual isomers are encompassed within the scope of the present invention. Compounds disclosed herein do not include those which are known in art to be too unstable to synthesize and/or isolate. The present disclosure is meant to include compounds in racemic and optically pure forms. Optically active (R)- and (S)-, or (D)- and (L)-isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques. When the compounds described herein contain olefinic bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers.
[0066] The compounds of the present invention may also contain unnatural proportions of atomic isotopes at one or more of the atoms that constitute such compounds. For example, the compounds may be radiolabeled with radioactive isotopes, such as for example tritium ( 3 H), iodine-125 ( 125 I), or carbon-14 ( 14 C). All isotopic variations of the compounds of the present invention, whether radioactive or not, are encompassed within the scope of the present invention.
[0067] The terms “treating” or “treatment” refers to any indicia of success in the treatment or amelioration of an injury, disease, pathology or condition, including any objective or subjective parameter such as abatement; remission; diminishing of symptoms or making the injury, pathology or condition more tolerable to the patient; slowing in the rate of degeneration or decline; making the final point of degeneration less debilitating; improving a patient's physical or mental well-being. The treatment or amelioration of symptoms can be based on objective or subjective parameters; including the results of a physical examination, neuropsychiatric exams, and/or a psychiatric evaluation. The term “treating,” and conjugations thereof, include prevention of an injury, pathology, condition, or disease.
[0068] An “effective amount” is an amount sufficient to accomplish a stated purpose (e.g. achieve the effect for which it is administered, treat a disease, reduce one or more symptoms of a disease or condition, and the like). An example of an “effective amount” is an amount sufficient to contribute to the treatment, prevention, or reduction of a symptom or symptoms of a disease, which could also be referred to as a “therapeutically effective amount.” A “reduction” of a symptom or symptoms (and grammatical equivalents of this phrase) means decreasing of the severity or frequency of the symptom(s), or elimination of the symptom(s). A “prophylactically effective amount” of a drug is an amount of a drug that, when administered to a subject, will have the intended prophylactic effect, e.g., preventing or delaying the onset (or reoccurrence) of an injury, disease, pathology or condition, or reducing the likelihood of the onset (or reoccurrence) of an injury, disease, pathology, or condition, or their symptoms. The full prophylactic effect does not necessarily occur by administration of one dose, and may occur only after administration of a series of doses. Thus, a prophylactically effective amount may be administered in one or more administrations. The exact amounts will depend on the purpose of the treatment, and will be ascertainable by one skilled in the art using known techniques (see, e.g., Lieberman, Pharmaceutical Dosage Forms (vols. 1-3, 1992); Lloyd, The Art, Science and Technology of Pharmaceutical Compounding (1999); Pickar, Dosage Calculations (1999); and Remington: The Science and Practice of Pharmacy, 20th Edition, 2003, Gennaro, Ed., Lippincott, Williams & Wilkins).
[0069] “Subject,” “patient,” “subject in need thereof” and the like refer to a living organism suffering from or prone to a disease or condition that can be treated by administration of a compound or pharmaceutical composition as provided herein. Non-limiting examples include humans, other mammals, bovines, rats, mice, dogs, monkeys, goat, sheep, cows, deer, and other non-mammalian animals. In embodiments, a subject is human.
[0070] As used herein, the term “administering” means oral administration, administration as an inhaled aerosol or as an inhaled dry powder, suppository, topical contact, intravenous, parenteral, intraperitoneal, intramuscular, intralesional, intrathecal, intranasal or subcutaneous administration, or the implantation of a slow-release device, e.g., a mini-osmotic pump, to a subject. Administration is by any route, including parenteral and transmucosal (e.g., buccal, sublingual, palatal, gingival, nasal, vaginal, rectal, or transdermal). Parenteral administration includes, e.g., intravenous, intramuscular, intra-arteriole, intradermal, subcutaneous, intraperitoneal, intraventricular, and intracranial. Other modes of delivery include, but are not limited to, the use of liposomal formulations, intravenous infusion, transdermal patches, etc. By “co-administer” it is meant that a composition described herein is administered at the same time, just prior to, or just after the administration of one or more additional therapies, for example cancer therapies such as chemotherapy, hormonal therapy, radiotherapy, or immunotherapy. The compound of the invention can be administered alone or can be coadministered to the patient. Coadministration is meant to include simultaneous or sequential administration of the compound individually or in combination (more than one compound or agent). The compositions of the present invention can be delivered transdermally, by a topical route, formulated as applicator sticks, solutions, suspensions, emulsions, gels, creams, ointments, pastes, jellies, paints, powders, and aerosols. Oral preparations include tablets, pills, powder, dragees, capsules, liquids, lozenges, cachets, gels, syrups, slurries, suspensions, etc., suitable for ingestion by the patient. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water/propylene glycol solutions. The compositions of the present invention may additionally include components to provide sustained release and/or comfort. Such components include high molecular weight, anionic mucomimetic polymers, gelling polysaccharides and finely-divided drug carrier substrates. These components are discussed in greater detail in U.S. Pat. Nos. 4,911,920; 5,403,841; 5,212,162; and 4,861,760. The entire contents of these patents are incorporated herein by reference in their entirety for all purposes. The compositions of the present invention can also be delivered as microspheres for slow release in the body. For example, microspheres can be administered via intradermal injection of drug-containing microspheres, which slowly release subcutaneously (see Rao, J. Biomater Sci. Polym. Ed. 7:623-645, 1995; as biodegradable and injectable gel formulations (see, e.g., Gao Pharm. Res. 12:857-863, 1995); or, as microspheres for oral administration (see, e.g., Eyles, J. Pharm. Pharmacol. 49:669-674, 1997). In another embodiment, the formulations of the compositions of the present invention can be delivered by the use of liposomes which fuse with the cellular membrane or are endocytosed, i.e., by employing receptor ligands attached to the liposome, that bind to surface membrane protein receptors of the cell resulting in endocytosis. By using liposomes, particularly where the liposome surface carries receptor ligands specific for target cells, or are otherwise preferentially directed to a specific organ, one can focus the delivery of the compositions of the present invention into the target cells in vivo. (See, e.g., Al-Muhammed, J. Microencapsul. 13:293-306, 1996; Chonn, Curr. Opin. Biotechnol. 6:698-708, 1995; Ostro, Am. J. Hosp. Pharm . 46:1576-1587, 1989).
[0071] The terms “disease associated with aberrant Aβ levels,” “neurodegenerative proteinopathies” and the like refer, in the context of Aβ peptide, to any condition characterized by an abnormal amount of at least one species of Aβ peptide (such as Aβ 43 , Aβ 42 , Aβ 40 , Aβ 39 , Aβ 38 , Aβ 37 , Aβ 34 , etc.); by an abnormal relative amount of different species of Aβ peptides (such as the ratio of Aβ 42 to Aβ 40 ); by an abnormal amount, or relative amount, of Aβ in a particular form (such as monomeric, oligomeric, or fibrillar form; in solution or aggregated in a plaque; in a particular conformation, etc.); and/or by an abnormal amount, or relative amount, of Aβ in a particular location (such as intracellular, membrane-associated or extracellular location, or in a particular tissue or body fluid). The abnormal amount of one or more Aβ peptides, Aβ forms and/or Aβ can be relative to a condition that is a normal, non-disease state. Diseases and disorders characterized by altered Aβ levels are known in the art and/or described herein, and include, for example, Down syndrome, Alzheimer's disease (AD), diffuse Lewy body disease, Hereditary Cerebral Hemorrhage with Amyloidosis-Dutch Type (HCHWA-D), cerebral amyloid angiopathy (CAA), and mild cognitive impairment (MCI). Embodiments of the invention include methods of treating any disease associated with aberrant Aβ levels, such as AD. Compounds of the present invention can be administered to a subject to treat (including to prevent or to ameliorate) conditions associated with altered Aβ production, fibril formation/deposition, degradation and/or clearance, or any altered isoform of Aβ.
[0072] The term “amyloid-beta” or “Aβ” refers to a peptide from a human or other species that (a) results from processing or cleavage of an APP-CTF that is amyloidogenic, (b) is one of the peptide constituents of β-amyloid plaques, (c) is the 42-amino acid sequence of Aβ (GenBank Accession No. P05067), (d) is a fragment of a peptide as set forth in (a), (b) or (c), and/or (e) contains one or more additions, deletions or substitutions relative to (a), (b), (c) or (d). Aβ is also referred to in the art as βAP, AβP, A4 or βA4. Aβ peptides derived from proteolysis of an APP-CTF, generally are about 4.2 kD proteins and are typically 39 to 43 amino acids in length, depending on the carboxy-terminal end-point, which exhibits heterogeneity. However, Aβ peptides containing less than 39 amino acids, e.g., Aβ 38 , Aβ 37 , and Aβ 34 , also may occur.
[0073] Aβ peptides can be produced in an amyloidogenic APP processing pathway in which APP is cleaved by β-secretase (BACE) and one or more gamma-secretase activities. Aβ peptides include those but are not limited to those that begin at position 672 of APP770 and those that begin at position 682 of APP770 (see, for example, GenBank Accession No. P05067). Generally, as used herein, “Aβ” includes any and all Aβ peptides, unless the amino acid residues are specified, such as, for example, 1-43 (Aβ 43 ), 1-42 (Aβ 42 ), 1-40 (Aβ 40 ), 1-39 (Aβ 39 ), 1-38 (Aβ 38 ), 1-37 (Aβ 37 ), 1-34 (Aβ 34 ). Additionally amino-terminally-truncated Aβ peptides exists such as 11-43, 11-42, 11-40, 11-39, 11-38, 11-37, 11-34, and other. The various Aβ peptides of differing lengths are referred to herein as “species” of Aβ.
[0074] The term “amyloid precursor protein” or “APP” refers to a protein that can be proteolytically processed or cleaved by one or more processing or cleavage reactions to produce Aβ. APP includes all isoforms that are generated by alternative splicing, which can be typically distinguished by the number of amino acids in the particular isoform. For example, APP embraces APP695, APP751, and APP770. Other isoforms of APP include, for example, APP714, L-APP752, L-APP733, L-APP696, L-APP677, APP563, and APP365.
[0075] APP also includes all isoforms containing mutations found in families with AD and other amyloidosis conditions. For example, these mutations include the Swedish double mutation; the London mutation, the Indiana mutation, the Austrian mutation, the Iranian mutation, the French mutation, the German mutation, the Florida mutation, the Australian mutation, the Flemish mutation, the Dutch mutation, the Arctic mutation, the Italian mutation, and the Iowa mutation, and the amyloidsis-Dutch type mutation, all as known in the art.
[0076] The term “APP” further includes proteins containing one or more additions, deletions or substitutions relative to the isoforms described above, and APP proteins from humans and other species. Unless a specific isoform is specified, APP when used herein generally refers to any and all isoforms of APP, with or without mutations, from any species.
[0077] The term “amyloid precursor protein fragment” refers to any portion of an APP that can be processed or cleaved, by one or more processing or cleavage reactions, to produce Aβ. Amyloid precursor protein fragments of APP generally contain either a beta-secretase cleavage site which, when cleaved, generates the N-terminus of Aβ, a gamma-secretase cleavage site which, when cleaved, generates the C-terminus of Aβ or both a beta- and a gamma-secretase cleavage site. Exemplary amyloid precursor fragments include the APP C-terminal fragments designated C99 and C83, as well as portions thereof lacking some or all C-terminal residues that normally reside in the cytosol.
[0078] The term “source of amyloid precursor protein (APP), amyloid precursor fragment thereof and/or Aβ” refers to any in vivo, ex vivo or in vitro substance containing APP, amyloid precursor fragment thereof and/or AB. For example, a “source” can be a live organism (including a human patient, or a laboratory or veterinary animal, such as dog, pig, cow, horse, rat or mice), a sample therefrom (such as a tissue or body fluid, or extract thereof), a cell (such as a primary cell or cell line, or extract thereof), extracellular medium or matrix or milieu, or isolated protein.
II. Compounds
[0079] In a first aspect, there is provided a compound having the formula:
[0000]
[0080] For Formulae (I)-(IV), z1 is 0, 1 or 2.
[0081] X 1 is C(R 3 ) or N.
[0082] R 1 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 1A , —NR 1A R 1B , —COOR 1A , —C(O)NR 1A R 1B , —NO 2 , —SR 1A , —S(O) n1 OR 1A , —S(O) n1 NR 1A R 1B , —NHNR 1A R 1B , —ONR 1A R 1B , —NHC(O)NHNR 1A R 1B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0083] R 2 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 2A , —NR 2A R 2B , —COOR 2A , —C(O)NR 2A R 2B , —NO 2 , —SR 2A , —S(O) n2 R 2A , —S(O) n2 OR 2A , —S(O) n2 NR 2A R 2B , —NHNR 2A R 2B , —ONR 2A R 2B , —NHC(O)NHNR 2A R 2B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0084] R 3 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 ONR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0085] R 4 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 4A , —NR 4A R 4B , —COOR 4A , —C(O)NR 4A R 4B , —NO 2 , —SR 4A , —S(O) n4 R 4A , —S(O) n4 OR 4A , —S(O) n4 NR 4A R 4B , —NHNR 4A R 4B , —ONR 4A R 4B , —NHC(O)NHNR 4A R 4B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0086] R 5 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 5A , —NR 5A R 5B , —COOR 5A , —C(O)NR 5A R 5B , —NO 2 , —SR 5A , —S(O) n5 R 5A , —S(O) n5 OR 5A , —S(O) n5 NR 5A R 5B , —NHNR 5A R 5B , —ONR 5A R 5B , —NHC(O)NHNR 5A R 5B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl, wherein R 4 and R 5 are optionally joined together to form a substituted or unsubstituted heterocycloalkyl, or substituted or unsubstituted heteroaryl.
[0087] R 6 is —CF 3 , substituted or unsubstituted cyclopropyl, or substituted or unsubstituted cyclobutyl.
[0088] R 7 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 7A , —NR 7A R 7B , —COOR 7A , —C(O)NR 7A R 7B , —NO 2 , —SR 7A , —S(O) n7 R 7A , —S(O) n7 OR 7A , —S(O) n7 NR 7A R 7B , —NHNR 7A R 7B , —ONR 7A R 7B , —NHC(O)NHNR 7A R 7B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0089] R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A and R 7B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl.
[0090] n1, n2, n3, n4, n5 and n7 are independently 1 or 2.
[0091] In embodiments, the compound having the structure of Formula (I) is not
[0000]
[0092] In embodiments of the compound with structure of Formula (I)-(IV), R 1 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 1A , —NR 1A R 1B , —COOR 1A , —C(O)NR 1A R 1B , —NO 2 , —SR 1A , —S(O) n1 R 1A , —S(O) n1 OR 1A , —S(O) n1 NR 1A R 1B , —NHNR 1A R 1B , —ONR 1A R 1B , —NHC(O)NHNR 1A R 1B , unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0093] In embodiments, R 2 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 2A , —NR 2A R 2B , —COOR 2A , —C(O)NR 2A R 2B , —NO 2 , —SR 2A , —S(O) n2 R 2A , —S(O) n2 OR 2A , —S(O) n2 NR 2A R 2B , —NHNR 2A R 2B , —ONR 2A R 2B , —NHC(O)NHNR 2A R 2B , unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0094] In embodiments, R 3 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 NR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0095] In embodiments, R 4 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 4A , —NR 4A R 4B , —COOR 4A , —C(O)NR 4A R 4B , —NO 2 , —SR 4A , —S(O) n4 R 4A , —S(O) n4 OR 4A , —S(O) n4 NR 4A R 4B , —NHNR 4A R 4B , —ONR 4A R 4B , —NHC(O)NHNR 4A R 4B , unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0096] In embodiments, R 5 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 5A , —NR 5A R 5B , —COOR 5A , —C(O)NR 5A R 5B , —NO 2 , —SR 5A , —S(O) n5 R 5A , —S(O) n5 OR 5A , —S(O) n5 NR 5A R 5B , —NHNR 5A R 5B , —ONR 5A R 5B , —NHC(O)NHNR 5A R 5B , unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl, wherein R 4 and R 5 are optionally joined together to form a unsubstituted heterocycloalkyl, or unsubstituted heteroaryl.
[0097] In embodiments, R 6 is —CF 3 , substituted or unsubstituted cyclopropyl, or substituted or unsubstituted cyclobutyl.
[0098] In embodiments, R 7 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 7A , —NR 7A R 7B , —COOR 7A , —C(O)NR 7A R 7B , —NO 2 , —SR 7A , —S(O) n7 R 7A , —S(O) n7 OR 7A , —S(O) n7 NR 7A R 7B , —NHNR 7A R 7B , —ONR 7A R 7B , —NHC(O)NHNR 7A R 7B , unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0099] In embodiments, R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A , R 7B , R 8A , R 8B , R 9A , R 9B , R 10A or R 10B are independently hydrogen, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0100] In embodiments of the compound with structure of Formula (I)-(IV), R 1 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 1A , —NR 1A R 1B , —COOR 1A , —C(O)NR 1A R 1B , —NO 2 , —SR 1A , —S(O) n1 R 1A , —S(O) n1 OR 1A , —S(O) n1 NR 1A R 1B , —NHNR 1A R 1B , —ONR 1A R 1B , —NHC(O)NHNR 1A R 1B , substituted or unsubstituted alkyl, R 1A1 -substituted or unsubstituted heteroalkyl, R 1A1 -substituted or unsubstituted cycloalkyl, R 1A1 -substituted or unsubstituted heterocycloalkyl, R 1A1 -substituted or unsubstituted aryl, or R 1A1 -substituted or unsubstituted heteroaryl. R 1A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 1A2 -substituted or unsubstituted alkyl, R 1A2 -substituted or unsubstituted heteroalkyl, R 1A2 -substituted or unsubstituted cycloalkyl, R 1A2 -substituted or unsubstituted heterocycloalkyl, R 1A2 -substituted or unsubstituted aryl, or R 1A2 -substituted or unsubstituted heteroaryl. R 1A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 1A3 -substituted or unsubstituted alkyl, R 1A3 -substituted or unsubstituted heteroalkyl, R 1A3 -substituted or unsubstituted cycloalkyl, R 1A3 -substituted or unsubstituted heterocycloalkyl, R 1A3 -substituted or unsubstituted aryl, or R 1A3 -substituted or unsubstituted heteroaryl. R 1A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0101] In embodiments, R 2 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 2A , —NR 2A R 2B , —COOR 2A , —C(O)NR 2A R 2B , —NO 2 , —SR 2A , —S(O) n2 R 2A , —S(O) n2 OR 2A , —S(O) n2 NR 2A R 2B , —NHNR 2A R 2B , —ONR 2A R 2B , —NHC(O)NHNR 2A R 2B , R 2A1 -substituted or unsubstituted alkyl, R 2A1 -substituted or unsubstituted heteroalkyl, R 2A1 -substituted or unsubstituted cycloalkyl, R 2A1 -substituted or unsubstituted heterocycloalkyl, R 2A1 -substituted aryl, or R 2A1 -substituted or unsubstituted heteroaryl. R 2A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 2A2 -substituted or unsubstituted alkyl, R 2A2 -substituted or unsubstituted heteroalkyl, R 2A2 -substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, R 2A2 -substituted or unsubstituted aryl, or R 2A2 -substituted or unsubstituted heteroaryl. R 2A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 2A1 -substituted or unsubstituted alkyl, R 2A3 -substituted or unsubstituted heteroalkyl, R 2A3 -substituted or unsubstituted cycloalkyl, R 2A3 -substituted or unsubstituted heterocycloalkyl, R 2A3 -substituted or unsubstituted aryl, or R 2A3 -substituted or unsubstituted heteroaryl. R 2A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0102] In embodiments, R 3 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 NR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , R 3A1 -substituted or unsubstituted alkyl, R 3A1 -substituted or unsubstituted heteroalkyl, R 3A1 -substituted or unsubstituted cycloalkyl, R 3A1 -substituted or unsubstituted heterocycloalkyl, R 3A1 -substituted or unsubstituted aryl, or R 3A1 -substituted or unsubstituted heteroaryl. R 3A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 3A2 -substituted or unsubstituted alkyl, R 3A2 -substituted or unsubstituted heteroalkyl, R 3A2 -substituted or unsubstituted cycloalkyl, R 3A2 -substituted or unsubstituted heterocycloalkyl, R 3A2 -substituted or unsubstituted aryl, or R 3A2 -substituted or unsubstituted heteroaryl. R 3A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 3A3 -substituted or unsubstituted alkyl, R 3A3 -substituted or unsubstituted heteroalkyl, R 3A3 -substituted or unsubstituted cycloalkyl, R 3A3 -substituted or unsubstituted heterocycloalkyl, R 3A3 -substituted or unsubstituted aryl, or R 3A3 -substituted or unsubstituted heteroaryl. R 3A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0103] In embodiments, R 4 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 4A , —NR 4A R 4B , —COOR 4A , —C(O)NR 4A R 4B , —NO 2 , —SR 4A , —S(O) n4 R 4A , —S(O) n4 OR 4A , —S(O) 4 NR 4A R 4B , —NHNR 4A R 4B , —ONR 4A R 4B , —NHC(O)NHNR 4A R 4B , R 4A1 -substituted or unsubstituted alkyl, R 4A1 -substituted or unsubstituted heteroalkyl, R 4A1 -substituted or unsubstituted cycloalkyl, R 4A1 -substituted or unsubstituted heterocycloalkyl, R 4A1 -substituted or unsubstituted aryl, or R 4A1 -substituted or unsubstituted heteroaryl. R 4A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 4A1 -substituted or unsubstituted alkyl, R 4A2 -substituted or unsubstituted heteroalkyl, R 4A2 -substituted or unsubstituted cycloalkyl, R 4A2 -substituted or unsubstituted heterocycloalkyl, R 4A2 -substituted or unsubstituted aryl, or R 4A2 -substituted or unsubstituted heteroaryl. R 4A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 4A2 -substituted or unsubstituted alkyl, R 4A3 -substituted or unsubstituted heteroalkyl, R 4A3 -substituted or unsubstituted cycloalkyl, R 4A3 -substituted or unsubstituted heterocycloalkyl, R 4A3 -substituted or unsubstituted aryl, or R 4A3 -substituted or unsubstituted heteroaryl. R 4A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0104] In embodiments, R 5 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 5A , —NR 5A R 5B , —COOR 5A , —C(O)NR 5A R 5B , —NO 2 , —SR 5A , —S(O) n5 R 5A , —S(O) n5 OR 5A , —S(O) n5 NR 5A R 5B , —NHNR 5A R 5B , —ONR 5A R 5B , —NHC(O)NHNR 5A R 5B , R 5A1 -substituted or unsubstituted alkyl, R 5A1 -substituted or unsubstituted heteroalkyl, R 5A1 -substituted or unsubstituted cycloalkyl, R 5A1 -substituted or unsubstituted heterocycloalkyl, R 5A1 -substituted or unsubstituted aryl, or R 5A1 -substituted or unsubstituted heteroaryl, wherein R 4 and R 5 are optionally joined together to form a substituted or unsubstituted heterocycloalkyl, or substituted or unsubstituted heteroaryl. R 5A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 5A2 -substituted or unsubstituted alkyl, R 5A2 -substituted or unsubstituted heteroalkyl, R 5A2 -substituted or unsubstituted cycloalkyl, R 5A2 -substituted or unsubstituted heterocycloalkyl, R 5A2 -substituted or unsubstituted aryl, or R 5A2 -substituted or unsubstituted heteroaryl. R 5A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 5A3 -substituted or unsubstituted alkyl, R 5A3 -substituted or unsubstituted heteroalkyl, R 5A3 -substituted or unsubstituted cycloalkyl, R 5A3 -substituted or unsubstituted heterocycloalkyl, R 5A3 -substituted or unsubstituted aryl, or R 5A3 -substituted or unsubstituted heteroaryl. R 5A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0105] In embodiments, R 6 is —CF 3 , R 6A1 -substituted cyclopropyl, or R 6A1 -substituted cyclobutyl. R 6A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 6A2 -substituted or unsubstituted alkyl, R 6A2 -substituted or unsubstituted heteroalkyl, R 6A2 -substituted or unsubstituted cycloalkyl, R 6A2 -substituted or unsubstituted heterocycloalkyl, R 6A2 -substituted or unsubstituted aryl, or R 6A2 -substituted or unsubstituted heteroaryl. R 6A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 6A3 -substituted or unsubstituted alkyl, R 6A3 -substituted or unsubstituted heteroalkyl, R 6A3 -substituted or unsubstituted cycloalkyl, R 6A3 -substituted or unsubstituted heterocycloalkyl, R 6A3 -substituted or unsubstituted aryl, or R 6A3 -substituted or unsubstituted heteroaryl. R 6A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0106] In embodiments, R 7 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 7A , —NR 7A R 7B , —COOR 7A , —C(O)NR 7A R 7B , —NO 2 , —SR 7A , —S(O) n7 R 7A , —S(O) n7 OR 7A , —S(O) n7 NR 7A R 7B , —NHNR 7A R 7B , —ONR 7A R 7B , —NHC(O)NHNR 7A R 7B , R 7A1 -substituted or unsubstituted alkyl, R 7A1 -substituted or unsubstituted heteroalkyl, R 7A1 -substituted or unsubstituted cycloalkyl, R 7A1 -substituted or unsubstituted heterocycloalkyl, R 7A1 -substituted or unsubstituted aryl, or R 7A1 -substituted or unsubstituted heteroaryl. R 7A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 7A2 -substituted or unsubstituted alkyl, R 7A2 -substituted or unsubstituted heteroalkyl, R 7A2 -substituted or unsubstituted cycloalkyl, R 7A2 -substituted or unsubstituted heterocycloalkyl, R 7A2 -substituted or unsubstituted aryl, or R 7A2 -substituted or unsubstituted heteroaryl. R 7A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 7A3 -substituted or unsubstituted alkyl, R 7A3 -substituted or unsubstituted heteroalkyl, R 7A3 -substituted or unsubstituted cycloalkyl, R 7A3 -substituted or unsubstituted heterocycloalkyl, R 7A3 -substituted or unsubstituted aryl, or R 7A3 -substituted or unsubstituted heteroaryl. R 7A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0107] In embodiments, R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A , R 7B , R 8A , R 8B , R 9A , R 9B , R 10A and R 10B are independently hydrogen, R 11A1 -substituted or unsubstituted alkyl, R 11A1 -substituted or unsubstituted heteroalkyl, R 11A1 -substituted or unsubstituted cycloalkyl, R 11A1 -substituted or unsubstituted heterocycloalkyl, R 11A1 -substituted or unsubstituted aryl, or R 11A1 -substituted or unsubstituted heteroaryl. R 11A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0108] In embodiments, one or more of R 1 , R 2 , R 3 , R 4 , R 5 , R 7 , R 8 , R 9 or R 19 is independently a size-limited substituent or a lower substituent. In embodiments, R 1 , R 2 , R 3 , R 4 , R 5 , R 7 , R 8 , R 9 or R 10 is independently substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0109] In embodiments, one or more of R 1A1 , R 1A2 , or R 1A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 1A1 is independently R 1A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 1A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 1A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 1A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 1A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 1A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 1A2 is independently R 1A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 1A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 1A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 1A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 1A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 1A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 1A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0110] In embodiments, one or more of R 2A1 , R 2A2 , or R 2A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 2A1 is independently R 2A1 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 2A1 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 2A2 -substituted or unsubstituted C 3 -C 6 (e.g., C 5 -C 7 ) cycloalkyl, R 2A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 2A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 2A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 2A2 is independently R 2A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 2A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 2A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 2A1 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 2A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 2A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 2A3 is independently unsubstituted (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g. C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0111] In embodiments, one or more of R 3A1 , R 3A2 , or R 3A3 is a size-limited substituent or a lower substituent. In embodiments, R 3A1 is independently R 3A2 -substituted or unsubstituted C 1 -C 13 (e.g., C 1 -C 6 ) alkyl, R 3A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 3A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 3A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 3A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 3A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 3A2 is independently R 3A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 3A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 3A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 3A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, R 3A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 3A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 3A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 5 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0112] In embodiments, one or more of R 4A1 , R 4A2 , or R 4A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 4A1 is independently R 4A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 4A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 4A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 4A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 4A2 -substituted or unsubstituted (e.g., C 5 -C 6 ) aryl, or R 4A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 4A2 is independently R 4A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 4A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 4A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 4A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 4A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 4A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 4A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0113] In embodiments, one or more of R 5A1 , R 5A2 , or R 5A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 5A2 is independently R 5A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 5A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 5A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 5A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 5A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 5A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 5A2 is independently R 5A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 5A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 5A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 5A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 5A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 5A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 5A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0114] In embodiments, one or more of R 6A1 , R 6A2 , or R 6A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 6A1 is independently R 6A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 6A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 6A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 6A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 6A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 6A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 6A2 is independently R 6A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 6A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 6A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 6A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 6A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 6A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 6A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0115] In embodiments, one or more of R 7A1 , R 7A2 , or R 7A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 7A1 is independently R 7A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 7A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 7A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 7A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 7A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 7A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 7A2 is independently R 7A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 7A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 7A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 7A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 7A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 7A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 7A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g. C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycbalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0116] In embodiments of any formula disclosed herein, one or more of R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A , R 7B , R 8A , R 8B , R 9A , R 9B , R 10A and R 10B is independently a size-limited substituent or a lower substituent. In embodiments, R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A , R 7B , R 8A , R 8B , R 9A , R 9B , R 10A or R 10B is independently R 11A1 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 1A1 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 11A1 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 11A1 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 11A1 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 11A1 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0117] In embodiments, R 11A1 is independently a size-limited substituent or a lower substituent. In embodiments, R 11A1 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 5 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0118] In embodiments of the compounds of Formulae (I)-(IV), the compounds have the structure of one of Formulae (Ia)-(IVa) following.
[0000]
[0119] In embodiments of the compound of Formulae (I)-(II), z1 is 0, 1 or 2. In embodiments, z1 is 0. In embodiments, z1 is 1. In embodiments, z1 is 2.
[0120] In embodiments, z1 is 0, and the compounds of Formulae (I)-(II) have the structures following:
[0000]
[0121] In embodiments, z1 is 1, and the compounds of Formulae (I)-(II) have the structures following:
[0000]
[0122] In embodiments, z1 is 2, and the compounds of Formulae (I)-(II) have the structures following:
[0000]
[0123] Further to the compounds with structure of any of Formulae (I)-(IV), and embodiments thereof, in embodiments R 1 is hydrogen, or substituted or unsubstituted alkyl. In embodiments, R 1 is unsubstituted alkyl. In embodiments, R 1 is substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl. In embodiments, R 1 is unsubstituted C 1 -C 6 alkyl. In embodiments, R 1 is methyl, ethyl, n-propyl, isopropyl, butyl, tert-butyl, pentyl or hexyl. In embodiments, R 1 is methyl.
[0124] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments R 2 is hydrogen or —OR 2A . In embodiments, R 2 is hydrogen. In embodiments, R 2 is —OR 2A , and the compounds have a structure following:
[0000]
[0125] In embodiments wherein R 2 is —OR 2A , R 2A is hydrogen, or substituted or unsubstituted alkyl. In embodiments, R 2A is hydrogen. In embodiments, R 2A is unsubstituted alkyl. In embodiments, R 2A is unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl. In embodiments, e is methyl, ethyl, n-propyl, isopropyl, butyl, tert-butyl, pentyl or hexyl. In embodiments, R 2A is methyl.
[0126] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments the compounds have a structure following:
[0000]
[0127] In embodiments, R 3 is hydrogen, halogen, —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl. In embodiments, R 3 is hydrogen. In embodiments, R 3 is substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl.
[0128] In embodiments, R 3 is unsubstituted alkyl. In embodiments, R 3 is unsubstituted C 1 -C 10 alkyl. In embodiments, R 3 is methyl, ethyl, n-propyl or isopropyl. In embodiments, R 3 is methyl.
[0129] In embodiments, R 3 is substituted alkyl. In embodiments, R 3 is substituted C 1 -C 10 alkyl. In embodiments, R 3 is substituted C 1 -C 6 alkyl. In embodiments, R 3 is substituted C 1 -C 3 alkyl. In embodiments, R 3 is substituted methyl or substituted ethyl. In embodiments, R 3 is substituted methyl.
[0130] In embodiments, R 3 is R 3A1 -substituted alkyl. In embodiments, R 3 is R 3A1 -substituted C 1 -C 10 alkyl, R 3A1 -substituted C 1 -C 6 alkyl or R 3A1 -substituted C 1 -C 3 alkyl. In embodiments, R 3 is R 3A1 -substituted methyl or R 3A1 -substituted ethyl. In embodiments, R 3 is R 3A1 -substituted methyl.
[0131] In embodiments, R 3 is R 3A1 -substituted alkyl, and R 3A1 is halogen. In embodiments, R 3 is R 3A1 -substituted C 1 -C 10 alkyl, and R 3A1 is halogen. In embodiments, R 3 is R 3A1 -substituted C 1 -C 6 alkyl, and R 3A1 is halogen. In embodiments, R 3 is R 3A1 -substituted C 1 -C 3 alkyl, and R 3A1 is halogen. In embodiments, R 3A1 is independently present at R 3 one or more times. In embodiments, R 3A1 is present at R 3 one time. In embodiments, R 3A1 is independently present at R 3 a plurality of times. In embodiments, R 3 is —CH 2 F, —CHF 2 , —CH 2 —CF 3 , —CH 2 —CHF 2 or —CH 2 —CH 2 F.
[0132] In embodiments, R 3A1 is —CF 3 .
[0133] In embodiments, R 3 is R 3A1 -substituted alkyl, and R 3A1 is —OH. In embodiments, R 3 is R 3A1 -substituted C 1 -C 10 alkyl, R 3A1 -substituted C 1 -C 6 alkyl or R 3A1 -substituted C 1 -C 3 alkyl, and R 3A1 is —OH. In embodiments, R 1A3 is independently present at R 3 one or more times. In embodiments, R 3A1 is present at R 3 one time. In embodiments, R 3 is —CH 2 OH, —(CH 2 ) 2 OH, —(CH 2 ) 3 OH, or —CH 2 —C(CH 3 ) 2 OH.
[0134] In embodiments, R 3A1 is R 3A2 -substituted or unsubstituted heterocycloalkyl. In embodiments, R 3A1 is unsubstituted heterocycloalkyl. In embodiments, R 3A1 is R 3A2 -substituted heterocycloalkyl. In embodiments, R 3A1 is R 3A2 -substituted or unsubstituted 3 to 8 membered heterocycloalkyl. In embodiments, R 3A1 is unsubstituted 3 to 8 membered heterocycloalkyl. In embodiments, R 3A1 is R 3A2 -substituted unsubstituted 3 to 8 membered heterocycloalkyl. In embodiments, R 3A2 is halogen or unsubstituted C 1 -C 6 alkyl. In embodiments, R 3A2 is halogen present one or more times. In embodiments, R 3A2 is unsubstituted C 1 -C 6 alkyl. In embodiments, R 3A2 is unsubstituted methyl, ethyl, n-propyl or isopropyl.
[0135] In embodiments, R 3 is methyl substituted with 4-methylpiperazin-1-yl, or methyl substituted with 3,3-difluoropyrrolidin-1-yl.
[0136] In embodiments, R 3 is substituted or unsubstituted heteroalkyl. In embodiments, R 3 is unsubstituted heteroalkyl. In embodiments, R 3 is unsubstituted 2 to 10 membered heteroalkyl. In embodiments, R 3 is substituted heteroalkyl. In embodiments, R 3 is substituted 2 to 10 membered heteroalkyl.
[0137] In embodiments, R 3 is R 3A1 -substitutedheteroalkyl. In embodiments, R 3 is R 3A1 -substituted 2 to 10 membered heteroalkyl. In embodiments, R 3 includes a nitrogen within the heteroalkyl chain. In embodiments, R 3 includes an oxygen within the heteroalkyl chain. In embodiments, R 3A1 is R 3A2 -substituted or unsubstituted alkyl. In embodiments, R 3A1 is R 3A2 -substituted C 1 -C 13 alkyl. In embodiments, R 3A1 is unsubstituted C 1 -C 10 alkyl. In embodiments, R 3A1 is unsubstituted C 1 -C 3 alkyl. In embodiments, R 3A1 is unsubstituted methyl. In embodiments, R 3A1 is unsubstituted ethyl. In embodiments, R 3A1 is unsubstituted isopropyl. In embodiments, R 3A2 is unsubstituted alkyl. In embodiments, R 3A2 is unsubstituted C 1 -C 10 alkyl. In embodiments, R 3A2 is unsubstituted C 1 -C 3 alkyl.
[0138] In embodiments, R 3 is —CH 2 —O—CH 3 , —(CH 2 ) 2 —O—CH 3 , —CH 2 NHCH 3 , —(CH 2 ) 2 NHCH 3 , —CH 2 N(CH 3 ) 2 , or —(CH 2 ) 2 N(CH 3 ) 2 .
[0139] In embodiments, R 3 is substituted or unsubstituted cycloalkyl. In embodiments, R 3 is substituted cycloalkyl. In embodiments, R 3 is unsubstituted cycloalkyl. In embodiments, R 3 is substituted C 3 -C 8 cycloalkyl. In embodiments, R 3 is unsubstituted C 3 -C 8 cycloalkyl. In embodiments, R 3 is unsubstituted C 3 -C 6 cycloalkyl. In embodiments, R 3 is unsubstituted cyclopropyl, unsubstituted cyclobutyl, unsubstituted cyclopentyl or unsubstituted cyclohexyl. In embodiments, R 3 is unsubstituted cyclopropyl. In embodiments, R 3 is unsubstituted cyclobutyl. In embodiments, R 3 is unsubstituted cyclopentyl. In embodiments, R 3 is unsubstituted cyclohexyl.
[0140] In embodiments, R 3 is R 3A1 -substituted cycloalkyl. In embodiments, R 3 is R 3A1 -substituted C 3 -C 6 cycloalkyl. In embodiments, R 3A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0141] In embodiments, R 3 is substituted or unsubstituted heterocycloalkyl. In embodiments, R 3 is substituted heterocycloalkyl. In embodiments, R 3 is unsubstituted heterocycloalkyl. In embodiments, R 3 is substituted 3 to 6 membered heterocycloalkyl. In embodiments, R 3 is unsubstituted 3 to 6 membered heterocycloalkyl. In embodiments, R 3 includes a nitrogen within the substituted or unsubstituted heterocycloalkyl. In embodiments, R 3 includes an oxygen within the substituted or unsubstituted heterocycloalkyl.
[0142] In embodiments, R 3 is unsubstituted 3 to 6 membered heterocycloalkyl, and R 3 is oxiranyl, oxetanyl, tetrahydrofuranyl, or tetrahydro-2H-pyranyl.
[0143] In embodiments, R 3 is R 3A1 -substituted heterocycloalkyl. In embodiments, R 3 is R 3A1 -substituted 3 to 6 membered heterocycloalkyl. In embodiments, R 3A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl. In embodiments, R 3A1 is independently halogen. In embodiments, R 3A1 is independently unsubstituted alkyl. In embodiments, R 3A1 is independently unsubstituted C 1 -C 3 alkyl.
[0144] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments R 4 is hydrogen, or substituted or unsubstituted alkyl. In embodiments, R 4 is hydrogen. In embodiments, R 4 is unsubstituted alkyl. In embodiments, R 4 is substituted alkyl. In embodiments, R 4 is unsubstituted C 1 -C 3 alkyl. In embodiments, R 4 is substituted C 1 -C 3 alkyl. In embodiments, R 4 is methyl, ethyl, n-propyl, or isopropyl.
[0145] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments R 5 is hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl.
[0146] In embodiments, R 5 is hydrogen.
[0147] In embodiments, R 5 is unsubstituted alkyl. In embodiments, R 5 is unsubstituted C 1 -C 10 alkyl. In embodiments, R 5 is unsubstituted C 1 -C 6 alkyl. In embodiments, R 5 is unsubstituted C 1 -C 3 alkyl. In embodiments, R 5 is methyl, ethyl, n-propyl, or isopropyl.
[0148] In embodiments, R 5 is substituted alkyl. In embodiments, R 5 is substituted C 1 -C 10 alkyl. In embodiments, R 5 is substituted C 1 -C 6 alkyl. In embodiments, R 5 is substituted C 1 -C 3 alkyl.
[0149] In embodiments, R 5 is R 5A1 -substituted alkyl. In embodiments, R 5 is R 5A1 -substituted C 1 -C 10 alkyl. In embodiments, R 5 is R 5A1 -substituted C 1 -C 6 alkyl. In embodiments, R 5 is R 5A1 -substituted C 1 -C 3 alkyl.
[0150] In embodiments, R 5A1 is substituted or unsubstituted heterocycloalkyl. In embodiments, R 5A1 is substituted heterocycloalkyl. In embodiments, R 5A1 is unsubstituted heterocycloalkyl. In embodiments, R 5A1 is substituted 3 to 8 membered heterocycloalkyl. In embodiments, R 5A1 is unsubstituted 3 to 8 membered heterocycloalkyl. In embodiments, the unsubstituted 3 to 8 membered heterocycloalkyl is morpholinyl. In embodiments, R 5 is —(CH 2 ) 2 -morpholinyl or —CH 2 CH(CH 3 )-morpholinyl.
[0151] In embodiments, R 5 is R 5A1 -substituted alkyl, and R 5A1 is halogen. In embodiments, R 5 is R 5A1 -substituted C 1 -C 10 alkyl, and R 5A1 is halogen. In embodiments, R 5 is R 5A1 -substituted C 1 -C 6 alkyl, and R 5A1 is halogen. In embodiments, R 5 is R 5A1 -substituted C 1 -C 3 alkyl, and R 5A1 is halogen. In embodiments, R 5A1 is independently present at R 5 one or more times. In embodiments, R 5A1 is present at R 5 one time.
[0152] In embodiments, R 5A1 is independently present at R 5 a plurality of times. In embodiments, R 5A1 is fluorine. In embodiments, R 5 is —CH 2 F, —CHF 2 , —CH 2 —CF 3 , —CH 2 —CHF 2 or —CH 2 —CH 2 F.
[0153] In embodiments, R 5A1 is —CF 3 .
[0154] In embodiments, R 5 is R 5A1 -substituted alkyl, and R 5A1 is —OH. In embodiments, R 5 is R 5A1 -substituted C 1 -C 10 alkyl, R 5A1 -substituted C 1 -C 6 alkyl or R 5A1 -substituted C 1 -C 3 alkyl, and R 5A1 is —OH. In embodiments, R 5A1 is independently present at R 5 one or more times. In embodiments, R 5A1 is present at R 5 one time. In embodiments, R 5 is —CH 2 OH, —(CH 2 ) 2 OH, —(CH 2 ) 3 OH, or —CH 2 —C(CH 3 ) 2 OH.
[0155] In embodiments, R 5 is R 5A1 -substituted alkyl, and R 5A1 is independently substituted or unsubstituted cycloalkyl. In embodiments, R 5A1 is independently substituted cycloalkyl. In embodiments, R 5A1 is independently unsubstituted cycloalkyl. In embodiments, R 5A1 is independently substituted or unsubstituted C 3 -C 8 cycloalkyl. In embodiments, R 5A1 is independently substituted C 3 -C 8 cycloalkyl. In embodiments, R 5A1 is independently unsubstituted C 3 -C 5 cycloalkyl. In embodiments, R 5A1 is independently unsubstituted cyclopropyl. In embodiments, R 5A1 is independently substituted cyclopropyl. In embodiments, R 5 is —(CH 2 )-cyclopropyl or —(CH 2 ) 2 -cyclopropyl.
[0156] In embodiments, R 5 is substituted or unsubstituted heteroalkyl. In embodiments, R 5 is substituted heteroalkyl. In embodiments, R 5 is unsubstituted heteroalkyl. In embodiments, R 5 is substituted 2 to 8 membered heteroalkyl. In embodiments, R 5 is unsubstituted 2 to 8 membered heteroalkyl. In embodiments, R 5 is —CH 2 OCH 3 , or —(CH 2 ) 2 OCH 3 .
[0157] In embodiments, R 5 is substituted or unsubstituted cycloalkyl. In embodiments, R 5 is substituted cycloalkyl. In embodiments, is unsubstituted cycloalkyl. In embodiments, R 5 is substituted C 3 -C 5 cycloalkyl. In embodiments, R 5 is unsubstituted C 3 -C 5 cycloalkyl. In embodiments, R 5 is cyclopropyl, cyclobutyl, cyclopentyl, or cyclohexyl.
[0158] In embodiments, R 5 is substituted or unsubstituted heterocycloalkyl. In embodiments, R 5 is substituted heterocycloalkyl. In embodiments, R 5 is unsubstituted heterocycloalkyl. In embodiments, R 5 is substituted 3 to 8 membered heterocycloalkyl. In embodiments, R 5 is unsubstituted 3 to 8 membered heterocycloalkyl. In embodiments, R 5 is tetrahydro-2H-pyranyl.
[0159] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments R 6 is —CF 3 .
[0160] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments R 7 is independently hydrogen, —CF 3 , or substituted or unsubstituted alkyl. In embodiments R 7 is substituted alkyl. In embodiments R 7 is unsubstituted alkyl. In embodiments, R 7 is present once. In embodiments, R 7 is independently present a plurality of times. In embodiments, R 7 is independently present twice. In embodiments, R 7 is independently present thrice. In embodiments, R 7 is independently unsubstituted C 1 -C 10 alkyl. In embodiments, R 7 is independently unsubstituted C 1 -C 6 alkyl. In embodiments, R 7 is independently unsubstituted C 1 -C 5 alkyl. In embodiments, R 7 is methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl.
[0161] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments X 1 is —C(R 3 ), and R 3 and R 7 are hydrogen. In embodiments X 1 is X 1 is —C(R 3 ), R 3 and R 7 are hydrogen, R 1 is unsubstituted alkyl, and R 2 is —OR 2A . In embodiments, X 1 is —C(R 3 ), R 3 and R 7 are hydrogen, R 1 is unsubstituted C 1 -C 5 alkyl, and R 2 is —OR 2A , wherein R 2A is unsubstituted C 1 -C 5 alkyl. In embodiments, the compounds have a structure following:
[0000]
[0162] In embodiments, X 1 is C(R 3 ), R 3 and R 7 are hydrogen, R 1 is methyl, and R 2 is —OCH 3 .
[0163] Further to the compounds with structure of any one of Formulae (I)-(IV), and embodiments thereof, in embodiments X 1 is N. In embodiments, the compounds have a structure following:
[0000]
[0164] Further to the compounds with structure of any one of Formulae (III)-(IV), and embodiments thereof, in embodiments the compounds have a structure following:
[0000]
[0165] Regarding Formulae (IIIb)-(IVb), R 8 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 8A , —NR 8A R 8B , —COOR 8A , —C(O)NR 8A R 8B , —NO 2 , —SR 8A , —S(O) n8 R 8A , —S(O) n8 R 8A , —S(O) n8 NR 8A R 8B , —NHNR 8A R 8B , —ONR 8A R 8B , —NHC(O)NHNR 8A R 8B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 8A and R 8B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. n8 is 1 or 2.
[0166] In embodiments, R 8 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CN, —CHO, —OR 8A , —NR 8A R 8B , —COOR 8A , —C(O)NR 8A R 8B , —NO 2 , —SR 8A , —S(O) n8 R 8A , S(O) n8 OR 8A , —S(O) n8 NR 8A R 8B , —NHNR 8A R 8B , —ONR 8A R 8B , —NHC(O)NHNR 8A R 8B , R 8A1 -substituted or unsubstituted alkyl, R 8A1 -substituted or unsubstituted heteroalkyl, R 8A1 -substituted or unsubstituted cycloalkyl, R 8A1 -substituted or unsubstituted heterocycloalkyl, R 8A1 -substituted or unsubstituted aryl, or R 8A1 -substituted or unsubstituted heteroaryl. R 8A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 8A2 -substituted or unsubstituted alkyl, R 8A2 -substituted or =substituted heteroalkyl, R 8A2 -substituted or unsubstituted cycloalkyl, R 8A2 -substituted or an substituted heterocycloalkyl, R 8A2 -substituted or unsubstituted aryl, or R 8A2 -substituted or unsubstituted heteroaryl. R 8A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 8A3 -substituted or unsubstituted alkyl, R 8A3 -substituted or unsubstituted heteroalkyl, R 8A3 -substituted or unsubstituted cycloalkyl, R 8A3 -substituted or unsubstituted heterocycloalkyl, R 8A3 -substituted or unsubstituted aryl, or R 8A3 -substituted or unsubstituted heteroaryl. R 8A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0167] In embodiments, one or more of R 8A1 , R 8A2 , or R 8A3 is a size-limited substituent or a lower substituent. In embodiments, R 8A1 is independently R 8A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 5 ) alkyl, R 8A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 8A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 8A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 8A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 8A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 8A2 is independently R 8A3 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 8A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 8A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 8A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 8A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 8A3 substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 8A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0168] In embodiments, R 8 is independently unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0169] In embodiments, R 8 is independently substituted alkyl, substituted heteroalkyl, substituted cycloalkyl, substituted heterocycloalkyl, substituted aryl, or substituted heteroaryl.
[0170] In embodiments, the compound of Formula (IIIb) has the structure following:
[0000]
[0171] In embodiments, the compound of Formula (IVb) has the structure following:
[0000]
[0172] In embodiments, the compound of Formula (IIIc) has the structure following:
[0000]
[0173] In embodiments, the compound of Formula (IIIc) has the structure following:
[0000]
[0174] Further to the compounds with structure of any one of Formulae (III)-(IV), and embodiments thereof, in embodiments the compounds have a structure following:
[0000]
[0175] Regarding Formulae (Ille) and (IVe), R 8 , R 8A , R 8B , n1, n2, n3, n4, n5, n7 and n8 are as disclosed for Formulae (IIIb)-(IVb).
[0176] In embodiments, the compounds of Formulae (IIIe)-(IVe) have the structure of Formulae (IIIf)-(IVf) following:
[0000]
[0177] Further to the compounds with structure of any one of Formulae (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, in embodiments R 8 is independently hydrogen, halogen, —CF 3 , or substituted or unsubstituted alkyl. In embodiments, R 8 is independently hydrogen. In embodiments, R 8 is independently halogen. In embodiments, R 8 is independently fluoro. In embodiments, R 8 is independently —CF 3 . In embodiments, R 8 is independently substituted or unsubstituted alkyl. In embodiments, R 8 is independently substituted alkyl. In embodiments, R 8 is independently unsubstituted alkyl. In embodiments, R 8 is independently substituted C 1 -C 6 alkyl. In embodiments, R 8 is independently unsubstituted C 1 -C 6 alkyl. In embodiments, R 8 is methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl. In embodiments, R 8 is methyl. In embodiments, R 8 is ethyl. In embodiments, R 8 is n-propyl. In embodiments, R 8 is isopropyl. In embodiments, R 8 is isobutyl. In embodiments, R 8 is pentyl.
[0178] Further to the compounds with structure of any one of Formulae (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, in embodiments X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted alkyl, R 2 is —OR 2A and R 8 is unsubstituted alkyl. In embodiments, X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted C 1 -C 5 alkyl, R 2 is —OR 2A and R 8 is unsubstituted C 1 -C 5 alkyl, wherein R 2A is unsubstituted C 1 -C 5 alkyl. In embodiments, X 1 is C(R 3 ), R 3 is hydrogen, R is methyl, R 8 is methyl and R 2 is —OCH 3 .
[0179] Further to the compounds with structure of any one of Formulae (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, in embodiments X 1 is N.
[0180] Further to the compounds with structure of any one of Formulae (I)-(IV), (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, in embodiments R 4 and R 5 are combined to form ring Z having the formula:
[0000]
[0181] Thus, in embodiments where R 4 and R 5 are combined to form ring Z, the compounds of Formulae (I)-(IV) and embodiments thereof have the respective structures:
[0000]
[0182] For Formula (Va) and embodiments thereof including Formulae (IZ)-(IVZ), z2 is 0, 1, or 2. R 9 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 9A , —NR 9A R 9B , —COOR 9A , —C(O)NR 9A R 9B , —NO 2 , —SR 9A , —S(O) n9 R 9A , —S(O) n9 R 9A , —S(O) n9 NR 9A R 9B , —NHNR 9A R 9B , —ONR 9A R 9B , —NHC(O)NHNR 9A R 9B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 9A and R 9B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. n9 is 1 or 2.
[0183] In embodiments, R 9 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 9A , —NR 9A R 9B , —COOR 9A , —C(O)NR 9A R 9B , —NO 2 , —SR 9A , —S(O) n9 R 9A , —S(O) n9 R 9A , —S(O) n9 R 9A R 9B , —NHNR 9A R 9B , —ONR 9A R 9B , —NHC(O)NHNR 9A R 9B , R 9A1 -substituted or unsubstituted alkyl, R 9A1 -substituted or unsubstituted heteroalkyl, R 9A1 -substituted or unsubstituted cycloalkyl, R 9A1 -substituted or unsubstituted heterocycloalkyl, R 9A1 -substituted or unsubstituted aryl, or R 9A1 -substituted or unsubstituted heteroaryl. R 9A1 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 9A2 -substituted or unsubstituted alkyl, R 9A2 -substituted or unsubstituted heteroalkyl, R 9A2 -substituted or unsubstituted cycloalkyl, R 9A2 -substituted or unsubstituted heterocycloalkyl, R 9A2 -substituted or unsubstituted aryl, or R 9A2 -substituted or unsubstituted heteroaryl. R 9A2 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, R 9A3 -substituted or unsubstituted alkyl, R 9A3 -substituted or unsubstituted heteroalkyl, R 9A3 -substituted or unsubstituted cycloalkyl, R 9A3 -substituted or unsubstituted heterocycloalkyl, R 9A3 -substituted or unsubstituted aryl, or R 9A3 -substituted or unsubstituted heteroaryl. R 9A3 is independently halogen, —CN, —CF 3 , —OH, —NH 2 , —SO 2 , —COOH, unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0184] In embodiments, one or more of R 9A1 , R 9A2 , or R 9A3 is independently a size-limited substituent or a lower substituent. In embodiments, R 9A1 is independently R 9A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 9A2 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 9A2 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 9A2 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 9A2 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 9A2 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 9A2 is independently R 9A2 -substituted or unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, R 9A3 -substituted or unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, R 9A3 -substituted or unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, R 9A3 -substituted or unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, R 9A3 -substituted or unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or R 9A3 -substituted or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl. In embodiments, R 9A3 is independently unsubstituted C 1 -C 10 (e.g., C 1 -C 6 ) alkyl, unsubstituted 2 to 10 membered (e.g., 2 to 6 membered) heteroalkyl, unsubstituted C 3 -C 8 (e.g., C 5 -C 7 ) cycloalkyl, unsubstituted 3 to 8 membered (e.g., 3 to 6 membered) heterocycloalkyl, unsubstituted C 5 -C 10 (e.g., C 5 -C 6 ) aryl, or unsubstituted 5 to 8 membered (e.g., 5 to 6 membered) heteroaryl.
[0185] In embodiments, R 9 is independently unsubstituted alkyl, unsubstituted heteroalkyl, unsubstituted cycloalkyl, unsubstituted heterocycloalkyl, unsubstituted aryl, or unsubstituted heteroaryl.
[0186] In embodiments, R 9 is independently substituted alkyl, substituted heteroalkyl, substituted cycloalkyl, substituted heterocycloalkyl, substituted aryl, or substituted heteroaryl.
[0187] Further to compounds having ring Z of Formula (Va), in embodiments the compound includes a plurality of independent: R 9 substituents. In embodiments, the compound includes one R 9 substituent. In embodiments, the compound includes two independent R 9 substituents. In embodiments, the compound includes three independent R 9 substituents.
[0188] Further to compounds of Formulae (I)-(IV) having ring Z of Formula (Va), in embodiments z2 is 0, 1 or 2. In embodiments, z2 is 0. In embodiments, z2 is 1. In embodiments, z2 is 2.
[0189] Further to compounds of Formulae (I)-(IV) having ring Z of Formula (Va), in embodiments R 9 is hydrogen, halogen, —OR 9A , —NR 9A R 9B , substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl. In embodiments, R 9 is hydrogen. In embodiments, R 9 is halogen. In embodiments, R 9 is fluoro. In embodiments, R 9 is —OR 9A . In embodiments, R 9 is —OH. In embodiments, R 9 is —NR 9A R 9B . In embodiments, R 9 is —N(CH 3 ) 2 .
[0190] In embodiments, R 9 is substituted or unsubstituted alkyl. In embodiments, R 9 is unsubstituted C 1 -C 6 alkyl. In embodiments, R 9 is methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl.
[0191] In embodiments, R 9 is substituted alkyl. In embodiments, R 9 is substituted C 1 -C 6 alkyl. In embodiments, R 9 is C 1 -C 6 alkyl substituted with —OH. In embodiments, R 9 is —CH 2 OH or —C(CH 3 ) 2 OH.
[0192] Further to compounds of Formulae (I)-(IV) having ring Z of Formula (Va), in embodiments R 9 is substituted or unsubstituted cycloalkyl. In embodiments, R 9 is unsubstituted cycloalkyl. In embodiments, R 5 is substituted cycloalkyl. In embodiments, R 9 is unsubstituted C 3 -C 8 cycloalkyl. In embodiments, R 9 is substituted C 3 -C 8 cycloalkyl.
[0193] Further to compounds of Formulae (I)-(IV) having ring Z of Formula (Va), in embodiments R 9 is substituted or unsubstituted heterocycloalkyl. In embodiments, R 9 is unsubstituted heterocycloalkyl. In embodiments, R 9 is substituted heterocycloalkyl. In embodiments, R 9 is unsubstituted 3 to 8 membered heterocycloalkyl. In embodiments, R 9 is substituted 3 to 8 membered heterocycloalkyl.
[0194] In embodiments, R 9 is pyrrolidinyl-2,5-dione. In embodiments, R 9 is pyrrolidin-1-yl.
[0195] Further to compounds of Formulae (I)-(IV) having ring Z of Formula (Va), in embodiments R 9 is X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted alkyl and R 2 is —OR 2A . In embodiments, X 1 is C(R 3 ), R 3 is hydrogen, R is unsubstituted C 1 -C 5 alkyl and R 2 is —OR 2A , wherein R 2A is unsubstituted C 1 -C 5 alkyl. In embodiments, X 1 is C(R 3 ), R 3 is hydrogen, R 1 is methyl and R 2 is —OCH 3 .
[0196] Further to the compounds with structure of any one of Formulae (I)-(IV), (IIIb), (IIIc), (IIId), (IIIe), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, in embodiments R 4 and R 5 are combined to form ring Y having the formula:
[0000]
[0197] Thus, in embodiments where R 4 and R 5 are combined to form ring Y, the compounds of Formulae (I)-(IV) and embodiments thereof have the respective structures:
[0000]
[0198] For Formula (Vb) and embodiments thereof including Formulae (IY)-(IVY), z3 is 0, 1, or 2. R 10 is ═O, ═S, ═CR 10A R 10B , or ═NR 10C . R 10A an R 10B are independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 NR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl. R 10C is hydrogen or —OR 10A .
[0199] In embodiments of compounds of Formulae (I)-(IV) having ring Y of Formula (Vb), z3 is O. In embodiments, z3 is 1. In embodiments, z3 is 2.
[0200] In embodiments of compounds of Formulae (I)-(IV) having ring Y of Formula (Vb), R 10 is ═CR 10A R 10B . In embodiments, R 10A and R 10B are hydrogen.
[0201] In embodiments of compounds of Formulae (I)-(IV) having ring Y of Formula (Vb), R 10 is ═NR 10C . In embodiments, R 10C is hydrogen. In embodiments, R 10A is unsubstituted alkyl. In embodiments, R 10A is unsubstituted C 1 -C 6 alkyl. In embodiments, R═N—OH. In embodiments, R 10 is ═NOCH 3 .
III. Pharmaceutical Compositions
[0202] In another aspect, there is provided a pharmaceutical composition including a compound with structure of any one of Formulae (I)-(IV), (IIIb), (IIIc), (IIId), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, in combination with a pharmaceutically acceptable excipient (e.g., carrier).
[0203] Pharmaceutical compositions provided herein include compositions wherein the active ingredient (e.g. compounds described herein, including embodiments or examples) is contained in a therapeutically effective amount, i.e., in an amount effective to achieve its intended purpose. The actual amount effective for a particular application will depend, inter alia, on the condition being treated. Determination of a therapeutically effective amount of a compound of the invention is well within the capabilities of those skilled in the art, especially in light of the detailed disclosure herein.
[0204] The dosage and frequency (single or multiple doses) administered to a mammal can vary depending upon a variety of factors, for example, whether the mammal suffers from another disease, and its route of administration; size, age, sex, health, body weight, body mass index, and diet of the recipient; nature and extent of symptoms of the disease being treated, kind of concurrent treatment, complications from the disease being treated or other health-related problems. Other therapeutic regimens or agents can be used in conjunction with the methods and compounds of Applicants' invention. Adjustment and manipulation of established dosages (e.g., frequency and duration) are well within the ability of those skilled in the art.
[0205] In embodiments, the pharmaceutical composition is formulated for administration once daily. In embodiments, the pharmaceutical composition is formulated for administration twice daily. In embodiments, the pharmaceutical composition is formulated for administration once weekly. In embodiments, the pharmaceutical composition is formulated for administration 1, 2, 3, 4, 5, 6, or 7 times weekly.
[0206] A. Formulations
[0207] The compounds disclosed herein can be prepared and administered in a wide variety of oral, parenteral, and topical dosage formulations. Thus, the compounds of the present invention can be administered by injection (e.g. intravenously, intramuscularly, intracutaneously, subcutaneously, intraduodenally, or intraperitoneally). Also, the compounds described herein can be administered by inhalation, for example, intranasally. Additionally, the compounds of the present invention can be administered transdermally or by ocular instillation. Multiple routes of administration (e.g., intramuscular, oral, transdermal, ocular instillation) are contemplated that can be used to administer the compounds disclosed herein. Accordingly, the present invention also provides pharmaceutical compositions which includes a pharmaceutically acceptable carrier or excipient and one or more compounds.
[0208] In one embodiment, the pharmaceutical composition includes a compound disclosed herein at a concentration in the range of about 0.01% to 1.00% (w/v). In one embodiment, the concentration of the compound is about 0 01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.30%, 0.40%, 0.50%, 0.60%, 0.70%, 0.80%, 0.90%, or 1.00% (w/v), or even greater.
[0209] In one embodiment, the pharmaceutical composition includes one or more viscosity-enhancing agents, or thickening agents. Thickening agents are used for a variety of reasons, ranging from improving the form of the formulation for convenient administration to improving contact with an organ to improve bioavailability. The viscosity-enhancing agent may comprise a polymer containing hydrophilic groups such as monosaccharides, polysaccharides, ethylene oxide groups, hydroxyl groups, carboxylic acids or other charged functional groups. While not intending to limit the scope of the invention, some examples of useful viscosity-enhancing agents are sodium carboxymethylcellulose, hydroxypropyl methylcellulose, povidone, polyvinyl alcohol, and polyethylene glycol. In one embodiment, viscosity-enhancing agents are employed at a level between about 0.01% and about 2% (w/v).
[0210] In one embodiment, the pharmaceutical composition includes one or more tonicity agents useful to adjust the pharmaceutical composition to the desired isotonic range. Tonicity agents are well known in the art and some examples include glycerin, mannitol, sorbitol, sodium chloride, and other electrolytes. In one embodiment, the concentration of tonicity agent is in the range of about 0.1 to 2.00% (w/v). In one embodiment, the concentration of tonicity agent is in the range of about 1.15 to 1.30% (w/v). In one embodiment, the concentration of tonicity agent is about 0.10%, 0.20%, 0.30%, 0.40%, 0.50%, 0.60%, 0.70%, 0.80%, 0.90%, 1.00%, 1.10%, 1.20%, 1.30%, 1.40%, 1.50%, 1.60%, 1.70%, 1.80%, 1.90%, or 2.00%. In one embodiment, the concentration of tonicity agent is about 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, or 1.30% (w/v).
[0211] In one embodiment, the pharmaceutical composition includes a solubilizer (e.g., surfactant or other appropriate co-solvent) in order to facilitate solubilization of one or more components of the pharmaceutical composition. Such solubilizers include Polysorbate 20, 60, and 80, Pluronic F-68, F-84, and P-103, cyclodextrin, hydroxy-beta-cyclodextrin, solutol, polyoxyethylene 40 stearate, and polyoxyl 35 castor oil. Such solubilizers can be employed at a level between about 0.01% and about 2% by weight. In one embodiment, the solubilizer is present in the range of about 0.01% to 0.20% (w/v). In one embodiment, the solubilizer is present at 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20% (w/v). In one embodiment, the solubilizer is polysorbate 80.
[0212] In embodiments, the pharmaceutical composition includes a preservative. In one embodiment, the preservative is benzalkonium chloride, chlorine dioxide, chlorobutanol, thimerosal, phenylmercuric acetate, or phenylmercuric nitrate. In one embodiment, the preservative is present at a concentration in the range of about 0.01% to 0.05% (w/v). In one embodiment, the preservative is present at a concentration in the range of about 0.015% to 0.025% (w/v). In one embodiment, the concentration of the preservative is about 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.020%, 0.021%, 0.022%, 0.023%, 0.024%, or 0.025% (w/v). In one embodiment, the preservative is benzalkonium chloride.
[0213] The compositions of the present invention may additionally include components to provide sustained release and/or comfort. Such components include high molecular weight, anionic mucomimetic polymers, gelling polysaccharides, and finely-divided drug carrier substrates. These components are discussed in greater detail in U.S. Pat. Nos. 4,911,920; 5,403,841; 5,212,162; and 4,861,760, the entire contents of each of which are incorporated herein by reference in their entirety and for all purposes.
[0214] B. Effective Dosages
[0215] Pharmaceutical compositions contemplated herein include compositions wherein the active ingredient is contained in an effective amount, i.e., in an amount effective to achieve its intended purpose. A “reduction” of a symptom or symptoms (and grammatical equivalents of this phrase) means decreasing of the severity or frequency of the symptom(s), or elimination of the symptom(s). The actual amount effective for a particular application will depend, inter alia, on the condition being treated. For example, when administered in methods to treat accumulation of Aβ 42 or Aβ 40 , such compositions will contain amounts of active ingredients effective to achieve the desired result (e.g. decreasing the extent of Aβ 42 or Aβ 40 in a subject).
[0216] The dosage and frequency (single or multiple doses) of compounds administered can vary depending upon a variety of factors, including route of administration; size, age, sex, health, body weight, body mass index, and that of the recipient; nature and extent of symptoms of the disease being treated; presence of other diseases or other health-related problems; kind of concurrent treatment; and complications from any disease or treatment regimen. Other therapeutic regimens or agents can be used in conjunction with the methods and compounds of the invention.
[0217] For any compound described herein or combination thereof, the therapeutically effective amounts can be initially determined from cell culture assays. Target concentrations will be those concentrations of active compound(s) that are capable of decreasing accumulation of Aβ 42 or Aβ 40 as measured, for example, using methods known in the art.
[0218] Therapeutically effective amounts for use in humans may be determined from animal models. For example, a dose for humans can be formulated to achieve a concentration that has been found to be effective in animals.
[0219] Dosages may be varied depending upon the requirements of the subject and the compound being employed. The dose administered to a subject, in the context of the present invention, should be sufficient to effect a beneficial therapeutic response in the subject over time. The size of the dose also will be determined by the existence, nature, and extent of any adverse side effects. Generally, treatment is initiated with smaller dosages, which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under circumstances is reached.
[0220] Dosage amounts and intervals can be adjusted individually to provide levels of the administered compounds effective for the particular clinical indication being treated. This will provide a therapeutic regimen that is commensurate with the severity of the individual's disease state.
[0221] Utilizing the teachings provided herein, an effective therapeutic treatment regimen can be planned that does not cause substantial toxicity and yet is entirely effective to treat the clinical symptoms demonstrated by the particular patient. This planning should involve the careful choice of active compound by considering factors such as compound potency, relative bioavailability, patient body weight, presence and severity of adverse side effects, preferred mode of administration, and the toxicity profile of the selected agent.
[0222] C. Toxicity
[0223] The ratio between toxicity and therapeutic effect for a particular compound is its therapeutic index and can be expressed as the ratio between LD 50 (the amount of compound lethal in 50% of the population) and ED 50 (the amount of compound effective in 50% of the population). Compounds that exhibit high therapeutic indices are preferred. Therapeutic index data obtained from cell culture assays and/or animal studies can be used in formulating a range of dosages for use in humans. The dosage of such compounds preferably lies within a range of plasma concentrations that include the ED 50 with little or no toxicity. The dosage may vary within this range depending upon the dosage form employed and the route of administration utilized. See, e.g. Fingl et al., In: T HE P HARMACOLOGICAL B ASIS OF T HERAPEUTICS , Ch. 1, p. 1, 1975. The exact formulation, route of administration, and dosage can be chosen by the individual physician in view of the patient's condition and the particular method in which the compound is used.
IV. Methods of Use
[0224] In another aspect, there is provided use of a compound with structure of any one of Formulae (I)-(IV), (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (We), or (IVf), and embodiments thereof, for inhibiting production of Aβ 42 or Aβ 40 by a protease which proteolyzes an amyloid precursor protein (APP) or fragment thereof. In embodiments, the use is a method of inhibiting production of Aβ 42 or Aβ 40 , the method including contacting a protease which proteolyzes an amyloid precusor protein (APP) or fragment thereof with an effective amount of a compound disclosed herein so as to inhibit production of Aβ 42 or Aβ 40 . Methods for assaying Aβ peptides are well known in the art.
[0225] In embodiments, the compound has no measurable effect on gamma-secretase-mediated processing of Notch-1 receptor or no adverse effect associated with any altered Notch-1 receptor signaling. Method for determining the effect on gamma-secretase-mediated processing of Notch-1 receptor, and on altered of Notch-1 receptor signaling are well known in the art.
[0226] In another aspect, there is provided use of a compound with structure of any one of Formulae (I)-(IV), (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof, for treating a disease or neurological disorder associated with elevated levels of specific fibrillogenic Aβ peptides by inhibiting production of Aβ 42 or Aβ 40 . In embodiments, the use is a method of treating a disease or neurological disorder associated with elevated levels of specific fibrillogenic Aβ peptides by inhibiting production of Aβ 42 or Aβ 40 , the method including administering to a subject in need thereof an effective amount of a compound with structure of any one of Formulae (I)-(IV), (IIIb), (IIIc), (IIId), (IIIe), (IIIf), (IVb), (IVc), (IVd), (IVe), or (IVf), and embodiments thereof.
[0227] In embodiments, the disease or neurological disorder is Alzheimer's disease (AD), Down Syndrome (DS), hemorrhagic stroke associated with cerebrovascular amyloidosis (HCHWA), cerebral amyloid angiopathy (CAA), idiophathic dilated cardiomyopathy, hereditary cerebral hemorrhage with amyloidosis, Dutch type (HCHWA-D), prion disorders, Creutzfeldt-Jakob disease (CJD), frontotemporal dementias (FTD), amyotropic lateral sclerosis (ALS), Huntington's disease (HD), Parkinson's disease (PD) and other neurodegenerative proteinopathies. In embodiments, the disease or neurological disorder is Alzheimer's disease (AD), Down Syndrome IDS), hemorrhagic stroke associated with cerebrovascular amyloidosis (HCHWA), cerebral amyloid angiopathy (CAA), idiophathic dilated cardiomyopathy, hereditary cerebral hemorrhage with amyloidosis, Dutch type (HCHWA-D), prion disorders, Creutzfeldt-Jakob disease (CJD), frontotemporal dementias (FTD), amyotropic lateral sclerosis (ALS), Huntington's disease (HD), Parkinson's disease (PD).
[0228] In embodiments, the disease or neurological disorder is Alzheimer's disease (AD).
[0229] Preferably, compounds of the present invention can be used in the treatment of neurological disorders, including but not limited to neurodegenerative conditions and other dementias or traumatic conditions. Exemplary neurological disorders may include diffuse Lewy body disease, Pick's disease, multisystem degeneration (Shy-Drager syndrome), motor neuron diseases including amyotrophic lateral sclerosis, degenerative ataxias, cortical basal degeneration, ALS-Parkinson's-Dementia complex of Guam, subacute sclerosing panencephalitis, Huntington's disease, synucleinopathies, primary progressive aphasia, striatonigral degeneration, Machado-Joseph disease/spinocerebellar ataxia type 3 and olivopontocerebellar degenerations, Gilles De La Tourette's disease, bulbar and pseudobulbar palsy, spinal and spinobulbar muscular atrophy (Kennedy's disease), primary lateral sclerosis, familial spastic paraplegia, Werdnig-Hoffinann disease, Kugelberg-Welander disease, Tay-Sach's disease, Sandhoff disease, familial spastic disease, Wohifart-Kugelberg-Welander disease, spastic paraparesis, progressive multSocal leukoencephalopathy, prion diseases (including Creutzfeldt-Jakob, Gerstmann-Straussler-Scheinker disease, Kuru and fatal familial insomnia), age-related dementia and other conditions with memory loss, such as vascular dementia, diffuse white matter disease (Binswanger's disease), dementia of endocrine or metabolic origin, dementia of head trauma and diffuse brain damage, dementia pugilistica and frontal lobe dementia, cerebral ischemia or infarction including embolic occlusion and thrombotic occlusion as well as intracranial hemorrhage of any type (including, but not limited to, epidural, subdural, subarachnoid and intracerebral), and intracranial and intravertebral lesions (including, but not limited to, contusion, penetration, shear, compression and laceration).
[0230] In embodiments, the compounds may be administered in combination, or sequentially, with another therapeutic agent. Such other therapeutic agents include those known for treatment, prevention, or amelioration of one or more symptoms of amyloidosis and neurodegenerative diseases and disorders. Such therapeutic agents include, but are not limited to, donepezil hydrochloride (ARICEPTS), rivastigmine tartrate (EXELON®), tacrine hydrochloride (COGNEX®) and galantamine hydrobromide (Reminyl).
V. Examples
[0231] The following examples are offered to illustrate, but not to limit the claimed invention.
[0232] General Chemistry Methods:
[0233] All reagents were of commercial quality and used without further purification unless indicated otherwise. Routine electrospray ionization mass spectra (ESI-MS) were recorded.
[0234] Screening Assays.
[0235] A variety of cell lines normally produce and secrete various Aβ peptide alloforms into the media upon culture in supportive media. Examples of cell lines routinely used to assess the ability of a compound to inhibit formation specific Aβ peptide alloforms such as Aβ 42 , upon treatment of the cells with various concentrations of the compound for approximately 16 h followed by determining the concentration of the various Aβ peptide alloforms in the media both with and without treatment with the compound [(e.g., HEK-293, N2a delta E9/Swe, SHSY5Y and primary cerebral cortical neuronal cultures from embryonic day 18 (E18) embryos from timed pregnant WT Sprague-Dawley rats) (Netzer, W I et al., Gleevec inhibits β-amyloid production but not Notch cleavage. See e.g., Proc. Natl. Acad. Sci. U.S.A . 2003; 100:12444-12449.
[0236] The SH-SY5Y-APP human cell line was derived by transfecting a human neuroblastoma (SH-SY5Y) cell line with a plasmid expressing wild type human APP 751 cDNA and selecting for stable expression of human APP and human Aβ. In each case, the levels of Aβ 42 or Aβ total or Aβ 38 peptides secreted into the media of these cells were measured using either two-site monoclonal antibody (mAb)-based sandwich ELISA assays (described herein for Aβ 42 and Aβ total ) or in the case of Aβ 38 EC50's, using either the Meso Scale Aβ 38, 40, 42 triplex kit along with the Meso Scale Sector Imager 6000 according to the manufacturer's protocols. This SH-SY5Y-APP human cell line was used for all cell-based Aβ peptide immunochemical assays.
[0237] SH-SY5Y-APP cells were plated at 75,000 cells/well in 96-well tissue culture plates. After 16-18 h, the culture medium was replaced with fresh medium containing either compound or vehicle. Replicates of 3 wells per test concentration were used, with 10 concentrations at ½ log step intervals. Vehicle (0.12% DMSO) is included as a control.
[0238] A variety of animal models (e.g., male Hartley guinea pigs) including transgenic mouse models (e.g., Tg2576 or APP23) are used to assess the ability of a compound to affect the levels of specific Aβ peptide alloforms upon treatment of the animal using various routes of administration and various concentrations of the compound for various lengths of time and comparing the levels of specific Aβ peptide alloforms such as Aβ 42 and/or the level of occupancy of a given organ, such as the brain, by pathological lesions associated with specific Aβ peptide alloforms (e.g., Aβ deposits and/or Aβ plaques) and comparing to those effects achieved on animals treated with vehicle alone. See e.g., Lanz T A, et al., 2006, J Pharmacol Exp Ther 2006; 319: 924-933; Abramoswki D, et al., 2008, J Pharmacol Exp Ther. 327:411-424.
[0239] It has been shown that attenuation of Aβ 42 levels over an extended period of time dramatically reduces the number of neuritic plaques in Tg2576 transgenic mice (14). See e.g., Kounnas, M. Z. et al., 2010, Id. These data were generated following chronic treatment (7 months) with 50 mg/kg/day of an aminothiazole-bridged aromatic GSM or AGSM, similar in structure and function to the SGSMs that we have been optimizing and characterizing over the past two years. We have demonstrated that our SGSMs (bridged heterocycles) have dramatically improved physicochemical properties compared to the original bridged aromates, which should considerably facilitate both preclinical and clinical development of SGSMs. We have also recently shown that these SGSMs are also capable of statistically significant lowering of Aβ 42 levels in both plasma and brain of the Tg2576 AD transgenic mouse model.
[0240] Both the earlier reported AGSMs and the recently developed SGSMs have been shown to bind directly to the highly purified T-secretase enzyme complex. Recent studies have shown that FAD (i.e., familial Alzheimer's Disease) patients do indeed have increased fractional synthetic rates of Aβ 42 relative to Aβ 40 in their CNS when compared to non-carrier siblings, thus validating the clinical relevance of CNS Aβ 42 as a disease biomarker.
Example 1
Compounds and Biological Activities
[0241] Compounds disclosed herein were synthesized and assayed for biological activity (EC50) in a cell-based moderate throughput Aβ 42 ELISA that utilizes human SHSY5Y neuroblastoma cells stably overexpressing human APP695 wild-type, as known in the art.
[0242] The results are tabulate in Table 1 following.
[0000]
TABLE 1
Compounds, Biological Activities, and Mass Spectrometric results
Cmpd No.
Structure
Aβ 42 -IC 50 , nM
ESI MS (M + H)
003077
56
436
003594
003625
003697
003783
33
422
003838
003929
004019
71
464
004051
004102
57
450
004173
004234
33
436
004269
004346
77
408
004365
38
450
004476
004721
004723
35
476
13563
24
436
13565
13636
6
448
13674
20
480
13680
17
454
13765
35
466
13886
75
422
13887
11
476
13921
27
490
13922
67
454
14034
14035
19
434
14104
39
466
14106
64
440
14200
44
450
14257
89
437
14507
17
464
14508
85
493
14548
98
548
14592
14676
10
466
14780
67
545
14789 A
5
464
14789 B
30
464
14839
57
463
14885
59
491
14945
35
460
14946
19
517
15001
34
494
15002
65
506
15003
50
566
15004
55
477
15188
76
491
15473
99
573
15495 A
53
450
15496 B
33
450
14777
22
436
15587
14
436
15635
7
448
15666
18
448
15669
5
434
15670
16
448
15717
48
454
15746
56
454
15830
12
462
15868
30
462
16211
41
449
S20
S21
[0243] It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims. All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety for all purposes.
VI. Embodiments
[0244] Embodiments P1-P12 follow:
Embodiment P1
[0245] An isolated soluble gamma secretase modulator (SGSM) or pharmaceutically acceptable salt or prodrug thereof, comprising lipophilic or hydrophilic group substitution(s) on aminothiazole “C” ring or pyrazole “D” ring of compound BPN-3077-AA-1,
[0000]
[0000] having the structure:
[0000]
Embodiment P2
[0246] The isolated soluble gamma secretase modulator (SGSM) or pharmaceutically acceptable salt or prodrug thereof of Embodiment P1, wherein the substitution(s) increases kinetic solubility.
Embodiment P3
[0247] The isolated soluble gamma secretase modulator (SGSM) or pharmaceutically acceptable salt or prodrug thereof of Embodiment P1, wherein the increased kinetic solubility is an increase of at least 2-fold in phosphate buffered saline at pH 7.4.
Embodiment P4
[0248] The soluble gamma secretase modulator or pharmaceutically acceptable salt or prodrug thereof of Embodiment P1, wherein the soluble gamma secretase modulator or pharmaceutically acceptable salt or prodrug thereof has the chemical structure of:
[0000]
Embodiment P5
[0249] A soluble gamma secretase modulator or pharmaceutically acceptable salt or prodrug thereof, wherein the soluble gamma secretase modulator or pharmaceutically acceptable salt or prodrug thereof has the chemical structure of:
[0000]
Embodiment P6
[0250] A pharmaceutical composition comprising the compound of Embodiment P1 and a pharmaceutically acceptable carrier.
Embodiment P7
[0251] The pharmaceutical composition of Embodiment P6, wherein the composition is compressed into a tablet, minitablet or caplet or encapsulated in a capsule.
Embodiment P8
[0252] The pharmaceutical composition of Embodiment P7, wherein the tablet, minitablet, caplet or capsule is administered to a patient once or twice daily.
Embodiment P9
[0253] A method of inhibiting production of Aβ 42 or Aβ 40 comprising contacting a protease which proteolyzes an amyloid precursor protein (APP) or fragment thereof with an effective amount of a compound of Embodiment P1 so as to inhibit production of Aβ 42 or Aβ 40 .
Embodiment P10
[0254] The method of Embodiment P9, wherein the compound of Embodiment P1 has no measurable effect on gamma-secretase-mediated processing of Notch-1 receptor or no adverse effect associated with any altered Notch-1 receptor signaling.
Embodiment P11
[0255] A method for treating a disease or neurological disorder associated with elevated levels of specific fibrillogenic Aβ peptides by inhibiting production of Aβ 42 or Aβ 40 by the method of Embodiment P9.
Embodiment P12
[0256] The method of Embodiment P11, wherein the disease is selected from a group consisting of but not limited to Alzheimer's disease, Down Syndrome (DS), hemorrhagic stroke associated with cerebrovascular amyloidosis (HCHWA), cerebral amyloid angiopathy (CAA), idiophathic dilated cardiomyopathy, hereditary cerebral hemorrhage with amyloidosis, Dutch type (HCHWA-D), prion disorders, Creutzfeldt-Jakob disease (CJD), frontotemporal dementias (FTD), amyolropic lateral sclerosis (ALS), Huntington's disease (HD), Parkinson's disease (PD) and other neurodegenerative proteinopathies.
[0257] Further embodiments 1-139 follow.
Embodiment 1
[0258] A compound having the formula:
[0000]
[0000] wherein, z1 is 0, 1 or 2; X 1 is C(R 3 ) or N; R 1 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 1A , —NR 1A R 1B , —COOR 1A , —C(O)NR 1A R 1B , —NO 2 , —SR 1A , —S(O) n1 OR 1A , —S(O) n1 NR 1A R 1B , —NHNR 1A R 1B , —ONR 1A R 1B , —NHC(O)NHNR 1A R 1B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 2 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 2A , —NR 2A R 2B , —COOR 2A , —C(O)NR 2A R 2B , —NO 2 , —SR 2A , —S(O) n2 R 2A , —S(O) n2 OR 2A , —S(O) n2 NR 2A R 2B , —NHNR 2A R 2B , —ONR 2A R 2B , —NHC(O)NHNR 2A R 2B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 3 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 NR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 4 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 4A , —NR 4A R 4B , —COOR 4A , —C(O)NR 4A R 4B , —NO 2 , —SR 4A , —S(O) n4 R 4A , —S(O) n4 OR 4A , —S(O) 4 NR 4A R 4B , —NHNR 4A R 4B , —ONR 4A R 4B , —NHC(O)NHNR 4A R 4B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 5 is hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 5A , —NR 5A R 5B , —COOR 5A , —C(O)NR 5A R 5B , —NO 2 , —SR 5A , —S(O) n5 R 5A , —S(O) n5 OR 5A , —S(O) n5 NR 5A R 5B , —NHNR 5A R 5B , —ONR 5A R 5B , —NHC(O)NHNR 5A R 5B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl, wherein R 4 and R 5 are optionally joined together to form a substituted or unsubstituted heterocycloalkyl or substituted or unsubstituted heteroaryl; R 6 is —CF 3 , substituted or unsubstituted cyclopropyl, or substituted or unsubstituted cyclobutyl; R 7 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 7A , —NR 7A R 7B , —COOR 7A , —C(O)NR 7A R 7B , —NO 2 , —SR 7A , —S(O) n7 R 7A , —S(O) n7 OR 7A , —S(O) n7 NR 7A R 7B , —NHNR 7A R 7B , —ONR 7A R 7B , —NHC(O)NHNR 7A R 7B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 1A , R 1B , R 2A , R 2B , R 3A , R 3B , R 4A , R 4B , R 5A , R 5B , R 7A and R 7B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; and n1, n2, n3, n4, n5 and n7 are independently 1 or 2.
Embodiment 2
[0259] The compound of embodiment 1, wherein z1 is 0.
Embodiment 3
[0260] The compound of embodiment 1, wherein z1 is 1.
Embodiment 4
[0261] The compound of embodiment 1, wherein z1 is 2.
Embodiment 5
[0262] The compound of embodiment 1, having the formula:
[0000]
Embodiment 6
[0263] The compound of embodiment 1, having the formula:
[0000]
Embodiment 7
[0264] The compound of embodiment 1, having the formula:
[0000]
Embodiment 8
[0265] The compound of any one of embodiments 1 to 7 wherein R 1 is substituted or unsubstituted alkyl.
Embodiment 9
[0266] The compound of embodiment 8, wherein R 1 is unsubstituted alkyl.
Embodiment 10
[0267] The compound of embodiment 9, wherein R 1 is unsubstituted C 1 -C 6 alkyl.
Embodiment 11
[0268] The compound of embodiment 10, wherein R 1 is methyl.
Embodiment 12
[0269] The compound of any one of embodiments 1 to 7, wherein R 2 is hydrogen or —OR 2A .
Embodiment 13
[0270] The compound of embodiment 12, wherein R 2A is hydrogen, or substituted or unsubstituted alkyl.
Embodiment 14
[0271] The compound of embodiment 13, wherein R 2A is unsubstituted alkyl.
Embodiment 15
[0272] The compound of embodiment 14, wherein R 2A is unsubstituted C 1 -C 6 alkyl.
Embodiment 16
[0273] The compound of embodiment 15, wherein R 2A is methyl.
Embodiment 17
[0274] The compound of any one of embodiments 1 to 7 wherein R 3 is hydrogen, halogen, —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl.
Embodiment 18
[0275] The compound of embodiment 17, wherein R 3 is hydrogen.
Embodiment 19
[0276] The compound of embodiment 17, wherein R 3 is unsubstituted alkyl.
Embodiment 20
[0277] The compound of embodiment 19, wherein R 3 is unsubstituted C 1 -C 10 alkyl
Embodiment 21
[0278] The compound of embodiment 20, wherein R 3 is methyl, ethyl, n-propyl or isopropyl.
Embodiment 22
[0279] The compound of embodiment 17, wherein R 3 is substituted alkyl.
Embodiment 23
[0280] The compound of embodiment 17, wherein R 3 is substituted C 1 -C 6 alkyl.
Embodiment 24
[0281] The compound of embodiment 23, wherein R 3 is R 3A1 -substituted alkyl.
Embodiment 25
[0282] The compound of embodiment 24, wherein R 3A1 is halogen.
Embodiment 26
[0283] The compound of embodiment 25, wherein R 3 is —CH 2 F, —CHF 2 , —CH 2 —CF 3 , —CH 2 —CHF 2 or —CH 2 —CH 2 F.
Embodiment 27
[0284] The compound of embodiment 24, wherein R 3A1 is —OH.
Embodiment 28
[0285] The compound of embodiment 27, wherein R 3 is —CH 2 OH, —(CH 2 ) 2 OH, —(CH 2 ) 3 OH, or —CH 2 —C(CH 3 ) 2 OH.
Embodiment 29
[0286] The compound of embodiment 24, wherein R 3A1 is R 3A2 -substituted or unsubstituted heterocycloalkyl.
Embodiment 30
[0287] The compound of embodiment 29, wherein R 3A2 is halogen or unsubstituted C 1 -C 6 alkyl.
Embodiment 31
[0288] The compound of embodiment 30, wherein R 3 is methyl substituted with 4-methylpiperazin-1-yl, or methyl substituted with 3,3-difluoropyrrolidin-1-yl.
Embodiment 32
[0289] The compound of embodiment 17, wherein R 3 is substituted or unsubstituted heteroalkyl.
Embodiment 33
[0290] The compound of embodiment 32, wherein R 3 is unsubstituted 2 to 10 membered heteroalkyl.
Embodiment 34
[0291] The compound of embodiment 32, wherein R 3 is substituted 2 to 10 membered heteroalkyl.
Embodiment 35
[0292] The compound of embodiment 34, wherein R 3 is R 3A1 -substituted 2 to 10 membered heteroalkyl.
Embodiment 36
[0293] The compound of embodiment 35, wherein R 3A1 is unsubstituted C 1 -C 3 alkyl.
Embodiment 37
[0294] The compound of embodiment 36, wherein R 3 is —CH 2 —O—CH 3 , —(CH 2 ) 2 —O—CH 3 , —CH 2 NHCH 3 , —(CH 2 ) 2 NHCH 3 , —CH 2 N(CH 3 ) 2 , or —(CH 2 ) 2 N(CH 3 ) 2 .
Embodiment 38
[0295] The compound of embodiment 17, wherein R 3 is substituted or unsubstituted cycloalkyl.
Embodiment 39
[0296] The compound of embodiment 38, wherein R 3 is unsubstituted C 3 -C 8 cycloalkyl.
Embodiment 40
[0297] The compound of embodiment 39, wherein R 3 is cyclopropyl, cyclobutyl, cyclopentyl or cyclohexyl.
Embodiment 41
[0298] The compound of embodiment 38, wherein R 3 is substituted C 3 -C 8 cycloalkyl.
Embodiment 42
[0299] The compound of embodiment 17, wherein R 3 is substituted or unsubstituted heterocycloalkyl.
Embodiment 43
[0300] The compound of embodiment 42, wherein R 3 is unsubstituted heterocycloalkyl.
Embodiment 44
[0301] The compound of embodiment 42, wherein R 3 is unsubstituted 3 to 6 membered heterocycloalkyl.
Embodiment 45
[0302] The compound of embodiment 44, wherein R 3 is oxiranyl, oxetanyl, tetrahydrofuranyl, or tetrahydro-2H-pyranyl.
Embodiment 46
[0303] The compound of any one of embodiments 1 to 7, wherein R 4 is hydrogen, or substituted or unsubstituted alkyl.
Embodiment 47
[0304] The compound of embodiment 46, wherein R 4 is hydrogen.
Embodiment 48
[0305] The compound of embodiment 46, wherein R 4 is unsubstituted alkyl.
Embodiment 49
[0306] The compound of embodiment 48, wherein R 4 is unsubstituted C 1 -C 3 alkyl
Embodiment 50
[0307] The compound of embodiment 49, wherein R 4 is methyl, ethyl, n-propyl, or isopropyl.
Embodiment 51
[0308] The compound of embodiment 50, wherein R 4 is methyl.
Embodiment 52
[0309] The compound of any one of embodiments 1 to 7, wherein R 5 is hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl.
Embodiment 53
[0310] The compound of embodiment 52, wherein R 5 is hydrogen.
Embodiment 54
[0311] The compound of embodiment 52, wherein R 5 is unsubstituted alkyl.
Embodiment 55
[0312] The compound of embodiment 54, wherein R 5 is unsubstituted C 1 -C 3 alkyl.
Embodiment 56
[0313] The compound of embodiment 55, wherein R 5 is methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl.
Embodiment 57
[0314] The compound of embodiment 52, wherein R 5 is substituted alkyl.
Embodiment 58
[0315] The compound of embodiment 57, wherein R 5 is substituted C 1 -C 10 alkyl.
Embodiment 59
[0316] The compound of embodiment 57, wherein R 5 is C 1 -C 10 alkyl substituted with unsubstituted heterocycloalkyl.
Embodiment 60
[0317] The compound of embodiment 59, wherein said unsubstituted heterocycloalkyl is morpholinyl.
Embodiment 61
[0318] The compound of embodiment 60, wherein R 5 is —(CH 2 ) 2 -morpholinyl or —CH 2 CH(CH 3 )-morpholinyl.
Embodiment 62
[0319] The compound of embodiment 58, wherein R 5 is —CH 2 F, —CH 2 CH 2 F, —CH 2 CF 3 , —(CH 2 ) 2 OH, —C(CH 3 ) 2 OH, —CH 2 CH(CH 3 )OH, or —CH 2 C(CH 3 ) 2 OH.
Embodiment 63
[0320] The compound of embodiment 58, wherein R 5 is R 5A1 -substituted C 1 -C 10 alkyl.
Embodiment 64
[0321] The compound of embodiment 63, wherein R 5A1 is substituted or unsubstituted cycloalkyl.
Embodiment 65
[0322] The compound of embodiment 64, wherein R 5 is —(CH 2 )-cyclopropyl or —(CH 2 ) 2 -cyclopropyl.
Embodiment 66
[0323] The compound of embodiment 52, wherein R 5 is substituted or unsubstituted heteroalkyl.
Embodiment 67
[0324] The compound of embodiment 66, wherein R 5 is unsubstituted 2 to 8 membered heteroalkyl.
Embodiment 68
[0325] The compound of embodiment 67, wherein R 5 is —CH 2 OCH 3 , or —(CH 2 ) 2 OCH 3 .
Embodiment 69
[0326] The compound of embodiment 52, wherein R 5 is substituted or unsubstituted cycloalkyl.
Embodiment 70
[0327] The compound of embodiment 69, wherein R 5 is unsubstituted C 3 -C 8 cycloalkyl.
Embodiment 71
[0328] The compound of embodiment 70, wherein R 5 is cyclopropyl, cyclobutyl, cyclopentyl, or cyclohexyl.
Embodiment 72
[0329] The compound of embodiment 52, wherein R 5 is substituted or unsubstituted heterocycloalkyl.
Embodiment 73
[0330] The compound of embodiment 72, wherein R 5 is unsubstituted 3 to 8 membered heterocycloalkyl.
Embodiment 74
[0331] The compound of embodiment 73, wherein R 5 is tetrahydro-2H-pyranyl.
Embodiment 75
[0332] The compound of any one of embodiments 1 to 7, wherein R 6 is —CF 3 .
Embodiment 76
[0333] The compound of any one of embodiments 1 to 7, wherein R 7 is independently hydrogen, —CF 3 , or unsubstituted alkyl.
Embodiment 77
[0334] The compound of embodiment 76, said compound comprising a plurality of independent R 7 substituents.
Embodiment 78
[0335] The compound of embodiment 77, said compound comprising two independent R 7 substituents.
Embodiment 79
[0336] The compound of embodiment 76, wherein R 7 is independently unsubstituted alkyl.
Embodiment 80
[0337] The compound of embodiment 79, wherein R 7 is independently unsubstituted C 1 -C 5 alkyl.
Embodiment 81
[0338] The compound of embodiment 80, wherein R 7 is independently methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl.
Embodiment 82
[0339] The compound of any one of embodiments 1 to 7, wherein X 1 is C(R 3 ), and R 3 and R 7 are hydrogen.
Embodiment 83
[0340] The compound of any one of embodiments 1 to 7, wherein X 1 is C(R 3 ), R 3 and R 7 are hydrogen, R 1 is unsubstituted alkyl, and R 2 is —OR 2A .
Embodiment 84
[0341] The compound of any one of embodiments 1 to 7, wherein X 1 is C(R 3 ), R 3 and R 7 are hydrogen, R 1 is unsubstituted C 1 -C 5 alkyl, and R 2 is —OR 2A , wherein R 2A is unsubstituted C 1 -C 5 alkyl.
Embodiment 85
[0342] The compound of any one of embodiments 1 to 7, wherein X 1 is C(R 3 ), R 3 and R 7 are hydrogen, R 1 is methyl, and R 2 is —OCH 3 .
Embodiment 86
[0343] The compound of any one of embodiments 1 to 7, wherein X 1 is N.
Embodiment 87
[0344] The compound of embodiment 1, having the formula:
[0000]
[0000] wherein, R 8 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CN, —CHO, —OR 8A , —NR 8A R 8B , —COOR 8A , —C(O)NR 8A R 8B , —NO 2 , —SR 8A , —S(O) n8 R 8A , S(O) n8 OR 8A , —S(O) n8 NR 8A R 8B , —NHNR 8A R 8B , —ONR 8A R 8B , —NHC(O)NHNR 8A R 8B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 8A and R 8B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; and n8 is 1 or 2.
Embodiment 88
[0345] The compound of embodiment 87 having the formula:
[0000]
Embodiment 89
[0346] The compound of embodiment 88, having the formula:
[0000]
Embodiment 90
[0347] The compound of embodiment 88, having the formula:
[0000]
Embodiment 91
[0348] The compound of embodiment 1, said compound having the formula:
[0000]
[0000] wherein, R 8 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CN, —CHO, —OR 8A , —NR 8A R 8B , —COOR 8A , —C(O)NR 8A R 8B , —NO 2 , —SR 8A , —S(O) n8 R 8A , S(O) n8 OR 8A , —S(O) n8 NR 8A R 8B , —NHNR 8A R 8B , —ONR 8A R 8B , —NHC(O)NHNR 8A R 8B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 8A and R 8B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; and n8 is 1 or 2.
Embodiment 92
[0349] The compound of embodiment 91 having the formula:
[0000]
Embodiment 93
[0350] The compound of embodiment 91 having the formula:
[0000]
Embodiment 94
[0351] The compound of any one of embodiments 87 to 93, wherein R 8 is independently hydrogen, halogen, —CF 3 , or substituted or unsubstituted alkyl.
Embodiment 95
[0352] The compound of embodiment 94, wherein R 8 is —CF 3 .
Embodiment 96
[0353] The compound of embodiment 94, wherein R 8 is unsubstituted alkyl.
Embodiment 97
[0354] The compound of embodiment 94, wherein R 8 is unsubstituted C 1 -C 6 alkyl.
Embodiment 98
[0355] The compound of embodiment 97, wherein R 8 is methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl.
Embodiment 99
[0356] The compound of embodiment 98, wherein R 8 is methyl.
Embodiment 100
[0357] The compound of any one of embodiments 87 to 93, wherein X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted alkyl, R 2 is —OR 2A and R 8 is unsubstituted alkyl.
Embodiment 101
[0358] The compound of any one of embodiments 87 to 93, wherein X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted C 1 -C 5 alkyl, R 2 is —OR 2A and R 8 is unsubstituted C 1 -C 5 alkyl, wherein R 2A is unsubstituted C 1 -C 5 alkyl.
Embodiment 102
[0359] The compound of any one of embodiments 87 to 93, wherein X 1 is C(R 3 ), R 3 is hydrogen, R 1 is methyl, R 8 is methyl and R 2 is —OCH 3 .
Embodiment 103
[0360] The compound of any one of embodiments 87 to 93, wherein X 1 is N.
Embodiment 104
[0361] The compound of any one of embodiments 1 to 7 or embodiments 87 to 93, wherein R 4 and R 5 are combined to form a ring Z having the formula:
[0000]
[0000] wherein z2 is 0, 1, or 2; R 9 is independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 9A , —NR 9A R 9B , —COOR 9A , —C(O)NR 9A R 9B , —NO 2 , —SR 9A , —S(O) n9 R 9A , —S(O) n9 OR 9A , —S(O) n9 NR 9A R 9B , —NHNR 9A R 9B , —ONR 9A R 9B , —NHC(O)NHNR 9A R 9B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; R 9A and R 9B are independently hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; and n9 is 1 or 2.
Embodiment 105
[0362] The compound of embodiment 104, said compound comprising a plurality of independent R 9 substituents.
Embodiment 106
[0363] The compound of embodiment 104, wherein z2 is 0.
Embodiment 107
[0364] The compound of embodiment 104, wherein z2 is 1.
Embodiment 108
[0365] The compound of embodiment 104, wherein z2 is 2.
Embodiment 109
[0366] The compound of embodiment 104, wherein R 9 is hydrogen, halogen, —OR 9A , —NR 9A R 9B , substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, or substituted or unsubstituted heterocycloalkyl.
Embodiment 110
[0367] The compound of embodiment 109, wherein R 9 is hydrogen.
Embodiment 111
[0368] The compound of embodiment 109, wherein R 9 is halogen.
Embodiment 112
[0369] The compound of embodiment 109, wherein R 9 is fluoro.
Embodiment 113
[0370] The compound of embodiment 109, wherein R 9 is —OH.
Embodiment 114
[0371] The compound of embodiment 109, wherein R 9 is —N(CH 3 ) 2 .
Embodiment 115
[0372] The compound of embodiment 109, wherein R 9 is unsubstituted alkyl.
Embodiment 116
[0373] The compound of embodiment 115, wherein R 9 is methyl, ethyl, n-propyl, isopropyl, isobutyl or pentyl.
Embodiment 117
[0374] The compound of embodiment 109, wherein R 9 is substituted alkyl.
Embodiment 118
[0375] The compound of embodiment 117, wherein R 9 is —CH 2 OH, —C(CH 3 ) 2 OH.
Embodiment 119
[0376] The compound of embodiment 109, wherein R 9 is substituted or unsubstituted cycloalkyl.
Embodiment 120
[0377] The compound of embodiment 109, wherein R 9 is substituted or unsubstituted heterocycloalkyl.
Embodiment 121
[0378] The compound of embodiment 120, wherein R 9 is pyrrolidinyl-2,5-dione.
Embodiment 122
[0379] The compound of embodiment 120, wherein R 9 is pyrrolidin-1-yl.
Embodiment 123
[0380] The compound of embodiment 104, wherein X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted alkyl and R 2 is —OR 2A .
Embodiment 124
[0381] The compound of embodiment 104, wherein X 1 is C(R 3 ), R 3 is hydrogen, R 1 is unsubstituted C 1 -C 5 alkyl and R 2 is —OR 2A , wherein R 2A is unsubstituted C 1 -C 5 alkyl.
Embodiment 125
[0382] The compound of one of embodiments 104 or 110, wherein X 1 is C(R 3 ), R 3 is hydrogen, R 1 is methyl and R 2 is —OCH 3 .
Embodiment 126
[0383] The compound of any one of embodiments 1 to 7 or embodiments 87 to 93, wherein R 4 and R 5 are combined to form a ring Y having the formula:
[0000]
[0000] wherein z3 is 0, 1, or 2; R 10 is ═O, ═S, ═CR 10A R 10B , or ═NR 10C ; R 10A and R 10B are independently hydrogen, halogen, —N 3 , —CF 3 , —CCl 3 , —CBr 3 , —CI 3 , —CN, —CHO, —OR 3A , —NR 3A R 3B , —COOR 3A , —C(O)NR 3A R 3B , —NO 2 , —SR 3A , —S(O) n3 R 3A , —S(O) n3 OR 3A , —S(O) n3 NR 3A R 3B , —NHNR 3A R 3B , —ONR 3A R 3B , —NHC(O)NHNR 3A R 3B , substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, or substituted or unsubstituted heteroaryl; and R 10C is hydrogen, or —OR 3A .
Embodiment 127
[0384] The compound of embodiment 126, wherein z3 is 0.
Embodiment 128
[0385] The compound of embodiment 126, wherein z3 is 1.
Embodiment 129
[0386] The compound of embodiment 126, wherein z3 is 2.
Embodiment 130
[0387] The compound of embodiment 126, wherein R 10 is ═CR 10A R 10B .
Embodiment 131
[0388] The compound of embodiment 130, wherein R 10 is —CH 2 .
Embodiment 132
[0389] The compound of embodiment 126, wherein R 10 is ═NR 10C .
Embodiment 133
[0390] The compound of embodiment 132, wherein R 10 is ═N—OH or ═NOCH 3 .
Embodiment 134
[0391] A pharmaceutical composition comprising a compound according to any one of embodiments 1 to 7 or embodiments 87 to 93 and a pharmaceutically acceptable carrier.
Embodiment 135
[0392] The pharmaceutical composition of embodiment 134, wherein said pharmaceutical composition is formulated for administration one or twice daily.
Embodiment 136
[0393] Use of a compound according to any one of embodiments 1 to 7 or embodiments 87 to 93 for inhibiting production of Aβ 42 or Aβ 40 by a protease which proteolyzes an amyloid precursor protein (APP) or fragment thereof.
Embodiment 137
[0394] The use of embodiment 136, wherein said compound has no measurable effect on gamma-secretase-mediated processing of Notch-1 receptor or no adverse effect associated with any altered Notch-1 receptor signaling.
Embodiment 138
[0395] Use of a compound according to any one of embodiments 1 to 7 or embodiments 87 to 93 for treating a disease or neurological disorder associated with elevated levels of specific fibrillogenic Aβ peptides by inhibiting production of Aβ 42 or Aβ 40 .
Embodiment 139
[0396] The use of embodiment 138, wherein the disease or neurological disorder is Alzheimer's disease, Down Syndrome (DS), hemorrhagic stroke associated with cerebrovascular amyloidosis (HCHWA), cerebral amyloid angiopathy (CAA), idiophathic dilated cardiomyopathy, hereditary cerebral hemorrhage with amyloidosis, Dutch type (HCHWA-D), prion disorders, Creutzfeldt-Jakob disease (CJD), frontotemporal dementias (FTD), amyotropic lateral sclerosis (ALS), Huntington's disease (HD), Parkinson's disease (PD) and other neurodegenerative proteinopathies. | There are provided, imer alia, compounds and methods for lowering total AB peptide production by inhibiting the catalytic activity of gamma-secretase. Since all of the major AB peptide variants, including the pathogenic AB42 as known in the art, are ultimately generated by gamma-secretase-mediated proteolysis of APP-C99 (i.e., the beta-secretase-mediated cleavage product of the amyloid protein precursor IAPPI), one approach to therapeutic intervention (e.g., intervention in Alzheimer's Disease, AD) relates to lowering total AB peptide production by inhibiting the catalytic activity of gamma-secretase. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a singeing apparatus and, more particularly, an apparatus for singeing chair cane material.
2. Description of the Prior Art
Singeing apparatus and singeing techniques have been used in many arts and are probably best known to most people for the purpose of singeing pin feathers from fowl.
In the furniture business, protruding cane fibers are normally removed from a woven chair cane seat by hand sanding.
SUMMARY OF THE INVENTION
The invention is directed to an apparatus for singeing cane material. A table structure is provided and in the surface of the table structure there are several recesses. Cane is dispensed from a recess in one end of the table and passes through a set of drive rolls positioned in another recess in the table. The drive roll then moves the cane past two additional recesses that have gas manifolds therein with a gas flame protruding above the top of the recess. As the cane passes across the gas flame, the excess or protruding cane fibers are singed off the woven cane seat. The processed cane is held by hold down rolls where necessary and is finally moved into a recess for roll up for subsequent processing and application to chairs.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of the apparatus herein, and
FIG. 2 is a top view of a woven cane fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is an apparatus for singeing cane material and it is shown in FIG. 1 wherein numeral 2 represents the apparatus. The apparatus constitutes a table structure which has an upper work surface 8 and this work surface is identified by the numerals 8, 8', 8" and 8"'. Several recessed areas 9, 11 and 13 are provided in the upper work surface 8 of the table. At one end of the table, there is a receiving department 6 and positioned in the receiving department 6 is the cane material 4 which has been woven in a pattern and will subsequently be cut into pieces to be used to form chair cane seats.
In the first recess of the table, adjacent the dispensing compartment 6, there is a dual roll drive means 10. The drive means is so positioned so that the lower surface of the upper roll and the upper surface of the lower roll define a nip therebetween and this nip is positioned in the plane of the upper work surface of the table. The two rolls make contact at the nip and are conventionally resiliently mounted so that the cane material 4 may be slipped between the nip of the rolls and then the rolls themselves may grip the cane material and move it across the upper work surface 8 of the table.
Adjacent the drive means 10 there is a second recess 11 and in this recess, below the upper surface of the table, is positioned a gas manifold 12. The manifold has a flame 14 exiting from the upper surface thereof and this extends to slightly above the upper surface 8 of the table. Consequently, any cane material moving along the plane of the upper surface 8 of the table will have to pass through the flame 14. The surface 8' is nothing more than an extension of the table surface 8. Surface 8' is positioned between roll means 10 and the first flame 14. Beyond flame 14 there is another portion 8" of the upper work surface of the table. Positioned on this surface is a hold down roll 16 which simply keeps the cane resting against the upper work surface 8" of the table.
A third recess 13 is provided and in this recess is a gas manifold 18 and a flame 20 which operate the same way as flame 14. Consequently, the cane is subjected to two singeing operations. Beyond the recess 13 there is another portion 8"' of the upper work surface of the table. Here another hold down roll 22 may be used to hold the cane down against the surface 8"'.
Finally, the cane moves into a receiving compartment 24 in which the cane is rolled up so that it may be stored for future use as a chair seat.
The cane material is shown in part in FIG. 2 and it is woven in the conventional manner of chair cane seats. Cane material is a flat strand material that is really formed from a plurality of fibers. Particularly along the ends of the strands and the sides of the strands of the cane sometimes fibers will tear loose and project from the body of the cane material. When cane material is used in a chair, it is provided with some type of coating and this coating tends to stiffen the cane fibers that are projecting from the cane material. This established a number of stiff protrusions which can project into your skin if you rub your hand across the cane material or if you sit on the cane material. Removal of these fibers, which are shown by numeral 5 in FIG. 2, would be desirable to have a smooth surface cane material for use as a seat. The singeing steps of the above-described apparatus remove these projections 5 by, in effect, burning off the projections without burning the main part of the cane strand. The operation is no different than the singeing of pin feathers from a chicken where the pin feathers are burned off, but the chicken skin is untouched by the singeing flame. The flame produced is a conventional gas flame which extends up approximately 11/2 inch from the manifold and approximately 1/2 inch above the upper surface 8 of the table. The flame is very comparable to the flame that you normally encounter in a typical gas range in the home. The cane is moved at a speed of approximately 28 feet per minute and this movement is sufficient to permit the gas flame to burn off the protrusions 5, but in no way, damage the main cane strand which forms the woven cane structure for a chair seat. | An apparatus is provided for singeing cane material to remove the protruding cane fiber that naturally exists with cane material. Cane is moved through gas flames which singe or burn off the cane fibers while leaving the basic cane body undamaged by the flames. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a spark plug which includes a partially cylindrical insulator element and a housing which surrounds the insulator element. The present invention also relates to a corresponding method of production. The insulator element typically includes a ceramic material. In contrast, the housing is made of metal.
BACKGROUND INFORMATION
[0002] Various methods are known for connecting the insulator element and the housing. Basically, these can be divided into hot assembly and cold assembly. In hot assembly, the insulator is inserted into the housing. The insulator is then pretensioned in the axial direction by reshaping an inwardly curved flange on the housing. The final pretension in the axial direction is achieved through a shrink fit process. During the shrink fit process, a shrinkage recess which surrounds the housing circumferentially is inductively heated to approximately 1050° C. by a current pulse. As the shrinkage recess cools, the material in the region of the shrinkage recess shrinks. The housing is thus essentially secured on a projection of the insulator element by axial forces. At the same time, the housing is axially friction-locked between two shoulders of the insulator.
[0003] In cold assembly, a talcum powder packet is inserted between the flange, which is not yet curved, and the insulator element. Subsequently, the talcum powder packet is compressed by the reshaping process of the flange. In cold assembly as well, the insulator element must have a projection on which the inwardly curved flange is secured.
[0004] The known spark plugs do have connections which have high mechanical strength and are gas-tight, but they require a comparatively costly reshaping process.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is the provision of a spark plug having a simple construction and a corresponding method of production, with the spark plug particularly being more compact than spark plugs, produced with typical methods of production, having similar or identical operating characteristics, e.g., with regard to thermal conductivity and with regard to electrical characteristics.
[0006] The present invention is based on the consideration that reshaping is only possible if the housing has a significantly larger diameter than the insulator element at the reshaping position. In addition, a peripheral projection of the insulator element in the region of the reshaping position must secure the housing.
[0007] In the spark plug according to the present invention, the insulator element and the housing are connected to one another by at least one material bond and/or one friction-lock connection aligned in the radial direction. The material bond is, e.g., a metallic soldered or welded connection and the radial friction-lock is a shrink fit connection.
[0008] This connection forms at least a significant portion of the cohesion of the housing and the insulator element. If the material bond and/or the friction-lock connection aligned in the radial direction absorb a part, e.g., approximately half, of the forces which act between housing and insulator element, reshaping can be reduced or even avoided completely, because the cohesion of insulator element and housing is achieved in another way. In addition, the peripheral projection on the insulator element can be designed smaller or even be dispensed with completely. If the other properties are unchanged, the spark plugs according to the present invention are more compact than comparable typical spark plugs, because the diameter of the housing selected can be smaller. Spark plugs according to the present invention have smaller internal thread diameters and smaller screw-in devices than known spark plugs having the same thermal value. For example, the outer diameter of the internal thread can be reduced from M14 to M12. Spark plugs produced until now with M8 threads can now be produced with M6 threads.
[0009] In a refinement of the spark plug according to the present invention, the diameter of the insulator core remains approximately the same or increases as the distance to the free end of the base part of the insulator (referred to in short in the following as base part) increases in the entire region surrounded by the housing. For example, the insulator core tapers in a stepped shape toward the free end of the base part. In other words, the insulator core does not have a projection in the region of the housing used to secure the housing and is therefore more compact than comparable known insulator elements.
[0010] In a subsequent refinement, the inner diameter of the housing in the region of the connection remains approximately the same or increases as the distance to the free end of the base part increases. In other words, the housing no longer has an edge which is curved inward. This allows the use of a housing with a smaller diameter, because reshaping of the edge is no longer necessary.
[0011] In a subsequent refinement, the diameter of the insulator element at the end further from the base part in the region adjoining the region surrounded by the housing is approximately equal to the largest diameter of the insulator core in the surrounded region. The insulator element is preferably cylindrical both inside a section of the housing and outside the housing, i.e., it has a uniform diameter. The fewer the projections and constrictions that are located on the insulator element, the more crack resistant it is.
[0012] In a subsequent refinement, the housing has at least one tubular section in which the diameter of the insulator core is only slightly smaller than the inner diameter of the housing lying at the same distance to the free end of the base part. The connection lies along the circumference of the insulator element in the gap between insulator element and housing. In this refinement, the connection has a double function, because it is used both for connecting insulator element and housing and for sealing the combustion chamber in which the spark plug is to be inserted.
[0013] The tubular section lies close to the base part and/or further from the base part. If the section is close to the base part, it is subjected to greater mechanical load and higher temperatures. On the other hand, the insulator element is thin near the base part, so that the circumference is smaller than further away from the base part. If the connection also seals the combustion chamber gas-tight, the combustion chamber is enlarged only insignificantly if the connection is near the free end of the base part. If the connection is at a greater distance from the free end of the base part, for example at the end of the housing further from the base part, the mechanical loads and the temperature effect are less. The connection will not be loaded as strongly during operation of the spark plug. If the connection is in multiple zones, the disadvantages of one position can be avoided by the advantages of the other position.
[0014] In embodiments, the connection is a soldered connection, e.g., a hard soldered connection, an active soldered connection, a welded connection, and/or an adhesive connection. For the welded connection, the known welding methods are used, e.g., friction welding or gas fusion welding. Reactive adhesives, whose components react during curing, are, for example, used as the adhesive for the adhesive connection. However, hard-setting adhesive materials whose components do not react during curing are, for example, also used.
[0015] In an alternative refinement, the housing contains at least one tubular section in which the diameter of the insulator element is slightly larger than the inner diameter of the housing, when the insulator element is not in place, lying at the same distance to the free end of the base part. Therefore, this is a compression connection, for example a longitudinal compression connection or a transverse compression connection. During the production of the transverse compression connection, for example, the housing is heated. Subsequently, the insulator core is inserted into the expanded housing. As the housing cools, it shrinks and tightly surrounds the insulator element.
[0016] In a refinement of the spark plug according to the present invention, insulator element and housing are connected with one another using an interlayer which was produced before housing and insulator were connected. The interlayer is produced from a material which is capable of being connected well on one side with the ceramic and on the other side with the metal of the housing. The interlayer can, for example, be formed by a thin sheet steel sleeve. However, interlayers made of other materials, e.g., plastic or glass melt, are also used. The interlayer is applied or attached to the insulator element. Thus, interlayers can be deposited directly on the insulator element. The interlayer is attached to the housing using a material bond and/or a friction-lock connection.
[0017] If, in an embodiment, the interlayer also extends into regions which lie outside the connection region, the interlayer can be attached better to the insulator, because the connection surface between the insulator and the interlayer is larger.
[0018] In a refinement, there is a gap between the housing and the interlayer in the region of the section lying closer to the base part. In the region of a section lying further away from the base part than this section, the interlayer is connected with the housing. In the section lying further away, the interlayer can also be connected with the insulator. However, in an alternative, there is a gap between interlayer and insulator in the section lying further away. In this refinement, a small peripheral ring of the interlayer is exposed in the gap between the insulator and housing. The ring-shaped section forms a kind of membrane which absorbs mechanical loads.
[0019] In refinements of the spark plug, the insulator element includes ceramic. The surface of the ceramic is treated in the region of the connection in such a way that the load capacity of the connection is enhanced. Roughening of the surface and/or applying a metallic topcoat are suitable methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1A is a first illustration of a compact spark plug with a damping resistor made of a solidified glass melt.
[0021] [0021]FIG. 1B is a second illustration of the compact spark plug shown in FIG. 1A.
[0022] [0022]FIG. 2A is a first illustration of a compact spark plug without a damping resistor.
[0023] [0023]FIG. 2B is a second illustration of the compact spark plug shown in FIG. 2A.
[0024] [0024]FIG. 3A is a first illustration of a compact spark plug with a nondestructively replaceable damping resistor.
[0025] [0025]FIG. 3B is a second illustration of the compact spark plug shown in FIG. 3B.
DETAILED DESCRIPTION
[0026] [0026]FIG. 1A shows a compact spark plug 10 in a partial section view. Spark plug 10 includes a cylindrical insulator 12 which tapers at its end toward an insulator base 14 . Insulator 12 is penetrated along its longitudinal axis 16 by a through hole 18 , whose diameter in the region of a central electrode 20 is somewhat smaller than along the rest of insulator 12 . The half of insulator 12 containing insulator base 14 is almost completely surrounded by a housing 22 . Viewed from insulator base 14 outward, housing 22 includes, in this sequence, a ground electrode 24 , a threaded sleeve 26 having, for example, M14 external thread 28 , a peripheral groove 30 for a sealing ring which provides a seal in the conical seal seat, a central part 32 , and a double hex insertion nut 34 . Housing 22 is screwed into an engine block of the vehicle and is connected with the ground electrode. Insulator 12 , which is made of ceramic, insulates housing 22 and central electrode 20 as well as further elements for current conduction located in through hole 18 .
[0027] In through hole 18 there are, in sequence from central electrode 20 to a terminal stud 36 screwed onto insulator 12 for connection of an ignition cable, an electrically conducting contact 38 , a glass melt 40 , which forms a damping resistor, an electrically conducting contact 42 , and an electrode 44 . Electrode 44 tapers toward insulator base 14 and forms a section 46 having a somewhat smaller diameter than the main part of electrode 44 .
[0028] Housing 22 is connected to insulator 10 by a welded connection 48 . Welded connection 48 extends longitudinally up into threaded sleeve 26 from the end of housing 22 further from the base part. Welded connection 48 extends completely around the circumference lying transverse to the longitudinal direction. A gap between insertion nut 34 and insulator 12 is completely closed by welded connection 48 . A gap formed between the end of threaded sleeve 26 further from the base part and insulator 10 is also completely closed by welded connection 48 .
[0029] [0029]FIG. 1B shows a connection 48 b , in which a housing 22 b , constructed like housing 22 , of a spark plug 10 b having an insulator 12 b is only welded in a region 50 which extends along the half of a threaded sleeve 26 b further from the base part. Region 50 extends, for example, 10=10 mm in the longitudinal direction, i.e. in the direction of a longitudinal axis 16 b of insulator 12 b . Welded connection 48 b extends along the lateral surface of insulator 12 b in region 50 .
[0030] In the region of a insertion nut 34 b constructed like insertion nut 34 , a peripheral gap 52 remains between insulator 12 b and insertion nut 34 b . Otherwise, spark plug 10 b is constructed like spark plug 10 .
[0031] Due to welded connection 48 or 48 b , spark plug 10 can be made very compact. The largest diameter D of insulator 12 is, for example, 10.4 mm. Diameter D remains constant in the main part of insulator 12 and therefore essentially determines the overall space for the installation of spark plug 10 . Insertion nut 34 is implemented as a double hex nut, e.g., for a width 14 across flats. This is only possible because insulator 12 has no projections in the region of insertion nut 34 .
[0032] In other exemplary embodiments, an interlayer is used, in place of welded connection 48 or 48 b , which is welded or soldered onto insulator 12 or 12 b and onto housing 22 or 22 b . The welded or soldered connections, respectively, between the interlayer and insulator 12 and between the interlayer and housing 22 are in the region of central part 32 and threaded sleeve 26 and in the region of insertion nut 34 . Alternatively, there are connections between the interlayer and insulator 12 b both in the region of threaded sleeve 26 b and in the region of insertion nut 34 b . In the alternative, a connection exists between the interlayer and housing 22 b only in the region of threaded sleeve 26 b . A gap remains between the interlayer and insertion nut 34 b in the region of insertion nut 34 b.
[0033] [0033]FIG. 2A shows, in a partial section view, a compact spark plug 10 c which has no damping resistor. Functional elements shown in FIG. 2A which are constructed essentially like those described with reference to FIG. 1A have the same reference numbers in FIG. 2A but are suffixed with the lowercase letter c. This particularly applies to reference numbers 12 c to 36 c . Central electrode 20 c has a diameter in its main part which is smaller than the diameter of central electrode 20 . This allows the diameter of through hole 18 c and outer diameter Dc of insulator 10 c to be reduced. Central electrode 20 c is coated with a hard solder paste and then inserted through hole 18 c into insulator 12 c . A contact pin 100 , made of, for example, a brass alloy, is inserted into through hole 18 c . When terminal stud 36 c is screwed in, contact pin 100 is compressed and buckles at multiple buckling positions.
[0034] Central electrode 20 c is secured by contact pin 100 . Insulator 10 is then transported through a high vacuum furnace at a temperature of a magnitude between 600° C. and 900° C., for example 800° C. The hard solder paste melts and connects central electrode 20 c firmly and permanently with insulator 12 c . This connection is also gas-tight. The hard solder paste is, for example, applied in the region of a shoulder 102 , at which the inner diameter of through hole 18 c decreases. Alternatively, central electrode 20 c can be coated almost completely with hard solder paste, so that central electrode 20 c and insulator 10 c are also connected in the region of insulator base 14 c.
[0035] There is an interlayer 104 on insulator 10 c which is less than, for example, 1 mm thick. Interlayer 104 is connected to insulator 10 c via, for example, a hard soldered connection, in the region of a step 106 of insulator 10 c , which is approximately, e.g., 11=12 mm long. At the end of step 106 further from the base part, interlayer 104 conforms to the shape of insulator 10 c , which widens. In a section 108 , however, interlayer 104 forms a tubular section having a larger inner diameter than outer diameter Dc of insulator 10 c . Thus, there is a gap 110 in the region of section 108 between interlayer 104 and insulator 10 c . In section 108 , interlayer 104 is connected on its outer side with the inner side of insertion nut 34 c , for example by a soldered or welded connection. In the region of step 106 , the outer side of interlayer 104 is not connected with housing 22 c , so that in this region a gap 111 lies between interlayer 104 and housing 22 c.
[0036] Through the shaping and nature of the attachment of interlayer 104 , forces which arise in housing 22 c as spark plug 10 c is screwed in cannot be transmitted directly to insulator 10 c . Interlayer 104 absorbs these forces in the transition region between step 106 and section 108 .
[0037] [0037]FIG. 2B shows a spark plug 10 d constructed similarly to spark plug 10 c . There are differences only in the region of an interlayer 104 d , which is used in place of interlayer 104 . Interlayer 104 d is connected in the region of a step 106 d with an insulator 12 d . In a transition region 112 , interlayer 104 d widens conically in correspondence with the shape of insulator 12 d . In transition region 112 , as well as in an adjacent section 114 , the inner side of interlayer 104 d is also connected with insulator 12 d , for example with the aid of a soldered or welded connection.
[0038] The outer side of interlayer 104 d is exposed in the region of step 106 d , so that a gap 110 d is formed between interlayer 104 d and housing 22 d . The outer side of interlayer 104 d is connected to housing 22 d in the region of section 114 , for example by soldering or welding. The connection has a length of, e.g., 12=8 mm along a longitudinal axis 16 d.
[0039] Mechanical stresses which arise in the region of a groove 30 d as spark plug 10 d is screwed in cannot be directly transmitted to insulator 12 d due to gap 110 d . The force lines first run into housing 22 d and only enter insulator core 12 d in section 114 . The forces are, however, already less at this point than in the region of groove 30 d.
[0040] A sealing ring, not shown, is located in the region of groove 30 d which forms a seal in the flat sealing seat between the engine block and a central part 32 d . Otherwise, spark plug 10 d is constructed like spark plug 10 c.
[0041] [0041]FIG. 3A shows a partial section view of a compact spark plug 10 e which is constructed similarly to spark plug 10 c , see FIG. 2A. Elements with reference numbers 12 e to 36 e correspond in their design and function to the elements 12 c to 36 c which were explained with reference to FIG. 2A.
[0042] Central electrode 20 e is again inserted first into through hole 18 e . Subsequently, a replaceable damping resistor 120 is inserted, which has a shape resembling a known fuse. Only then is a contact pin 122 inserted, which buckles at multiple buckling positions as terminal stud 36 e is screwed in. Insulator 12 e , which was screwed on in this way, is in turn heated to approximately 800° C., with a soldering paste applied to central electrode 20 e melting and central electrode 20 e connecting with insulator 12 e.
[0043] An interlayer 124 corresponds to interlayer 104 in its design, function, and type of attachment to insulator 12 e and housing 22 e , see FIG. 2A.
[0044] [0044]FIG. 3B shows a part of a spark plug 10 f , which is designed like spark plug 10 e , see FIG. 3A. An interlayer 126 f is soldered onto insulator 12 f of spark plug 10 f in a section 130 . Section 130 lies within threaded sleeve 26 f . The inner diameter of interlayer 126 f and the diameter of insulator 12 f increase uniformly within a transition section 132 . In the region of a section 134 lying within insertion nut 34 f , the inner diameter of the sleeve formed by interlayer 126 f remains constant. The diameter of insulator 12 f also remains constant within section 134 . In section 134 , interlayer 126 f is soldered to both insulator 12 f and housing 22 f . In contrast, in the region of section 130 and in the region of transition section 132 , a gap 136 lies between housing 22 f and insulator 12 f. | A spark plug is described having a partially cylindrical insulator element and a housing surrounding the insulator element on the side of a base part. The insulator element and the housing are connected with one another by at least one material bond and/or one friction-lock connection aligned in the radial direction. A compact spark plug can be produced using this type of connection. In particular, the diameter of the spark plug is smaller than the diameter of known spark plugs having the same characteristics. | 7 |
This is a continuation of application Ser. No. 08/394,087, filed Feb. 24, 1995, now abandonded, which was a divisional application of Ser. No. 08/018,845, filed Feb. 17, 1993, now issued as U.S. Pat. No. 5,492,607.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to laser systems and associated fabrication methods for directing a laser beam away from a substrate, and more particularly to the use of an external turning mirror to redirect an in-line beam from a monolithically fabricated laser away from its substrate.
2. Description of the Related Art
Ultra-high speed interconnect links between integrated circuit (IC) chips and data busses are needed for 3-dimensional optoelectronic systems. Currently available electronic systems incorporate optical isolation and optical data paths between larger subsystems, but the optical elements are discrete. A more compact, less expensive and more reliable system would result if the optical elements could be monolithically integrated on the same chip substrates as the electronic circuitry as surface emitting (optical output directed away from the substrate surface) elements. Applications for such 3-D interconnects include computers and processors, optical displays, optical signal processing and computing, intersatellite communication, the pumping of solid state crystals, and visual displays.
Three approaches have been developed to achieve out-of-plane laser emissions:
(1) Vertical cavity lasers, in which the laser beam is initially emitted vertically upward and away from the substrate upon which the laser is formed. This type of laser is described in Tell et al., "High-power cw vertical-cavity top surface-emitting GaAs Quantum Well Lasers", Applied Physics Letters, Vol. 57, No. 18, 29 Oct. 1990, pages 1855-1857. They have very short optical cavities, on the order of an optical wavelength, and require high reflecting mirrors, typically using epitaxially grown Bragg reflectors for the mirrors. However, such lasers exhibit poor efficiency and high electrical resistance. Also, it is difficult to produce high reflectivity semiconductor quarter wavelength Bragg mirrors, due to the low index of refraction modulation in such mirrors.
(2) A periodic grating on the laser's upper cladding layer to couple light vertically out of the laser plane. See, for example, Itaya et al., "New 1.5 Micron Wavelength GaInAsP/InP Distributed Feedback Laser", Electronics Letters, Vol. 18, No. 23, 1982, pages 1006-1007, and Ng et al., "Highly collimated broadside emission from room temperature GaAs distributed Bragg reflector lasers", Applied Physics Letters, Vol. 31, No. 9, 1 Nov. 1977, pages 613-615. Unfortunately, lasers of this type suffer from having extremely elliptical output beams and they require long sections of the grating, which increases the device size.
(3) In-plane surface emitting lasers, in which a laser beam is initially generated generally parallel to the substrate, and then deflected by a turning mirror so that the beam travels away from the substrate. The turning mirror can either be part of the laser cavity (a "folded-cavity" laser), or external to the laser.
An early folded-cavity laser contained a 45° surface that was etched into the topside of the wafer to deflect light into the substrate; SpringThorpe, "A novel double-heterostructure p-n-junction laser", Applied Physics Letters, Vol. 31, No. 8, 15 Oct. 1977, pages 524-525. A disadvandage of this type of laser is that it must be made on a transparent substrate material, or have a deep via etched into the substrate. In addition, the device must be mounted top-side down, and thus is not readily integrated with electronic circuits, whose connections are typically formed by wire bonding to the top surface. Folded-cavity lasers with an emission from the top surface have also been demonstrated. The 45° mirror of such lasers is made by dry-etching a slot into the top surface, which involves a more complicated procedure. See Goodhue et al., "Monolithic Two-Dimensional GaAs/AlGaAs Laser Arrays Fabricated by Chlorine Ion-Beam-Assisted Micromachine", Journal of Electronic Materials, Vol. 19, No. 5, 1990, pages 463-469.
Surface-emitted beams with good far-field patterns have been produced with folded-cavity lasers, since it is possible to form an integrated lens on the emitting surface of the device to collimate or focus the output beam. However, the design and fabrication of this lens is very complicated, since it must perform the dual functions of cavity reflection and beam shaping; see Liau et al., "GaInAsP/InP buried heterostructure surface-emitting diode laser with monolithic integrating bifocal microlens", Applied physics Letters, Vol. 56, No. 13, 26 Mar. 1990, pages 1219-1221.
Most surface emitting lasers incorporate external-cavity turning mirrors that are spaced from one or both ends of the laser cavity. Such a device is shown in Liau et al., "Surface Emitting GaInAsP/InP Laser with Low Threshold Current and High Efficiency", Applied Physics Letters, Vol. 46, No. 2, 15 Jan. 1985, pages 115-117. These lasers are fabricated by growing a conventional (parallel to the substrate) in-line laser structure, and then forming the vertical cavity mirrors and a 45° tilted deflecting mirror that is opposite one of the cavity mirrors. A common method is to form both the cavity mirror and the turning mirror at one end of the cavity by ion-beam milling, with the wafer surface inclined away from normal to the incident beam direction (see Goodhue et al., cited above). The turning mirror can be provided with a curved surface to collimate or focus the beam which it deflects. A second milling step may be used to form the mirrors at the opposite end of the cavity, if desired. Since the laser cavity is similar to that of edge-emitting lasers, the device's performance is likewise as good as that of edge emitting lasers in most respects. However, these lasers suffer from a distorted far-field pattern and reduced output efficiency.
FIG. 1 shows a conventional horizontal cavity surface emitting laser system. A laser 2 extends upward from a semiconductor substrate 4, with an active lasing layer 6 sandwiched between upper and lower semiconductor cladding layers 8 and 10; the body of the substrate can itself serve as the lower cladding layer. The laser's rear surface 12 is coated with a fully reflective mirror (not shown), while an angled trench 14 is formed immediately in front of the laser to permit the deposition of a partially reflective mirror (not shown) over the front end 16 of the laser. The trench wall 18 opposite the laser is formed at an angle, typically 45°, that causes at least part of the emitted laser beam 20 to be deflected generally perpendicular to the substrate.
The laser's active (light emitting) layer 6 is typically located between 1 and 2 microns below the device's upper surface. Since the vertical height of the active layer is quite small, on the order of 0.1 micron, the output beam 20 (indicated by dashed lines) has an appreciable vertical divergence or "fanning". The beam will in general diverge vertically beyond the mirror surface 18, with as much as 20%-40% of the beam (indicated by shaded region 22) passing above the mirror and not being deflected along with the rest of the beam. This optical loss reduces the laser's efficiency, and distorts the resultant beam pattern. Interference effects from the light hitting the edges of the turning mirror also produce unwanted ripples or side lobes in the far-field pattern.
SUMMARY OF THE INVENTION
The present invention seeks to provide an external cavity surface emitting laser that improves upon both the efficiency and optical quality of prior devices by deflecting a substantially greater portion of the laser beam into the ultimate output from the device, along with special fabrication techniques to obtain the new laser structure.
These goals are accomplished by fabricating an external turning mirror on the same substrate with an in-line laser, with the mirror including both a portion that is generally in-line with the laser and an extension that extends beyond the upper laser surface to deflect the portion of the laser beam that would otherwise be lost to the system. To this end the height of the mirror extension above the laser can be comparable to the vertical height of the laser itself.
One fabrication technique for the new structure involves the use of a novel masking and ion beam milling technique that uses an accumulation of redeposited material to form the mirror extension. A thick masking layer, which is later removed, is used to both pattern the base portion of the mirror and to provide a backing for the accumulation of redeposited material into a mirror extension. For a laser height of about 3-6 microns, the etch mask is preferably formed as a photoresist which extends about 5-10 microns above the substrate prior to the ion beam milling, and is reduced to a height of about 3-6 microns by the milling process. An opening is patterned in the photoresist to expose the substrate over the mirror area, including a setback to allow for the accumulation of the redeposited etched material which forms the mirror extension.
In an alternate fabrication method, a mirror extension layer is first formed over the substrate, and an angled opening is then etched into both the extension layer and the underlying active and cladding layers. This opening defines both the emitting edge of the laser and an opposed turning mirror which extends above the upper laser surface. The extension layer is then removed from over the laser. Epitaxial growth methods can be used to form the extension layer, with an etch stop layer provided immediately below the extension layer to assist in removing the extension layer from over the laser. The etch stop layer is then itself removed from over the laser, but remains in place within the mirror. Mirror and etch stop materials with similar refractive indices are selected to prevent optical distortions from the residual etch stop layer. In removing the extension layer from over the laser, protection of the laser emitting edge is assured by having a mirror mask overlap several microns onto the upper laser surface.
The fabrication methods involved require only conventional processing equipment, and are compatible with lasers made from various materials. These and further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, described above, of a prior surface emitting laser with an external deflecting mirror;
FIG. 2 is a perspective view of a laser and turning mirror structure in accordance with the invention;
FIGS. 3a and 3b are diagrams illustrating the angled ion milling technique used in the preferred embodiment of the invention;
FIGS. 4a-4d are sectional views that show successive steps in the formation of the laser mirror structure in accordance with one fabrication technique provided by the invention;
FIGS. 5a-5d are sectional views showing successive steps in the formation of a laser-mirror structure with an alternate fabrication technique provided by the inventions;
FIG. 6 is a perspective view of a laser-mirror structure of the invention with a curved laser emission surface; and
FIG. 7 is a perspective view of another laser-mirror embodiment with a mirror surface that has been processed with a focused ion beam.
DETAILED DESCRIPTION OF THE INVENTION
A surface-emitting laser system that illustrates the invention is shown in FIG. 2, with elements that are the same as in the prior art device of FIG. 1 indicated by the same reference numerals. One of the advantages of the invention is that it is compatible with various material systems for the laser 2, such as InP cladding layers and substrate with an InGaAs active region, or GaAs-based materials. It can also be monolithically integrated on the same substrate with electronic circuitry. However, instead of the upper edges of the laser and turning mirror being coplanar, an upward extension 24 is added to the mirror structure. The mirror thus comprises a lower section 18' that is aligned with the laser as in the prior device, and also an extended surface 26 that rises above the level of the laser's upper surface. If the extension is made high enough to accommodate the laser beam's vertical divergence from its nominal axis, which is generally parallel to the substrate, substantially the entire beam can be deflected and included in the out-of-plane output beam 28. The extended mirror can be curved, as shown, to collimate or focus the beam as desired. The new structure is preferably fabricated from a standard laser epilayer wafer, similar to conventional devices.
Two fabrication methods for the new laser-turning mirror structure are described below. The preferred implementation for both methods employs directional ion beam milling to form both a vertical or near-vertical laser emitting face 16, and the angled turning mirror. The manner in which an ion beam that is directed at a single fixed angle can produce a pair of opposed etched surfaces at two different angles is illustrated in FIGS. 3a and 3b. In FIG. 3a an ion beam 30 is shown directed vertically downward against the horizontal upper surface of a substrate 32. The etching proceeds laterally as well as vertically downward, producing sloped sidewalls 34a and 34b at an angle to vertical, rather than parallel to the beam. Depending upon the characteristics of the beam and of the substrate material, the beam can be tilted to a particular off-vertical angle such that one of the sidewalls is vertical, while the other sidewall is offset from vertical by a greater angle than the beam. This is illustrated in FIG. 3b, in which the beam 34' is now at an angle to vertical, resulting in the sidewall 30a' being vertical and the opposed sidewall 34b' having a greater angle to vertical than in FIG. 3a. For the laser-turning mirror fabrication methods described below, in which an InP substrate with an InGaAs active layer was used, a vertical laser emitting surface and a 45° tilted mirror surface were obtained concurrently with a 500 eV argon ion beam at a 30° angle to vertical (the term "vertical" is arbitrary and is used for ease of description; it actually refers to a direction normal to the substrate surface, regardless of the substrate orientation). Other inclination angles may be necessary for beams at other energies or having other ion constituents, such as chlorine.
The first fabrication method is illustrated in FIGS. 4a-4d. Assuming a total thickness of about 3-6 microns for the laser cladding layers 8 and 10 and the active region 6, a first etch mask 36, preferably a photoresist, is formed over the upper cladding layer 8, preferably to a thickness of about 5-10 microns. An interlayer 38 of a material such as titanium is formed over the first photoresist layer 36, followed by an upper mask layer 40, preferably also photoresist. The upper photoresist layer 40 is patterned by conventional photolithography techniques to establish an opening 42 over the intended area for both the aligned and extended portions of the mirror. Other mask materials, such as a polyimide for the lower mask 36 and a silicon dioxide for the interlayer 38, could also be used. The upper photoresist layer 40 acts as a mask for reactive ion etching (RIE) of the underlying exposed titanium, which is preferably removed by etching with a fluorocarbon gas. This removes the titanium layer from the area between the upper photoresist posts 44 and 46 on opposite sides of the patterned opening 42. The remaining titanium below the posts 44 and 46 then serves as a mask for RIE of the lower photoresist layer 36, which is preferably accomplished with oxygen. The photoresist etch removes the portion of the first photoresist layer 36 below the opening 42, and also the posts 44 and 46 from the upper photoresist layer. Finally, the remaining titanium layer is removed by etching in hydrofluoric acid. The result is shown in FIG. 4b, in which an opening 48 is left in the lower photoresist layer 36, with photoresist posts 50 and 52 bounding the opening on its opposite sides. By adjusting the RIE conditions, the width and sidewall profile of the opening 48 formed in the lower photoresist layer can be varied as desired.
The photoresist posts 50 and 52 serve as a mask for ion beam milling of a deep beveled groove 54 through the upper and lower cladding layers 8 and 10 and the intervening active layer 6. The preferred parameters for the ion beam 56 are described above, and result in a vertical (or near vertical) laser emitting surface 58 on one side of the groove 54, and a mirror surface 60 on the other side of the groove that is tilted at an angle of about 45° to vertical.
During the ion beam milling process, cladding material (along with a small portion of active layer material) that is sputtered by the applied ions redeposits and accumulates as a mirror extension 62 in the corner formed by the upper surface of the laser epilayers and the edge of the photoresist post 52, as shown in FIG. 4c. This post 52 shades the redeposition area during the ion beam milling process, allowing the redeposited material to accumulate there. For the beam conditions described above and a total laser thickness of about 3-6 microns, forming the initial photoresist posts 50 and 52 (FIG. 4b) with heights of about 5-10 microns will leave the post heights at about 3-6 microns after the etching has been completed, since the etchant preferably attacks the laser material but also attacks the photoresist to a lesser degree. A desired curvature can be established for the nominally 45° tilted mirror surface by adjusting the initial width and shape of the photoresist opening 48, and also the thickness of the photoresist posts 50 and 52.
The successful redeposition of a mirror extension 62 depends primarily upon the height of the photoresist posts 50, 52 and the distance between them, the type of photoresist used, the depth of the etch, and the ion beam angle. The ion beam angle can be adjusted if necessary to obtain proper redeposition. While such adjustment can effect the angle of the laser's emitting surface 58, there is normally about a 2° tolerance from absolute vertical for this surface. If the width of the etch is substantially greater than the etching depth, a flat rather than a curved mirror surface can result. While this might be desirable in some instances, such as when further processing of the mirror surface with a focused ion beam (FIB) is performed to obtain a precise mirror curvature, it is normally desirable to establish a mirror curvature that is concave with respect to the laser to limit the beam divergence.
After the ion milling has been completed, the remaining photoresist posts 50 and 52 are removed with an appropriate solvent, leaving a mirror that includes both the section 60 that is horizontally aligned with the laser 2, and the redeposited mirror extension 62 that projects above the upper laser surface, as shown in FIG. 4d. The mirror extension 62 is generally triangular in shape, reaching an apex 64 at its point of maximum height above the substrate, and generally expanding in width as it approaches the laser level.
To increase the surface emitted light output, the mirror surfaces 60 and 62 can be coated with a highly reflective surface by evaporating a layer of metal onto the upper side of the substrate. The substrate is mounted at an angle to the evaporation during this process, approximately 30° so that the laser emitting surface 58 is shadowed and not covered with the metal. The metal may be additionally patterned using conventional lift-off lithography techniques. Also, the laser-emitting surface 58 may be covered with an anti-reflection coating by conventional plasma-enhanced chemical vapor deposition (CVD) of silicon nitride. A fully or partially reflective coating can also be applied to the opposite laser face to complete the resonating cavity.
Other laser processing steps depend upon the specific type of laser to be fabricated (such as ridge-waveguide or buried heterostructure). Such steps can be performed either before or after the turning mirror fabrication, and are conventional for laser fabrication. The mirror fabrication technique itself only requires the use of commonly found processing equipment, such as reactive-ion etchers, ion beam millers and evaporators.
A second fabrication technique is illustrated in FIGS. 5a-5d. Again, elements that are the same as those described previously are identified by the same reference numerals. In this embodiment standard laser epilayers are grown, followed by the growth of an etch-stop layer 66 over the upper cladding layer 8, and then a thick upper epitaxial extension layer 68. Depending upon the particular material system, the epitaxial layer 68 can be either the same material or a different material from the upper cladding layer 8. For example, with GaAs lasers the upper cladding layer is AlGaAs and the epitaxial layer 68 is preferably GaAs, while with InP lasers both the upper cladding and epitaxial layers are InP.
The etch stop layer 66 and upper epitaxial layer 68 should have refractive indices that are similar to those of the laser cladding layers to minimize optical distortion in the final turning mirror, unless that mirror is further covered with a highly reflective layer. For a GaAs-based laser, for example, the etch stop layer 66 may comprise GaAlAs, with the upper epitaxial layer 68 formed from GaAs. Various epitaxial growth techniques can be used, such as metal organic vapor phase epitaxial or molecular beam epitaxy. Following the growth of these layers, a mask layer 70 is deposited on the wafer and patterned with a mirror opening 72, as shown in FIG. 5a.
In the next step, illustrated in FIG. 5b, a beveled groove 74 is etched into the wafer by a technique such as ion beam milling. One groove wall 76 is vertical to establish the laser emitting surface, while the opposed groove wall 78 is tilted at about 45° to vertical to form the mirror surface. The ion beam milling technique can be similar to that used for etching the mirror groove of a conventional external cavity 45° mirror laser. Since a deep groove is required if the mirror is to extend all the way to the bottom of the laser, the mask layer 70 must be capable of withstanding a prolonged etching. Examples of appropriate mask materials are a thick layer of photoresist for argon ion beam milling, or a thick layer of nickel for chlorine RIE. A section of redeposited material 80 will generally be formed in the shadow of the ion beam mask 70, as with the fabrication method of FIGS. 4a-4d. Since the primary mirror extension is provided by the upper epitaxial layer 68, this additional section 80 can either be left in place or removed; it is accordingly indicated in dashed lines in the subsequent figures.
After the mirror region has been etched, the mask material 70 is removed by a solvent or a chemical etchant. The wafer is then covered with a layer of photoresist 82, which is patterned so that it covers only the vicinity of the mirror groove, as shown in FIG. 5c. To protect the laser's emitting surface during a subsequent etch step, the photoresist should fill the entire groove. To ensure that this has occurred, the photoresist is patterned so that it extends over the upper epitaxial layer 68 above the laser area by several microns. The wafer is next subjected to a selective RIE, plasma etching or wet chemical etching that removes the upper epitaxial layer 68 from the exposed region overlying the laser; the etching extends laterally as well as vertically downward, thereby undercutting the overlapping photoresist and removing all of the upper epitaxial layer from above the laser. The selective etchant, which for GaAs could be a CCl 2 F 2 plasma, does not attack the underlying etch stop layer 66, which protects the laser itself. The etch stop layer is then removed by another selective etchant, such as hydrofluoric acid for GaAlAs, that does not attack the laser epilayers below. This is followed by a removal of the photoresist mask 82 to complete the fabrication of the cavity mirror as shown in FIG. 5d.
The remaining steps for fabricating the laser, such as the definition of the laser stripe and the electrical contacts, can be accomplished using standard techniques. As with the embodiment of FIGS. 4a-4d, the mirror surface can be provided with a highly reflective coating and the vertical laser emission surface with an anti-reflection coating to increase the system's optical output intensity.
The final device structure includes a finished laser 84, a lower mirror section 86 that is aligned with the laser, and an upper mirror extension 88 that extends generally parallel to the substrate and laser and includes a mirror surface that generally faces the laser. The provision of a reflective coating on the mirror surface would also prevent the etch stop layer 66 from distorting the reflected beam.
With either fabrication method, the turning mirror extends far enough above the upper laser surface to ensure that substantially all of the light emitted from the laser is reflected into the ultimate output beam. Although the turning mirror illustrated in FIG. 5d is shown with a flat surface, in practice it would normally also have a concave curvature relative to the laser, as with the mirror of FIG. 4d. This curvature tends to focus the beam with respect to its vertical divergence when first emitted from the laser. For narrow stripe lasers, such as single transverse-mode devices, it may be desirable to also focus or collimate the beam in a horizontal plane.
Several techniques for shaping the beam in a horizontal plane have been developed previously for edge emitting lasers, and could be incorporated into the present surface emitting laser for this purpose. The resultant structure for a ridge-waveguide laser 90 is illustrated in FIG. 6 The laser is fabricated on a substrate 92, and a turning mirror 94 with an upper extension is provided as described above. A region 96 is provided at the end of the laser cavity with a wide or flared stripe so that it does not provide optical waveguiding in the lateral horizontal direction. The light diverges and the beam expands in the horizontal plane, although it is still guided in the vertical direction by the laser cladding layers. The laser's output mirror, which is only partially reflective, is then patterned by lithography to have a curved shape and forms a cylindrical mirror to focus or collimate the beam. This curved vertical laser cavity mirror can be etched or milled in the same way as a flat cavity mirror.
Another approach to achieving a surface-emitting laser with a beam that is shaped in both directions, both parallel and perpendicular to the laser cavity, is illustrated in FIG. 7. An enlarged 45° turning mirror 98 is formed opposite a conventional laser 100 on a substrate 102. In this case, however, a flat rather than a curved mirror is etched during the ion beam milling step. A bowl-shaped recess 104 is then machined into the mirror surface, as described in co-pending application Ser. No. 07/971,383, "3-D Opto-Electronics System With Laser Inter-Substrate Communications, and Fabrication Method", filed Nov. 4, 1992 by Kubena et al., and assigned to Hughes Aircraft Company, the assignee of the present invention.
In each of the above embodiments, the expanded mirror area results in a larger f-number, increases the output efficiency, and yields a smoother beam pattern. While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims. | A surface-emitting laser system includes a laser that emits a vertically divergent beam generally parallel to the substrate on which it is formed, and a turning mirror in the path of the beam that extends up from the substrate to a level well above the laser height. The extended mirror area reflects a greater portion of the beam than prior planar designs, increasing the output efficiency and providing a smoother beam pattern. One fabrication method employs a masking and ion beam milling technique that uses an accumulation of redeposited material to form the additional mirror area, with a thick mask layer that is later removed guiding the redeposition. An alternate fabrication method involves epitaxial growth of an additional layer of material above the conventional laser epilayers, with the additional layer subsequently removed from the laser region but retained in the mirror region. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 828,145 filed Aug. 26, 1977, now abandoned.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a system and apparatus for processing printed data.
It is well known in order to conserve storage space to condense the bulk of a document, book or other printed media by photographically reproducing the printed matter on a reduced scale on for instance microfilm and enlarging the printed matter to a size readily recognisable to a reader, by advancing the microfilm past an optical reading head. Such a process has the advantage of condensing the information contained in for instance, a book, thereby reducing the size and bulk of the vehicle required to carry the printed matter.
An object of the present invention is to provide a system and apparatus for converting original data to a different form and reconverting the data to a form recognisable by a reader, with the apparatus being compact so as to be sufficiently portable to be carried in a person's pocket and comparatively inexpensive and of low power consumption.
A more specific object of one aspect of the invention is to convert the original data to a coded form and recording the same magnetically or photographically, and to reconvert the coded form of the data back to a form recognisable by a reader.
Another object of the invention is to convert the original data into a different form e.g. by reduction and to reconvert the reduced form to a form recognisable by a reader.
Thus, according to one aspect of the present invention there is provided a data processing unit including means for converting original data to a different form e.g. a reduced and/or coded form, and recording the same on photographic or magnetic record media, means for scanning the data recorded on said media, to produce electrical signals indicative thereof and means responsive to the said signals for reproducing the original data on a static visual reading device in a legible form recognisable by a reader.
According to a further aspect of the invention there is provided a data processing unit including data reading means for scanning coded data recorded on photographic or magnetic record media as it advances past a reading head, decoding means responsive to address data signals from said reading means to produce output signals indicative of the coded data in decoded form and a static visual display device including means responsive to signals from the decoding means for producing the original data in legible form recognisable to a reader.
In one embodiment of the invention there is provided a system and apparatus for processing printed data including means for recording the data in coded form on photographic or magnetic media, means for scanning the coded data to produce signals indicative thereof, means responsive to said signals for decoding the coded data and viewing means responsive to signals from the decoding means for converting signals from the decoding means into a legible form recognisable to a viewer.
In a further embodiment of the invention the original data is photographically reduced on to a microrecord e.g. a microfische or microfilm and reproduced on a visual display device in a legible form recognisable to a reader, without requiring the intermediate stages of coding of the original data and subsequent decoding of the coded data, thereby enabling existing libraries of photographically reduced information to be used.
The visual display device for the reproduction of data in legible form may utilise electrophoretic, electrochromic or electrochromatic material or plasma panels, or thermionics or electroluminescent materials capable of converting coded data into a legible form recognisable by a reader.
In an embodiment of the invention where a microrecord of the original data is produced, a data reading unit including, for example, a photocell reading head, is arranged to scan a small portion, e.g. a line of a larger portion e.g. a page of the original data photographically reduced and recorded on the microrecord e.g. a microfische. The scanning is performed by a scanning generator operating in synchronism with the designated columns of a matrix of a visual display device. To effect scanning of the selected portion of the microfische, the latter is moved on a rotating mirror or prism. This vertical scan of the microfische is synchronised with the designated rows of the matrix of the display device via, for example, a position encoder on the shaft of the rotating mirror, or with the movement of the Y axis of the microfische. In a further embodiment of the invention applicable to microrecords, the reading head is replaced by a raster scan camera.
In an embodiment of the invention where the original data is coded and subsequently decoded, there is provided a reading head past which photographic film is advanced. The film from a supply spool is wound on a take-up spool provided with a manual winder and the reading head scans the coded data on the film to produce electrical signals indicative of the coded data and which are supplied to a decoding unit. The decoder converts the incoming signals into signals having a matrix form of points corresponding to the crossover coordinates of the rows and columns of a matrix. These crossover points may be defined by small dot matrices of a predetermined number of columns and rows. Signals from the X and Y coordinates of the matrix are supplied to discrete electrophoretic devices of a display panel such that the original printed data is reproduced in legible, recognisable form.
The original data may be specially typed data e.g. as the output from a computer programmed to print out data in any required code.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only with particular reference to the accompanying drawings wherein:
FIG. 1 is a block diagram showing the general layout of a data processing unit of the present invention where the original data is recorded in coded form on photographic film and the coded data subsequently decoded;
FIG. 2 is a block diagram of a general layout similar to that of FIG. 1 but where the original data is recorded on a microfische;
FIG. 3 is a block diagram similar to that of FIG. 2 but where the photocell reading head is replaced by a raster scan camera;
FIG. 4 is a schematic layout of a further embodiment of the invention where a photographic disc is used instead of the photographic film of the arrangement of FIG. 1;
FIG. 5 is a side elevational view of the arrangement of FIG. 4;
FIG. 6 is a block diagram of the scanning method used in the embodiment of FIGS. 4 and 5 and
FIG. 7 is a more detailed circuit diagram of the components of the scan generator used in the embodiment of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the embodiment shown in FIG. 1 original printed data is reproduced in coded form on photographic film 1 e.g. 16 mm film, which is fed from a supply spool 2 to a take-up spool 3 provided with a manual winder 4, and the film advances past the reading head 5 intermediate a light source 6 and the head 5. A decoder and temporary data processor 7 receives signals from the reading head 5 and supplies decoded signals to the X and Y scan generators of the display unit.
The film is divided into a plurality of `frames` and each frame corresponds to a page of printed matter, with each frame containing a plurality of `lines`, each `line` corresponding to a line of print. Each `line` on the film is arranged transversely to the direction of movement of the film and consists of a series of black and white dots corresponding to a binary `0` or `1`. For standard codes such as ASC II, seven dots is typically required to represent any alphanumeric character in binary coded form. Because of the high resolution of the film, the dots may be placed quite close together.
The first `line` of a `frame` represents the page number and other organisational data required by the decoder and processor. A feature of the encoding system of the present invention is that a first predetermined number of dots e.g. 7, in a `line` define the `address` i.e. the position on the page of the remaining characters in the line of typescript which is to be reproduced. This allows for overprinting and correction which simplifies the initial manufacture of the film strip. A further advantage is that precise location of the coded data on the film and the precise positioning of the reading head is not necessary. Thus, for instance, if the film is advanced too much, the `line` addressed will write up its correct position on the display preceded by a blank, which can subsequently be filled in by moving the film strip in reverse. However, the reading speed is such that the film may be advanced continuously at a relatively slow speed and the coding on the film strip is grouped in accordance with the page numbering as in a conventional book. A gap in the information will indicate to the operator that all the lines on a page of the printed matter have been completed. Thus, each `line` in a `frame` on the film strip would contain at least some of the following:
(a) A first dot for registration purposes. This will always be present.
(b) A first character group of a predetermined number of dots e.g. 7 giving the line address of the page corresponding to the `frame` in which the dots are located; the precise number of dots depending on the scan technique.
(c) A second group of a number of dots e.g. 7 to 9 giving the inter line address for diagrams or special characters on a page, or to take account of different widths of characters. It should be noted that not all letters and alpha-numeric characters are of the same width and occupy the space scanned by the scanning generators e.g. shift registers. Where a narrow letter is scanned the start of the next letter may be delineated on the same forward scan of the shift register. It is only necessary to ensure that the decoder or processor unit is programmed to recognise the narrow characters and advance the `bright up` timing accordingly.
(d) At least some of the remaining groups of dots each defining the characters, spaces and punctuation in each line of print.
(e) Additional dots providing an error checking code facility using parity code techniques.
The reading head 5 is conveniently an integrated circuit consisting of a self-scanned I.C. array consisting of a shift register and photodiode rectilinear array which may be spaced 0.001" apart. Alternatively a multiple rectilinear array may be used, e.g. seven arrays may simultaneously scan the coded characters on the film. Thus, a complete line of typescript which is normally up to 60 characters will be accommodated within the width of a 16 mm film strip. With the alternative multiple array scanning method, a narrower film strip can be used and by `track shifting` laterally across the film, additional data scans may be made. Synchronisation of the scanning and film positioning is based on the first dot of the address code or on another dot and separate photocell which when energised initiates the scanning of the shift register. By using a serial/parallel data transfer technique, only the minimum number of inter-connections are required to the decoder circuit 7 thereby achieving economy with increased reliability. Thus, the reading head 5 senses the coded data on the film 1 to produce electrical signals indicative of the coded address data and which are supplied to the matrix of the decoder unit 7 over ASC II serial code line 5a.
The decoder 7 converts the incoming signals into signals having a matrix form of points corresponding to the crossover coordinates of the rows and columns of a matrix. Signals from the X and Y coordinates of the matrix are supplied to discrete electrophoretic devices of a visual display panel 8 via X and Y lines 9, 10.
The visual display device 8 consists of two glass plates with transparent conducting patterns on the inner surface of the glass which are separated by a small gap of approximately 20 microns. The space between the glass plates is filled with a mixture of a darkly coloured non-polar dispersant, e.g. dyed thin oil and titanium dioxide. The titanium dioxide is surface activated so that it carries a surface charge such that when the two electrodes are connected to a potential source, the pigment will migrate through the solvent and appear as a pattern on one of the glass plates. The essential feature of this process is that once the pigment has moved to the plate, it is held there by electrostatic forces even after the electrodes are disconnected from the potential source, thus providing a permanent memory device. To erase the display, it is necessary to reverse the polarity of the electrodes, and it is this feature which permits the addressing of successive lines of typescript to occur until a page is complete. It follows therefore that once the page has been written, the electronic controls may be switched off for as long as required to read the page on the visual display. The organisation of the dots on the page is achieved by having vertical columns on the upper glass plate; some 1000 conducting electrodes being required with small spaces therebetween. The electrodes for the rows are carried on the lower glass plate but this time grouped in batches of any required number say 9 or 11 to encompass any typescript with a spare line or lines above and below which would not normally be written on and corresponding to the space between each line of typescript. This line is addressed by an additional coding arrangement on the original film strip. Subsidiary coding circuits with two or more groups of rows and column matrices may be used to show an expanded character which would be suitable for people with poor eyesight. The number of electrodes which require to be connected on the glass plates presents a special problem but this is overcome by the use of thin film transistors. If the electrodes are deposited by a vacuum deposition process e.g. metal evaporation through a mask, then these electrodes may be brought out to the edge of the glass and themselves form the connections to logic circuits consisting of thin film transistors, deposited in the same vacuum chamber as the original electrodes. Typical semi-conductor materials are cadmium selenide and indium arsenide. The semi-conductor material may be deposited on a silicon dioxide layer which is itself compatible and commonly deposited on glass substrates. The transistors are preferably of the field effect type and would be protected after deposition with a further layer of, for example, silicon dioxide, or other suitable encapsulant. The inherent advantage of this process is the low cost of the materials and the fact that inter-connections are easily made by metal deposition without the need for bonding wires. A typical production technique uses a tunnel vacuum oven with automatic mask positioning so that each part of the process of putting the electrodes and semi-conductor logic circuits together with the connections to the edge of the glass is done on a continuous process. The logic circuit may be considered as a shift register which transfers potential across each row and column sequentially under the control of decoder circuit 7. Because the scanning generator is in fact part of the glass electrodes; the matrix of the display device forms an extension of the scanning generator connections; it is therefore unnecessary to provide enough connectors to define completely the address of the rows and columns and the pattern of the dot matrix. Typically therefore there are 4 connectors to the upper panel and approximately 16 to the lower panel for the sequential scan method. Between the scanning generator, display unit and the photocells, the decoder circuit is introduced. This decoder circuit controls the scanning matrix of the display. It receives the serial information from the photocell array of the reading head, holds it in a temporary store, recodes it and releases data in a modified form so that the ASC II code dot pattern is translated into a brightness modulation signal which gates the output potential of one of the scanning registers in accordance with the character shape as defined by a character matrix of predetermined size. This decoder circuit may be a special purpose integrated circuit or alternatively a general purpose microprocessor programmed for the purpose. The X scan generator and Y scan generator are shown diagrammatically at 11, 12 in FIG. 1.
Such a display device, by virtue of a re-addressing technique, allows overwriting by re-addressing parts of the display, firstly with a reversed polarity to cancel any previous information when required and then with fresh information to present a slowly changing pattern or picture or diagram e.g. mimic diagrams as the record media is slowly moved past the reading head.
FIGS. 2 and 3 illustrate embodiments of that aspect of the invention where no decoding of data is required. One such arrangement is illustrated in FIG. 2 in which a selected portion a of a microfische A is scanned by a photocell reading head B controlled by signals derived from a scan generator C. The generator C also receives input signals from a mechanically driven position encoder D, which signals represent the position of the mirofische A, and output signals from the encoder are fed to the scan generator and also to the rows of the matrix E of the visual device; output signals from the reading head B being supplied via a gating device F to the columns of the matrix E.
In an alternative embodiment of the aspect of the invention relating to microrecords, the photocell reading head of the previous embodiment is replaced by a raster scan camera which is controlled by signals devised from a scan generator which also provides signals for the rows and columns of the matrix of the visual display device. Such an arrangement is shown by way of example only in block form in FIG. 3 in which a portion x of a microfische A, is scanned by a raster scan camera B via a lens system C, the camera B being controlled by signals derived from a scan generator D which also supplies signals via line b and gate E to the columns, and via line C to the rows of the matrix F of the visual display device.
In a further embodiment of the invention illustrated in FIG. 4, the film of the embodiment of FIG. 1 is replaced by a photographic film disc 20 located in a cassette 21. The periphery of the disc is provided with a photographically recorded coded pattern of tracks 22, a track of the pattern representing for instance, a line of print of the original data. The disc is rotated manually at slow speed by means of a knurled wheel 23 partially projecting through the side of the cassette 21, rotation of wheel 23 effecting rotation of a V drive roller 24 which engages the peripheral edge of disc 20. A further V guide roller 25 engages the peripheral edge of disc 20 and a spring loaded V guide roller 26 is biassed into engagement with the peripheral edge of the disc 20.
Light from a light source 27 is projected on to the film surface of disc 20 and reflected from prism 28 and via lens 29 to a line scan photoelectric reading head 30. The output from the reading head 30 is supplied serially to the input of a multi-stage shift register 31 (FIG. 6) via line 32.
The shift register 31 is preferably a 9-stage shift register. As previously indicated, the decoder circuit comprising X and Y scan sections is introduced between the respective X and Y scanning generators of the display and the photocells of the photoelectric reading head 30, and controls the scanning matrix of the display panel. Coded data from the photoelectric reading head is supplied serially to the recycling shift register 31. The coded data represents say a page of original data divided into groups of lines, say 9 or more, which are scanned, one by one from the recycling shift register 31, which selects each line in response to the receipt of a clock pulse applied to the register 31 over line 33 and recodes the data in response to a brightness modulation signal applied to transmission gate 34 over line 35, together with the outputs from shift register 31. It should be noted that transmission gate 34 is used for the Y scan only and that this gate selects the polarity of the signals for the Y scan relative to the X axis.
Address data representative of the location of the original data is present on address lines a, b, c, the data comprising a 12 bit address (3×4 bit hexadecimal code) and supplied to 4 input/16 output lines address decoders 36, 37, 38, each connected to a plurality of transmission gates 39 to 44 inclusive, each having a plurality of groups of output lines d, e, f, g, h, connected to the X or Y scan generators of the visual display device, the particular group of output lines d to h enabled depending on the particular transmission gate 39 to 44 selected by the line address decoders 36, 37, 38.
In the above described embodiment the visual display device is of the electrophoretic type described previously and the matrix of the display device forms an extension of the scanning generator connections. Four connectors are required for the upper glass panel i.e. one for the clock pulse input, one for the `bright up` modulation signal and two voltage supply connections, the lower plate requiring in addition connections corresponding to the twelve inputs to the address decoders 36, 37, 38.
It should be noted that the output lines from the transmission gates 39 to 44 are contiguous but are shown separately grouped in FIG. 6 for illustrative purposes only. Furthermore, for the Y scan, similar groupings to those used for the X scan are used, but since a page of original data is narrower than its length, fewer address decoders are required and in fact only two address decoders are required for the X scan compared with three for the Y scan. The grouping of the vertical lines or columns of the matrix are one alpha numerical character plus its spacing in width.
Synchronism between the X and Y scans is maintained by driving the X scan shift register from the last Y scan address.
A more detailed circuit for the X scan is shown in FIG. 7. The shift register 31 includes 9 stages S 1 to S 9 and is supplied with clock pulses over line 33. As previously indicated, the X scan does not require transmission gate 34 (FIG. 6) and shift register 31 feeds all typescript lines selected by the address decoder. The 4-line address data is supplied in parallel on input lines a, b, c to the hexadecimal address decoders 36, 37, 38, three of which are used for the X scan. The outputs of the 4-line-input to 16-line-output matrix connections of the decoders 36, 37, 38 are connected to a plurality of script line select gates 39,40 and the outputs from the select gates are connected to the X scan coordinates of the matrix of the visual display device (not shown).
It will be appreciated that although the invention has been described with particular reference to the recording of original data photographically reproduced on photographic record media, the record media may be other than photographic films, for example magnetic tape or other magnetic record media. By means of a different decoder circuit, e.g. an alternative programme on the microprocessor, serial information may be collected from a telephone to produce a page of typescript.
A further use of the data processing unit is as a fascimile transmitter since the matrix may be coded in any way and hence could produce pictorial information.
In the embodiment of the invention relating to microrecords e.g. microfische or microfilm, any means for securing the data on the mirorecord may be used, and any means for correlating the position of the data on the mirorecord with the edge or reference point of the display matrix. | A data processing unit including means for reducing original data or producing the data in coded form and for recording the same on photographic or magnetic media e.g. photographic film or disc or magnetic tape, scanning means for sensing the data recorded on the record media to produce electrical signals indicative of the reduced or coded data and means including decoding means where the original data is coded and responsive to the signals from the scanning means for reproducing the data on a static visual reading device e.g. an electrophoretic memory unit, in a legible form recognizable by a reader. The decoding means is responsive to address data signals from the scanning means to produce output signals indicative of the coded data in decoded form. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of low level light detectors, especially those based on the superconducting nanowire single photon detection effect.
BACKGROUND OF THE INVENTION
[0002] Sensitive light detectors are needed in various fields, such as quantum communication, space communication, astronomy, motion detection, molecule sequencing and others. The ultimate light sensitivity is reached when detecting a single quantum of light, the photon. Achieving reliable single photon detection at a high rate requires a high detection efficiency, a fast response, as well as negligible dark counts. Superconducting nanowire single photon detectors (SNSPD) currently are one of the devices used to provide such performance. Such SNSPDs are typically constructed of a thin (≈5 nm) and narrow (≈100 nm) superconducting nanowire, generally formed on a substrate such as silicon, sapphire, magnesium oxide, glass or the like, by means of conventional microelectronic fabrication techniques. The length is typically hundreds of microns, and the nanowire is patterned in a compact meander geometry to create a square or circular pixel with high area filling factor. The nanowire is cooled below its superconducting critical temperature and biased with a DC current that is close to but less than the superconducting critical current of the wire. The detection mechanism utilizes a fast avalanche process, in which an absorbed photon incident on the nanowire breaks hundreds of Cooper pairs and reduces the local critical current below that of the bias current. This results in the formation of a localized non-superconducting region, or hotspot, with finite electrical resistance. This resistance is generally larger than the load resistance (typically of 50 ohm), and hence most of the bias current is shunted to the load resistor. This produces a measurable voltage pulse that is approximately equal to the bias current multiplied by the load resistance (typically 50 ohms). With most of the bias current now flowing through the load resistor, the non-superconducting region cools and returns to the superconducting state. The time for the current to return to the nanowire is typically set by the inductive time constant of the nanowire, equal to the kinetic inductance of the nanowire divided by the impedance of the load resistor. Proper self-resetting of the device requires that this inductive time constant be slower than the intrinsic cooling time of the nanowire hotspot. However, the reset time should be kept to the minimum imposed by this limit; the detection time is inversely proportional to the detection rate. Hence, detector length should be kept to minimum to decrease the inductive time. Typical reset time scales of SNSPDs can be of the order of tens of picoseconds, requiring detection rates of well over the GHz. range. Current SNSPDs can thus provide fast response, as well as negligible dark counts, but suffer from detection efficiencies well below 100%.
[0003] The detection efficiency η, also referred to as the quantum efficiency, is defined as the percentage of photons detected by the detector, out of those received. The detection efficiency can be calculated as η=η C ×η A ×η P , where: the coupling efficiency η C is the percentage of photons impinging on the detector element itself out of those received at the optical input, the absorption efficiency η A is the percentage of photons absorbed in the detector out of those impinging on it, and the pulse efficiency η P is the percentage of photons creating a pulse out of those absorbed.
[0004] There are several prior art means of inputting light to be detected by the detector. One type of prior art detector systems input the light by means of free space coupling between the detector and the source, using complex lens systems. Other systems input light from a fiber. In order to ensure good coupling to the device (high η C ) one method used in the prior art is to align the end of the input fiber with the device using precise piezoelectric motors, whose positioning is controlled by a feedback mechanism based on the output level resulting from a probe illumination beam used to align the fiber end. Either of these systems is complex, costly, and slow to operate. Alternatively, the fiber end is roughly fixed relative to the device, and the light is focused onto the SNSPD device in the cryostat. These methods may result is light losses of the order of 50% or more.
[0005] A photon impinging upon the detector has a limited chance of being absorbed by the nanowire structure of the detector, because of the partially transparent nature of the thin layer of detector superconductor. In order to increase the value of the pulse absorption efficiency, η A , it has been proposed in a number of prior art references to use an optical cavity, with the detector element itself acting as one mirror and a second metallic mirror disposed opposite it, or with a simple reflective element added opposite the detector element. Thus, for instance, in the article entitled “An Ultra-low Dark-count and Jitter, Superconducting Single Photon Detector for Emission Timing Analysis of Integrated Circuits” by P. LeCoupanec et al., published in Microelectronics Reliability, Vol. 43, pp. 1621-1626 (2003), an aluminum mirror is deposited onto the SSPD active area, to retro-reflect photons transmitted through the NbN layer, to increase its apparent thickness. In U.S. Pat. No. 6,812,464 to R. Sobolewski et al, for “Superconducting Single Photon Detector”, a concave mirrored surface is used to reflect and focus any photons which have passed through the SNSPD element without being absorbed, back onto the SNSPD element. In the article entitled “Nanowire Single Photon Detector with an Integrated Optical Cavity and Antireflection Coating” by K. M. Rosfjord et al, published in Optics Express, Vol. 14, No. 2, pp. 527-534 (2006), there is described an optical cavity fabricated on top of the detector structure, using a titanium/gold mirror on the detector surface remote from the optical input surface.
[0006] In general, these cavities have resulted in only a modest increase in the detection efficiency presumably because the detector element itself has a substantially transparent section. Moreover, the light is not generally confined in the directions perpendicular to the beam propagation direction, which result in light loss to the sides. As such the cavities produced have low finesse; the number of traverses of a photon within the cavity before it escapes without being absorbed by the NbN meander element is limited.
[0007] Furthermore, the above described prior art devices still require a sensitive and time consuming alignment procedure to ensure that the light input fall entirely on the SNSPD element.
[0008] There therefore exists a need for novel low light level detection devices, and especially SNSPD devices which overcome at least some of the disadvantages of presently available detectors.
[0009] The disclosures of each of the publications mentioned in this section and in other sections of the specification, are hereby incorporated by reference, each in its entirety.
SUMMARY
[0010] The present disclosure describes new exemplary light detection devices, especially using SNSPD detection elements, having novel configurations for increasing the detector efficiency. Firstly, the detector is fabricated directly on the tip of an optical fiber used for inputting the light. The fabrication on the tip of the fiber allows precise alignment of the detector to the fiber core, where the field mode is maximal. This construction maximizes the coupling efficiency η C to close to unity, without the need for complex alignment procedures, as is necessary with prior art devices in which the input fiber is brought into proximity and aligned with a previously fabricated device.
[0011] Additionally, the device can be constructed to include a high-Q optical cavity, such that any photon entering the device will be reflected to and fro within the cavity numerous times. This is achieved by ensuring that both end reflectors of the resonant optical cavity are mirrors having as high a reflectivity as possible. This construction is achieved by incorporating dedicated mirrors at both ends of the cavity, rather than using the nanowire structure itself, or a reflective coating on it, as one of the cavity mirrors, which is the configuration shown in at least some of the prior art. The cavity is thus characterized in that the meander nanowire structure is contained within the cavity between the end mirrors. Therefore, the above mentioned effect of photons being reflected to and fro within the cavity numerous times, and traversing the meander nanowire structure at every pass, thus results in their having greatly increased chances of absorption by the nanowire structure.
[0012] Such an optical cavity can be constructed in one of two configurations. In the first configuration, the mirror at the output end of the fiber, which is thus the input end of the cavity, may be a dielectric fiber Bragg grating mirror (FBG) having a very high reflectivity over a narrow band centered on the wavelength of the photons to be detected. This configuration provides a very high absorption probability of an impinging photon, approaching essentially unity. In the second configuration, the mirror at the output end of the fiber may be a partially transmitting mirror, such as a silver mirror of suitable thickness.
[0013] In either of these two configurations, the second mirror of the cavity should preferably be a full reflector mirror, having as high a reflectivity as possible. When the chance of a photon to pass through the first mirror is equal to the chance of it being absorbed in the detector, the cavity is said to be in critical coupling. Control over the first mirror, whether dielectric or metallic, allows engineering of the cavity to have what is known as critical coupling. When the critical coupling condition is fulfilled, optical physics predicts that light traveling with the resonance wavelength of the cavity will be fully absorbed in the cavity, hence the absorption efficiency η A becomes close to unity. Therefore, with the exception of the pulse efficiency η P , which is a property of the nanowire structure and its operating conditions, all of the efficiencies concerned can be maximized to be close to unity, such that the proposed detector should allow a great increase in the detection efficiency.
[0014] The extent to which the coupling is close to critical is determined for these devices, inter alia, by the reflectivity level of the first mirror, according to the requirements of the detector. The closer the coupling is to critical, the higher the detection efficiency achieved, but generally, the more wavelength selective is the detector.
[0015] The intra-fiber construction in combination with the optical cavity has the added advantage in that for the majority of its passage along the cavity, the light is essentially confined by the fiber, such that no photons are lost by divergence away from the optical input axis. This feature is important for a high-Q cavity, where a photon may perform many traverses before it is absorbed by the nanowire structure.
[0016] Although this disclosure uses the example of the superconductor nanowire structure as the detection element for the novel detector device configurations described—the SNSPD devices being probably the most sensitive types currently available—it is to be understood that this is only one possible implementation of such detector devices described herewithin, and that this application is not intended to be limited for use only with a superconductor nanowire detector element. In effect, any suitable detector element may be used in the configurations described, on condition that such elements can be readily formed on the end of the input fiber, preferably by means of a planar deposition process, or on condition that they do not absorb light to such an extent that the Q-factor of the resonant optical cavity is reduced too much. One example of such a detection element is a bolometer, which can be readily deposited by thin film processes, and can be made sufficiently thin that it does not damp the resonant cavity too much.
[0017] There is thus provided in accordance with one exemplary implementation of the devices described in this disclosure, a superconducting nanowire detector device, comprising:
[0018] (i) a section of optical fiber for inputting an optical signal to be detected, and
[0019] (ii) an optical cavity associated with the end of the optical fiber, the cavity comprising serially:
(a) a first reflective element, (b) a superconductive nanowire meander structure, which, when cooled to its operating temperature, is adapted to provide a detector output signal responsive to the incidence of photons, and (c) a high reflectivity mirror disposed at the end of the cavity remote from the optical fiber,
wherein the optical cavity is constructed such that it provides coupling close to critical for light incident thereon from the input fiber. In such a detector device, the coupling of light incident from the input fiber into the cavity may be sufficiently close to critical coupling that the light has a likelihood of at least 80% that it will be absorbed in the cavity.
[0023] Furthermore, in such detector devices, the first reflective element may be either a Bragg Grating Mirror formed within the optical fiber, or a partially transmitting metallic mirror, formed on the end of the optical fiber. Advantageously, the second reflective element should be an essentially fully reflective metallic or dielectric mirror. In such exemplary implementations of the above described detector devices, the cavity may be constructed to have a Q of at least 10, or of at least 100, or even more. In any of the described implementation of such detector devices, the superconductive nanowire detector structure may be formed directly on the end of said input fiber and in a location such that it is essentially aligned with the core of said fiber. Additionally, at least the superconductive nanowire detector structure and the high reflectivity mirror may be formed using planar deposition and lithographical processes.
[0024] Yet other implementations of the superconducting nanowire single photon detector devices described in this disclosure may comprise:
[0025] (i) a section of optical fiber for inputting an optical signal to be detected, and
[0026] (ii) a superconductive nanowire detector structure, which, when cooled to its operating temperature, is adapted to provide a detector output signal responsive to the incidence of photons from the input fiber, wherein the superconductive nanowire detection structure is formed directly on the end of the input fiber in a location such that it is essentially aligned with the core of the fiber. In such an exemplary device, the superconductive nanowire detection structure may be formed using planar deposition and lithographical processes.
[0027] The above described other implementations may further comprise an optical cavity associated with the end of the input fiber, wherein the superconductive nanowire detector structure may be contained within the optical cavity. This optical cavity should comprise a first reflective element at the optical fiber end of the cavity and a high reflectivity mirror at the end of the cavity remote from the optical fiber. The first reflective element may be either a Bragg Grating Mirror formed within the optical fiber, or a partially transmitting metallic mirror, formed on the end of the optical fiber.
[0028] Yet other exemplary implementations perform a method of constructing a superconducting nanowire single photon detector device, comprising:
[0029] (i) providing a section of input optical fiber for inputting an optical signal to be detected, and
[0030] (ii) forming directly on the end of the fiber in a location that is laterally aligned with the core of the fiber, a superconductive nanowire detector, which, when cooled to its operating temperature, provides a detector output signal responsive to the input of photons through the input fiber.
[0031] This method may further comprise the step of providing an optical cavity on the end of the fiber, wherein the superconductive nanowire detector is disposed within the optical cavity. In such a case, the optical cavity may comprise (a) either a Bragg Grating Mirror formed in the end section of the optical fiber or a partially transmitting mirror formed on the end of the optical fiber as the first cavity mirror, and (b) a high reflectivity mirror as the second cavity mirror.
[0032] In any such methods, the direct forming of the superconductive nanowire detector on the end of the fiber may be operative to optimize the coupling of the optical signal to the superconductive nanowire detector. Furthermore, such optimizing of the coupling may provide increased coupling of the optical signal to the superconductive nanowire detector compared to superconductive nanowire detectors disposed discretely on the end of the input fiber.
[0033] Such optimizing of the coupling may provide increased coupling of the optical signal to the superconductive nanowire detector compared to a superconductive nanowire detector disposed discretely on the end of the input fiber. Additionally, the optimizing of the coupling may provide increased coupling of the optical signal to the superconductive nanowire detector compared to a superconductive nanowire detector disposed outside of the optical cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
[0035] FIGS. 1A to 1C illustrate schematically a prior art SNSPD incorporating an optical cavity on top of the nanowire meander device;
[0036] FIG. 2 illustrates schematically a first exemplary implementation of an SNSPD device of the type described in the present application, using a Bragg grating mirror as the input mirror to the optical cavity;
[0037] FIG. 3 illustrates schematically a plot of the optical absorption in a cavity such as that shown in the device of FIG. 2 , as a function of the wavelength of the incident light;
[0038] FIG. 4 illustrates schematically another exemplary implementation of an SNSPD device, similar to that of FIG. 2 , but using a semitransparent mirror as the input to the cavity; and
[0039] FIGS. 5A to 5G , illustrate schematically one exemplary method by which an SNSPD of the type shown in FIG. 2 can be constructed.
DETAILED DESCRIPTION
[0040] Reference is now made to FIGS. 1A , 1 B and 1 C, which illustrate schematically a prior art SNSPD, of the type shown in the above referenced article entitled “Nanowire Single Photon Detector with an Integrated Optical Cavity and Antireflection Coating” by K. M. Rosfjord et al, published in Optics Express, Vol. 14, No. 2, pp. 527-534 (2006). FIG. 1A is a schematic representation of the device, and FIG. 1B is a representation of a transmission electron micrograph of the cross-section of such a fabricated device. The light is input to the device by coupling from the end of a fiber optical feed 10 , through an antireflection coating (ARC) 11 at the optical input surface to reduce loss of photons from reflection at this surface. The NbN nanowire device 12 , as shown schematically in FIG. 1C , is formed on a sapphire (Al 2 O 3 ) substrate 13 , and on top of it, the optical cavity is formed of a Hydrogen silsesquioxane (HSQ) dielectric layer 14 with a high reflective Ti/Au mirror layer 15 deposited on top of it. Electrical connection to the NbN nanowire device 12 is made through contact pads 16 . Because of the level of transparency of the NbN meander device 12 , the reflection from which may be of the order of 30% or less, the finesse of such a cavity is limited. Results obtained showed an increase in the average measured detection efficiency of devices cooled to 1.8° K and at 1550 nm from 18% for the bare device to 48% for the improved device with cavity and ARC. This implies that the Q of the cavity formed is low, probably having a value of the order of less than 5.
[0041] Reference is now made to FIG. 2 , which illustrates schematically a first exemplary implementation of an SNSPD device of the type described in the present application. The light from the source 29 being measured may be transferred by means of an optical fiber 20 , and the output end of the input fiber 20 incorporates an integral Bragg grating mirror 21 near its end face, with a short stub section of fiber 22 spliced onto the output end of the Bragg grating mirror. The function of this short additional section will be described hereinbelow. The nanowire detector 23 is formed directly on the output face of the fiber assembly. The construction may be most readily formed by inserting the input fiber into a fiber optical connector, with the Bragg grating mirror at the inner end, and the short section of fiber spliced onto the output end of the Bragg grating mirror. A protective layer may be formed on top of the nanowire detector. Although the fiber component of the structure shown in FIG. 2 includes separate sections comprising the input fiber itself, the Bragg grating mirror, and the stub section of fiber, all of these segments are described in this disclosure to constitute the “input fiber”, with the nanowire structure being formed on the end of this “input fiber”. Although the SNSPD devices are generally described in this disclosure using nanowire structures made of NbN, this being one of the currently commonly used and cost effective materials, it is to be understood that the devices are not meant to be limited to use of NbN, but that any suitable superconducting material, such as TiNbN, W x Si 1-x or others, is also intended to be covered by this application.
[0042] The construction of the NbN nanowire structure directly on the end of the input fiber provides the significant advantages over prior art detectors, in which the NbN nanowire detector is constructed on a separate chip which is then attached to the end of the optical input fiber and aligned as best as possible, which results in potentially reduced coupling efficiency and complex alignment procedures. The construction of the NbN nanowire structure directly on the end of the input fiber results in tight coupling of the input photons from the center of the fiber core, where the field amplitude is maximal, onto the center of the nanowire structure. Furthermore, since the device, which has an overall length of about 2 cm, is formed within the fiber, with the exception of the few nm thickness of the nanowire structure and any protective layer, the light is confined by the fiber, and no incident photons can be lost by escaping in directions perpendicular to the fiber axis.
[0043] The advantages of forming the nanowire detector structure directly on the end of fiber can be compounded by means of a further improvement in which the detector structure on the end of the fiber is built inside an optical cavity having a high Q-factor The cavity comprises the fiber Bragg grating mirror 21 at its input end, which can have a reflectivity in its pass band as determined by the FBG characteristics, of up to 99.99%, or even more. Such fiber implanted Bragg grating mirrors can be supplied by O/E Land Inc. of LaSalle, Quebec, Canada. At the remote end of the cavity, beyond the nanowire structure 23 , a full reflector 24 is used, which too can have a reflectivity of well over 99%. This remote mirror is shown in FIG. 2 as a silver mirror, having a reflectivity of up to 99.6% at wavelengths in the 1550 nm. region. An intermediate buffer layer of a dielectric 25 , shown in FIG. 2 as silicon dioxide, electrically insulates the silver mirror 24 from the nanowire structure 23 and its electrical connections. Any other suitable high reflectivity mirror may be used, and in particular metallic or dielectric mirrors. Use of such FBG mirrors together with end mirrors having such high reflectivities enables cavities to be obtained having Q-values of well over 100, and even 1000 or more.
[0044] As previously stated, the extent to which the cavity coupling is close to critical is determined, inter alia, by the reflectivity level of the input mirror, according to the requirements of the detector. The closer the coupling is to critical, the more sensitive is the detector, but generally, the less broadband is the detector. Thus, closeness to critical coupling is a characteristic of the device which is selected in accordance with the ultimate detection sensitivity desired, and the spectral breadth desired. Thus, the devices shown in FIG. 2 with the very high Q cavities will have a detection efficiency much closer to 100% than those to be described hereinbelow in FIG. 4 , but will have much higher wavelength detection specificity.
[0045] In the implementation shown in FIG. 2 , the total length of the cavity may need to be as much as a few centimeters, for the following reasons:
[0046] (A) In order to achieve a high reflectivity for the Bragg grating mirror and to fit critical coupling requirements, it may need to have a length of the order of 0.1 to 2 cm. or even more.
[0047] (B) The spacing, Δλ, between sequential resonance wavelengths is approximately given by the formula:
[0000] Δλ=λ 2 /L (1)
[0000] where λ is the wavelength and L is the cavity length. In one exemplary implementation, the FBG used is centered on λ=1550 nm, and has a high-reflectivity bandwidth of only 0.2 nm. In order to operate practically with such a narrow bandpass mirror such that at least a few cavity resonance wavelengths will be in the narrow bandpass (Δλ<0.2 nm), a long cavity is needed, which from equation (1) is found to be of the order of (1550 nm) 2 /0.2 nm=1.2 cm. This is achieved by adding a fiber stub 22 to the cavity, typically of length between 0.25 to 2 cm, depending on the bandwidth of the FBG, such that the total cavity length (FBG+Stub) may be of the order of up to a few centimeters.
[0048] A cavity of this length has a further advantage, in that almost the entire length of the cavity, up to the nanowire structure itself, is contained within the optical fiber. The only parts of the cavity which are outside of the effective fiber length are the nanowire device 23 , typically of the order of 4 nm, the buffer layer 25 , typically 150 nm, and the end mirror 24 , typically 150 nm. Thus the majority of the cavity length is within the confines of the fiber. The light traversing within that length of fiber is confined to the fiber and cannot escape in directions perpendicular to the light propagation direction. The only region of the cavity where light can escape is therefore the approximately 300 nm end section. Because of the excellent confinement along the propagation direction, there is therefore very little loss due to light escaping from the sides of the cavity. Calculations show that such losses for a cavity having the dimensions and properties mentioned herewithin can be as small as 10 −6 or even less. This is a substantive improvement over prior art cavities, where the propagation is performed in free space and not within a fiber medium. Thus even if the prior art cavities described hereinabove were capable of being constructed with considerably higher Q values (which does not seem readily achievable because of the use of the nanowire structure as the basis of one of the mirrors), the efficiencies of the detectors thereby achieved would still not approach those of the devices of the present disclosure, because of their losses of photons laterally from the cavity.
[0049] Reference is now made to FIG. 3 , which illustrates schematically a plot of the optical absorption coefficient in a cavity such as that shown in the device of FIG. 2 , as a function of the wavelength λ of the incident light. As explained above, the cavity is said to be critically coupled when the reflection component is zero and the absorption coefficient is unity, such that all of the light enters the cavity and none is returned. Since the dielectric buffer layers have a very low absorption, the incident light is absorbed within the cavity either in the detector or the silver mirror. Since in a single pass, the absorption in the silver mirror is less than 0.5% whereas the absorption in the detector is of the order of 10% it is clear that most of the light is absorbed in the detector, as is desired of the device. This is the optimal case for such a cavity implemented detector.
[0050] The exemplary cavity whose plot is shown in FIG. 3 has critical coupling at a number of wavelengths within the 0.2 nm. passband of the FBG used in the device. The parameters for this exemplary cavity are:
[0000] n Ag =0.514+ i* 20.8
[0000] n NbN =5.23+ i* 5.82
[0000] n SiO2 =1.5 The detector fill factor over the beam area=0.3 FBG length, L=0.32 cm. FBG maximal wavelength bandpass=0.2 nm. Cavity length, d SiO2 =1.2 cm.
where the n are the complex refractive indices of the materials involved, and the other terms are self explanatory. For such a cavity, critical coupling is achieved for wavelengths λ of 1549.893; 1549.955; 1550.017 and 1550.080 nm.
[0055] Reference is now made to FIG. 4 , which illustrates schematically another exemplary implementation of an SNSPD device of the type described in the present application. The drawing of FIGS. 2 and 4 are not scale drawings, such that dimensioned comparisons should be made only from the exemplary dimensions given in their associated descriptions in this disclosure. Like FIG. 2 , the implementation of FIG. 4 is achieved by forming the complete detector assembly with its associated optics, directly on the end of the input optical fiber 20 . Furthermore, the implementation of FIG. 4 also utilizes a cavity with high reflection mirrors at its ends and with the nanowire device disposed within the cavity. However, unlike the implementation of FIG. 2 , the high reflection mirror used at the input of the implementation shown in FIG. 4 is a conventional partially reflective mirror 40 , enabling the input light to penetrate, but providing sufficient reflection to ensure critical coupling to the cavity. The extent to which the coupling is close to critical is determined, inter alia, by the reflectivity level of the input mirror, according to the requirements of the detector. The closer the coupling is to critical, the more sensitive is the detector, but generally, the less broadband is the detector. Thus, coupling which ensures that, for instance, at least 80%, or 90% or 95% or 99% or even more of the incident light is absorbed in the cavity, will result in detectors having different sensitivities and for different spectral breadth use.
[0056] On top of the partially reflective mirror 40 , a buffer layer of dielectric 42 is deposited, to electrically insulate the nanowire detector structure 23 from the input mirror. This layer is shown exemplarily in FIG. 4 as silicon dioxide. This is followed by the nanowire detector structure 23 , followed by another buffer dielectric layer 25 . The total thickness of the two SiO 2 layers should be selected so that the cavity will support the light wavelength to be detected. It may typically be a few μm thick, or more. The outer high reflection mirror follows, shown in FIG. 4 too as a silver mirror 24 . Since all of the manufacturing steps are performed by planar depositions on the end of the fiber, the construction of this implementation is therefore simpler and less costly than that of FIG. 2 . However, since the cavity is essentially entirely in free space, since the fiber terminates at the partially silvered mirror 40 and the buffer layer of dielectric 42 does not necessarily efficiently contain the light, even though the cavity is short, the losses due to escape of photons laterally from the cavity are higher than those of the implementation of FIG. 2 , where almost the entire cavity, up to the nanowire detector, is contained within the fiber structure. Furthermore, as mentioned above, since the Q of the cavity is lower, and the cavity significantly shorter than that of FIG. 2 , this type of detector will generally have a broader wavelength response than those of FIG. 2 . This type of detector may thus be more useful for biological and astronomical detection applications, where the light to be detected does not have the same sharply predetermined defined wavelengths as are common in telecommunication applications with their closely controlled channel frequencies.
[0057] Reference is now made to FIGS. 5A to 5G , which illustrate schematically one exemplary method by which an SNSPD of the type shown in FIG. 2 can be constructed. Although the particular steps are described as performed in a laboratory environment, and should not therefore be taken as limiting production methods of such devices, similar steps can be adapted for commercial industrial production use.
[0058] In order to fabricate the detector, a standard ferule Fiber Connector (FC) 52 is used as a base substrate. FIG. 5A shows, in side cut-away view, an input fiber 50 in the form of a section of fiber having the selected Fiber Bragg Grating, 51 , near its extremity, and the FC 52 into which the fiber is to be inserted. The fiber is chosen to suit the wavelength of the photons needed to be detected. Such a fiber may be Corning SM-28, which has an 8.2 μm core, and a 125 μm cladding layer, with a 10.4 μm mode field diameter, this being suited to transmission of 1550 nm wavelength light. Other fibers may be well selected for visible light, or for other telecommunication wavelengths or for any other wavelength. The section of clear fiber 53 beyond the FBG 51 is selected to fulfill the cavity length requirement as previously discussed, for the ultimate cavity configuration.
[0059] In FIG. 5B , the fiber is shown inserted into the FC 52 to a depth such that the end of the fiber protrudes very slightly beyond the output face 54 of the fiber connector FC, though because of the scale of the drawing, this protrusion is not apparent in FIG. 5B . The fiber may then be epoxy glued to the FC, as is known in standard fiber optical fabrication techniques, and the overhang of the fiber polished to ensure the “ultra high polish” quality needed for the ensuing fabrication steps (known as FC-UPC). The bottom section of FIG. 5B shows an enlarged representation of the end of the FC, in section and end view of the face 54 .
[0060] FIGS. 5C to 5G now illustrate schematically, the various planar deposition and fabrication steps carried out on the end of the installed fiber, according to one exemplary procedure used, in order to construct the device. These steps are also shown on the right hand side of each drawing, in end views of the FC and fiber assembly.
[0061] In FIG. 5C , the gold contact layers 55 , are shown evaporated onto the end face 54 of the FC and the fiber, preceded by a thin chromium layer (not shown) to provide good adhesion of the gold. The leads are evaporated in such way that the ferrule-fiber interface is fully covered by this thick layer, but the core of the fiber 50 is clear, to enable the light input from the fiber core to reach the nanowire detector element. Evaporation is most readily performed through a mechanical mask to enable the shaped profile to be formed, the broad wings 55 at top and bottom of the drawing being used to facilitate ultimate electrical connection by wire bonding to the coaxial cable connector for output of the signal.
[0062] In FIG. 5D , a layer 56 of the superconductive nanowire material is sputtered over the fiber end, most conveniently Niobium Nitride, NbN. The sputtering may be performed using a DC-magnetron sputtering system at room temperature from a Niobium target with a partial pressure of Ar and N gasses, as is known in the art. Typical sputtering parameters used may be a base pressure of 1˜2×10 −7 Torr, a working pressure of 5×10 −3 Torr, relative Ar—N partial pressure of 5:1, a discharge current of 900 mA, a discharge voltage of 200 V, a deposition rate of 5 Å/sec, and a target-substrate distance of 140 mm. On top of the NbN layer, a thick aluminum layer is deposited in order to protect the NbN layer during the following focused ion-beam lithography process shown in FIG. 5E .
[0063] In FIG. 5E , using focused ion beam (FIB) milling, the meander nanowire structure ( 23 of FIGS. 2 and 4 ) is then fabricated in the NbN layer. The actual size of this structure is too small to be seen in FIG. 5E , but its position is indicated thereon. According to one exemplary procedure, the sample may undergo a first lithography step using FIB, where the NbN is narrowed to a 25 μm width and 150 μm length bridge. The purpose of this step is to reduce the capacitance between the NbN layer and the nearby metallic mirrors. This step is done using a high current and at relatively low precision (1 μm). During this step, the Al mask layer protects the NbN film from exposure to the ion beam, and prevents Gallium poisoning of the layer, as is known in the art. At the end of the first photolithography step, the Al layer is completely removed using TMAH-DI (1:10) solution. The sample then undergoes a second FIB step, this time with low current and high precision (<10 nm), and the precision meander is formed. The size of the meander conductors so formed may be such that each line may exemplarily be 5 nm thick and 100 nm wide, and the meander covers a circle of at least the diameter of the mean optical mode.
[0064] An alternative to the process described in connection with FIG. 5E could be to remove the Al layer and then to perform photo-lithography or Electron Beam (e-beam) lithography. Such steps may require the deposition of photo- or e-beam resists, on a non-planar substrate (the end of the FC connector). Such methods known in the art include spray coating, drop casting, spin coating and other methods. Imposing such a photolithography step will require a machine operating at short wavelengths (deep-UV region) to achieve the required 100 nm resolution limit Achieving a resolution of 100 nm or less using e-beam lithography is a practice known in the art. The lithography step may then be sequentially followed by chemical dry etching procedures, which are well established, using gasses such as CF 4 or SF 6 or others, in an electron cyclotron resonance machine (ECR) or reactive ion etching (RIE) or ion milling or another suitable type of machine.
[0065] For all methods of lithography (FIB, e-beam lithography, photolithography or any other) an alignment of the nanowire to the fiber core is necessary. Such alignment may be achieved using the circumference of the fiber. Since the fiber has a defined diameter, and its shape is an accurate circle, it may be used to find the center of the fiber. The fiber and the fiber core are concentric circles, hence have common centers. Once the position of the center of the core is found, the meander can be formed accurately aligned to this core.
[0066] In the step shown in FIG. 5F , a cap layer of SiO 2 57 , typically of thickness 150 nm, is thermally evaporated through a mechanical mask, in order to provide the electrically insulating buffer layer before applying the silver mirror shown in FIG. 5G . Since the SiO 2 is optically transparent (glass), the NbN underlayer is still visible through it.
[0067] In FIG. 5G , the top silver mirror 58 , also typically of thickness 150 nm, is thermally evaporated over the center section of the SiO 2 layer, to provide the end mirror of the device optical cavity. The NbN underlayer is now no longer visible through the opaque mirror.
[0068] For constructing the implementation shown in FIG. 4 , using a semitransparent metallic mirror instead of an FBG mirror, the initial steps of FIGS. 5A and 5B are the same, except that a standard single mode fiber is used for inputting the light to the device. As before, the fiber should be selected to suit the light wavelength to be transmitted. After gluing and polishing, a layer of silver is evaporated onto the ferrule end face, having a predetermined thickness determined by the reflection/transmission ratio needed for the cavity. This mirror should then be covered by an evaporated dielectric layer, such as SiO 2 to avoid shorting of the following detector by the mirror, and to ensure correct cavity length. Production then continues with deposition and fabrication of the NbN nanowire detector element and successive layers, as described in the steps shown in FIGS. 5C to 5G hereinabove.
[0069] It is appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of various features described hereinabove as well as variations and modifications thereto which would occur to a person of skill in the art upon reading the above description and which are not in the prior art. | A fiber optical superconducting nanowire detector with increased detector efficiency, fabricated directly on the tip of the input optical fiber. The fabrication on the tip of the fiber allows precise alignment of the detector to the fiber core, where the field mode is maximal. This construction maximizes the coupling efficiency to close to unity, without the need for complex alignment procedures, such as the need to align the input fiber with a previously fabricated device. The device includes a high-Q optical cavity, such that any photon entering the device will be reflected to and fro within the cavity numerous times, thereby increasing its chances of absorption by the nanowire structure. This is achieved by using dedicated cavity mirrors with very high reflectivity, with the meander nanowire structure contained within the cavity between the end mirrors, such that photons impinge on the nanowire structure with every traverse of the cavity. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to the field of orthopedics, and more particularly to a bone pin for the coupling of two separate pieces of bone together for use in the surgical correction of hammer toe.
[0003] 2. Description of the Prior Art
[0004] One surgurical method of treatment of hammer toe involves the surgurical implantation of bone pins, and more particularly, an interphalangeal fusion pin which provides an anatomically correct angle between a first phalange and a second adjacent phalange, such as the proximal phalange and the intermediate phalange which exists at the proximal interphalangeal joint, wherein the pin is comprised of a resorbable or permanant material.
[0005] Digital deformities of the fingers and toes are some of the most common conditions encountered by orthopedists and podiatrists. Patients with digital deformities often experience significant pain from structural abnormalities. Some of these abnormalities are acquired, caused by traumatic injuries, neuromuscular pathologies, systemic diseases, or mechanical problems secondary to extrinsic pressures. The deformities are popularly known as either mallet finger, jersey finger, coach's finger, hammer toe, as well as a host of others indicative of several different pathologies.
[0006] Hammer toe is generally described in the medical literature as an acquired disorder, typically characterized by hyperextension of the metatarsophalangeal joint (MTPJ), hyperflexion of the proximal interphalangeal joint (PIPJ), and hyperextension of the distal interphalangeal joint (DIPJ). Although this condition can be conservatively managed (e.g., through the use of orthotic devices), in certain instances surgical intervention is required.
[0007] In order to prevent recurrence of the deformity and ensure the success of the surgical procedure, a proximal interphalangeal (PIP) joint arthrodesis is typically performed. The “end-to-end” or “peg-in-hole” techniques are the most commonly used procedures. The PIPJ is aligned with the rest of the toe in a corrected anatomical position and maintained in place by the use of a 0.045 Kirschner wire (K-wire) which is driven across the joint. Initially, the wire is placed from the PIPJ through the tip of the toe. It is then driven in retrograde fashion into the proximal phalanx. The exposed wire exiting the toe is bent to an angle greater than 90 degrees, and the bent portion is cut at 1 cm from the bend. At the conclusion of the surgical procedure, a small compressive dressing is placed around the toe, with a Jones compression splint being used for three to four weeks to protect the pin and the toe in order to maintain correction. The K-wire and the Jones splint are generally removed three weeks after surgery. Similar procedures may be followed to create arthrodesis of the distal interphalangeal joint (DIP) of the toe or for arthrodesis performed in the finger to correct digital abnormalities of the hand.
[0008] Although this type of surgical procedure has alleviated the discomfort of hammer toe and other abnormalities of the toe and finger joints for countless patients, the use of K-wire can result in the possible post-surgical misalignment of the phalanges (e.g., caused by distraction of the K-wire), as well as swelling, inflammation, and possible infection at the site of the exposed K-wire segment.
[0009] Of recent interest in the treatment of toe deformities, such as hammer toe, are prosthetic devices which have been used to treat deformities of the finger joints. For example, these devices can be inserted into adjoining phalanges of the finger and can serve to function ostensibly as a normal knuckle would. Because it is generally necessary to permit one or more of the joints of the finger to flex and bend, some of these devices are slightly angled to provide for an anatomically acceptable interphalangeal joint angle of the finger. Furthermore, some of these devices allow the joint portion to bend to a significant degree, thus permitting the finger a relatively wide range of articulation.
[0010] These devices are typically comprised of metallic or thermoplastic materials which, while being biocompatible, are also physiologically inert and thus are not resorbed by the body. There are, however, conditions in which an arthrodesis, or fusing of the affected finger or toe joint is desired, making a permanent device which is designed to permit joint flexion/extension inappropriate. Thus, the use of these permanent prosthetic devices in the treatment of hammer toe and other digital deformities, wherein the goal of the operation is arthrodesis, whereby the presence of the device would only be required for a short number of weeks to aid in maintaining correct anatomical alignment of the phalanges for fusion, would not be indicated. Additionally, these permanent devices would also be contraindicated in the treatment of certain finger conditions where the phalanges need to be correctly anatomically aligned for only a few weeks until a proper amount of healing for fusion has occurred.
BRIEF SUMMARY OF THE INVENTION
[0011] The illustrated embodiments of the disclosed apparatus and method is directed to a pair of self-tapping, interconnecting, externally and internally threaded cylindrical bone pin halves that when installed between two separate pieces of material or bone, will draw and hold the bone together as a single unit. The pin halves have an axial bore defined therethrough. One half with internal threading defined in the bore and mating external threading defined into a exterior surface of a male peg from the other half. The two halves are threaded together by means of mating internal threading and the external threading on the male peg. While the pair of threaded pin halves are being fastened into the host material or bone, due to the unique design of their external threads no radial outward forces are produced that could cause cracking or splitting of the sections of the bone into which they are implanted. The external threads are defined into the exterior surface of each half of the pin, one half with a right hand thread and the other half with a left hand thread. When the two halves are joined together, the increased thread pitch on one of the halves continuously draws bone segments into which the halves have been implanted into each other even when the internal threads of each half have already been fully tightened.
[0012] The current device also comprises interlocking hook self-tapping threads which provide sharp and efficient cutting edges for self-tapping into the host material. Repository spaces are present in each of the device halves for collecting all of the chips created in the tapping process.
[0013] Another component of the current device is the adjustable drawing capability of the opposing halves of the device. The opposing force creates a clamping load that secures the bone pin immediately and permanently into the host material or bone. The combination of the interlocking hook threads and the opposing pressure flanks of each half of the bone pin together form the perfect thread engagement produce a strong and durable connection between the two halves.
[0014] The interlocking external threads of the device mechanically join with the surrounding host material or bone segments when the two halves are assembled and tightened together. When used in bone, this interlocking function promotes bone regeneration for faster healing due to the unique load bearing capability and the ability to draw the mating ends of the bone tightly together and hold them firmly. This is the single most important factor in promoting rapid bone remodeling and shortening the post-operative recovery period.
[0015] In a simple and effective way, the disclosed thread design creates an instant interlocking threaded union, excellent uniform axial load-bearing capability, and very good resistance to vertical shear and bending loads. The unique interlocking hook thread prevents radial outward spreading forces from occurring when the device is tightened and or loaded. The device can also be easily removed and reinstalled if needed.
[0016] While the following description will describe an apparatus and method for inserting the current device into bone, and more specifically to treat the medical condition known commonly as hammer toe, it is to be expressly understood that the current device may be used for any similar type of medical procedure without departing from the original spirit and scope of the invention. Similarly, it is to be expressly understood that the current device may be installed in other host materials such as wood, plastic, metal, or any other material now known or later devised in order to couple two separate pieces of the said host material together.
[0017] More formally, the illustrated embodiment of the invention includes an apparatus for coupling at least two pieces of host material together, such as two phlanges in a hammer toe, comprising: a hollow proximal half with an internal surface and an external surface for implantation into one of the two pieces of the host material; a hollow distal half with an internal surface and an external surface for implantation into the other one of the two pieces of host material; and threading for threadably engaging the distal half and proximal half together.
[0018] The proximal half and the distal half each comprise a helical external thread the external surface of each respective half for engagement with the two pieces of host material.
[0019] The proximal half and the distal half each comprise at least two opposing self-tapping bores defined through the internal and external surfaces and the external threads of each respective half to act as a repository for the removed debris of the host material.
[0020] The external threads on the proximal half are arranged and configured in the opposite helical sense to that of the external threads on the distal half.
[0021] The threading for threadably engaging the distal half and proximal half together comprise: a peg comprising a male threaded portion disposed on a distal end of the proximal half; and a female threaded portion defined on the internal surface of the distal half.
[0022] The proximal half and the distal half both comprise a hexagonally shaped internal bore defined in at least a portion of each respective half.
[0023] The apparatus distal half further comprises at least two opposing wrench flats defined on the external surface.
[0024] The external threads on the proximal half are orientated at a different pitch to that of the external threads on the distal half.
[0025] The external threads that have the at least two self-tapping bores defined therethrough comprise sharp, angled open faces to cut into the host material when the proximal half and distal half are rotated.
[0026] The illustrated embodiment of the invention also includes a method for coupling at least two pieces of host material together, such as two phlanges of a hammer toe, with an adjustable device comprising the steps of: inserting a proximal half of the device into a proximal one of the two pieces of the host material; inserting a distal half of the device into a distal one of the two pieces of the host material; and coupling the proximal one of the two pieces of the host material to the distal one of the two pieces of the host material by means of the proximal half of the device.
[0027] The step of inserting the proximal half of the device in the proximal one of the two pieces of the host material comprises the steps of: rotating the proximal half of the device into a predrilled bore; cutting a female thread into the predrilled bore in the host material by means of an external thread disposed around the proximal half of the device; and engaging the female thread cut into the host material by means of the external thread disposed around the proximal half of the device.
[0028] The step of inserting the distal half of the device in the distal one of the two pieces of the host material comprises the steps of: rotating the distal half of the device into a predrilled bore; cutting a female thread into the predrilled bore in the host material by means of an external thread disposed around the distal half of the device; and engaging the female thread cut into the host material by means of the external thread disposed around the distal half of the device.
[0029] The method further comprises the steps of collecting any debris from the host material in a repository defined into each of the proximal and distal halves of the device when each respective device half is being inserted into its respective one of the two pieces of the host material.
[0030] The step of coupling the proximal portion of the host material to the distal one of the two pieces of the host material by means of the proximal half of the device and the distal half of the device inserted into each respective one of the two pieces of the host material comprises the steps of: disposing or sliding the distal half of the device over a male peg disposed on the distal end of the proximal half of the device; rotating the distal half of the device about the male peg disposed on the distal end of the proximal half of the device; and engaging a female threaded portion defined in an interior surface of the distal half of the device to a male thread portion disposed on the male peg of the proximal half of the device.
[0031] The step of rotating the distal half of the device about the male peg disposed on the distal end of the proximal half of the device comprises the steps of: inserting a hex shaped driving tool into a distal end of the distal half of the device; engaging the hex shaped driving tool in a hexagonally shaped interior bore of the distal half of the device; and rotating the hex shaped driving tool.
[0032] The method further comprises the step of adjusting the distance between the proximal one of the two pieces of the host material and the distal one of the two pieces of the host material by means of rotating the distal and proximal halves of the device after they have been joined together.
[0033] The step of rotating the distal half of the device comprises the steps of: inserting a hex shaped driving tool into a distal end of the distal half of the device; engaging the hex shaped driving tool in a hexagonally shaped interior bore of the distal half of the device; and rotating the hex shaped driving tool.
[0034] The illustrated embodiment of the invention still further includes a method for coupling at least two pieces of host material together, such as adjacent phlanges of a hammer toe, with an adjustable device comprising the steps of: inserting a proximal half of the device into a proximal one of the two pieces of the host material; inserting a distal half of the device into a distal one of the two pieces of the host material; coupling the proximal one of the two pieces of the host material to the distal one of the two pieces of the host material by means of the proximal half of the device and the distal half of the device which has been inserted into each respective one of the two pieces of the host material; collecting any debris from the host material in a repository defined into each of the proximal and distal halves of the device when each respective device half is being inserted into its respective one of the two pieces of the host material; and adjusting the distance between the proximal one of the two pieces of the host material and the distal one of the two pieces of the host material by means of rotating the distal half of the device after it has been jointed to the proximal half of the device.
[0035] The step of inserting the proximal half of the device in the proximal one to the two pieces of the host material and inserting the distal half of the device in the distal one to the two pieces of the host material comprises the steps of: rotating each of the proximal and distal halves of the device; cutting a female thread into each respective one to the two pieces of the host material by means of an external thread disposed around each of the proximal and distal halves of the device; and engaging the female thread in the host material by means of the external thread disposed around each of the proximal and distal halves of the device.
[0036] The step of rotating of each of the proximal and distal halves of the device comprises the steps of: inserting a hex shaped driving tool into each of the distal ends of the distal and proximal halves of the device respectively; engaging each hex shaped driving tool in a hexagonally shaped interior bore in each of the distal and proximal halves of the device respectively; and rotating each hex shaped driving tool.
[0037] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is an exploded view of the threaded device depicting both the distal and proximal portions of the threaded device.
[0039] FIG. 2 is a partially cutaway cross-sectional view of the distal portion of the threaded device shown in FIG. 1 .
[0040] FIG. 3 is a partially cutaway cross-sectional view of the proximal portion of the threaded device shown in FIG. 1 .
[0041] FIG. 4 is a side cross-sectional view of a hammer toe in which the illustrated embodiment of the invention is employed.
[0042] FIG. 5 is a side cross-sectional view of a hammer toe after the joint has been opened and guide pins inserted in preparation for drilling of a receiving bore into each of the opposing phlanges into which bores the halves of the bone pin of the illustrated embodiment will be implanted.
[0043] FIG. 6 is a side cross-sectional view of a hammer toe after the bone pin halves of the illustrated embodiment have been implanted, but before they have been joined together.
[0044] FIG. 7 is a side cross-sectional view of a hammer toe after the bone pin halves of the illustrated embodiment have joined together.
[0045] The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Turning now to FIG. 1 , a distal half 1 and a proximal half 5 of the bone pin 34 are shown. As described below distal half 1 is implanted in the distal phlange and proximal half 5 is implanted into the proximal phlange of a hammer toe joint. Both halves 1 , 5 are generally cylindrical with a longitudinal bore define therethrough on the longitudinal axis of each half. The distal half 1 includes an external helical thread 3 defined into the exterior surface of the distal half 1 . The tooth 32 of the external helical thread 3 is defined between a minor diameter 8 and a major diameter 7 . Similarly, an external helical thread 4 is also defined into the exterior surface of the proximal half 5 , however the external thread 3 of the distal half 1 has a greater pitch than that of the threads 4 of the proximal half 5 . The proximal half 5 further comprises a male peg 29 on its distal end. An external helical thread 6 is defined into the exterior surface of the male peg 29 . A mating internal female thread 10 is defined into a bore 11 of the proximal end of the distal half 1 .
[0047] Both the distal and proximal halves 1 , 5 include at least a pair of diametrically opposed tapping bores 30 perpendicularly defined through the cylindrical surface and perpendicular to the longitudinal axis of each half. The tapping bores 30 are preferably oval shaped and are defined on opposing sides through the threads 3 , 4 of each of the halves 1 , 5 respectively, however other shapes or other configurations may be used without departing from the original spirit and scope of the invention. The tapping bores 30 are defined with very sharp cutting edges through the thread 3 , 4 to enable the threads 3 , 4 to become self-tapping. The perpendicular bores 30 also serve as a repository for the bone chips created during the thread cutting process. This allows the chips to be moved into and contained within the perpendicular bore 30 in each half 1 , 5 thereby preventing galling, interference and radial forces during the thread cutting process. This produces clean cut threads within the friable bone or other host material similar to those cut with a tap, but unlike the imperfect threads cut by the crude and dull edges of prior art self-tapping devices.
[0048] The internal components of the distal half 1 of the current device can been seen in the partially cutaway cross-sectional view of FIG. 2 . The distal half 1 has an internal bore 11 with a smooth portion for receiving peg 29 and followed by a threaded portion carrying mating threads 10 , which bore 11 extends from the proximal end 24 of the distal half 1 to an internal hexagonally shaped bore 12 . Internal female quick lock thread 10 is defined within a portion of the smooth internal surface 11 . The internal hexagonally shaped bore 12 is disposed along the longitudinal axis of the distal half 1 and extends to distal end 23 of the distal half 1 .
[0049] Also seen in FIG. 2 is the orientation of the external threads 3 in relation to the longitudinal axis of the distal half 1 . Those external threads 3 located proximally of the tapping bores 30 are leading tooth flanks 13 , and those external threads 3 through which tapping bores 30 are defined are trailing tooth flanks 14 . The leading tooth flanks 13 are orientated at less than a 90 degree angle from the longitudinal axis of the distal half 1 . The trailing tooth flanks 14 are orientated at an angle between 90 and 95 degrees relative to the longitudinal axis of the distal half 1 . The recited angles of the leading and trailing tooth flanks 13 , 14 , when engaged in a host material or bone, help produce an interlocking mechanical grip on the host material or bone. The trailing tooth flanks 14 , unlike the leading tooth flanks 13 , are open faced due to the oval shaped tapping bores 30 being defined through them. This configuration results in the trailing tooth flanks 14 having a sharp, angled edge, which when rotated about the longitudinal axis will cut into the surrounding bone or host material and thus render bone pin 34 self-tapping.
[0050] The corresponding internal components of the proximal half 5 of the current device can be seen in FIG. 3 . The proximal half 5 includes a smooth, hexagonally shaped internal bore 19 which extends from the proximal end 26 of the proximal half 5 , to the distal end 25 of the proximal half 5 . The external threads 4 helically disposed around the proximal half 5 have a major diameter 22 and a minor diameter 21 . Those external threads 4 located distally with respect to the tapping bores 30 are leading tooth flanks 17 , and those external threads 4 through which the tapping bores 30 are defined are trailing tooth flanks 18 . The leading tooth flanks 17 are orientated at an angle 90 to 95 degrees relative to the longitudinal axis of the proximal half 5 . The trailing tooth flanks 18 are orientated at an angle less than 90 degrees relative to the longitudinal axis of the proximal half 5 . The recited angles of the leading and trailing tooth flanks 17 , 18 , when engaged in a host material or bone, help produce an interlocking mechanical grip on the host material or bone. The cutting faces of the thread teeth are open faced due to the oval shaped tapping bores 30 defined through them. This configuration results in the teeth faces having sharp, angled edges which when rotated about the longitudinal axis will cut into the surrounding bone or host material and thus enable the bone pin 34 to be self-tapping.
[0051] Currently, well established medical procedures teach that solid fixation of the toe joint to eliminate articulation is the most satisfactory solution for treating the common malady of hammer toe. The current device helps accomplish this procedure in a novel and improved way by being inserted between the proximal and distal phalanges of a patient.
[0052] First, a surgeon or other medical professional opens the soft tissues of the patient's hammer toe as shown in FIG. 4 and then surgically partially separates the joint. The joint is then opened furthered by bending the partially disconnected distal phalanges downward to expose the proximal end of the bone as shown in cross-sectional view of FIG. 5 . A guide pin hole is then drilled through the end of the proximal portion of the bone and then a guide pin 36 is then installed to help facilitate the use of a cannulated drill bit to further open the inside of the bone into a large enough cavity to accommodate the proximal half 5 of the bone pin 34 .
[0053] The proximal end 26 of the proximal half 5 is inserted into the drilled hole in the proximal phlange. A hex shaped driving tool, commonly known in the art, is then inserted into the distal end 25 of the proximal half 5 and extended into the hexagonally shaped internal bore 19 . The proximal half 5 is then screwed into the surrounding bone in the proximal phlange by rotating the hex shaped driving tool. As the proximal half 5 is being rotated, the open faced trailing tooth flanks 18 cut into the surface of the surrounding bone of the proximal phlange and allow the external threads 4 to dig deeper into the bone. Bone chips or any other refuse from the host material is removed by the external threads 4 and pushed into the oval shaped tapping bores 30 and out of the way of the self-tapping external threads 4 , thus preventing galling and any unnecessary radial forces from being produced. As the proximal half 5 is rotated into the bone, the external threads 4 self-tap the proximal half 5 more deeply into the proximal phlange and more securely implant half 5 into the host material, until just the male peg 29 is left protruding beyond the end of the proximal phlange.
[0054] With the distal phalanges bent downward a second pilot hole is drilled into the proximal end of the bone of the distal phalanges entirely through to the distal end of the toe. An alignment pin is inserted into the pilot hole in the proximal end of the distal bone at the opened joint. The cannulated drill is inserted over the pin and used to increase the size of the pilot hole to a depth to allow insertion of the distal half 3 of the bone pin 34 .
[0055] The distal end 23 of the distal half 1 is first inserted into the proximal end of the distal phlange and a hex shaped driving tool, commonly known in the art, is inserted into the proximal end 24 of the distal half 1 . In order to be inserted correctly, the hex shaped driving tool extends past the internal female quick lock thread 10 and into the internal hexagonally shaped bore 12 . Once the hex driving tool is in place, the distal half 3 is then rotated into the pilot hole in the same fashion as the proximal half 5 . As the distal half 1 is being rotated, the open faced trailing tooth flanks 14 cut into the surface of the surrounding bone and allow the external threads 3 to dig deeper into the bone of the distal phlange. Bone chips or any other refuse from the host material is removed by the external threads 3 and pushed into the oval shaped tapping bores 30 and out of the way of the self-tapping external threads 3 , thus preventing galling and any unnecessary radial forces from being produced. As the distal half 1 is rotated into the bone, the external threads 3 self-tap the distal half 1 more deeply into the bone and half 1 is more securely implanted into the bone, until just a fillet 27 defined on the proximal end 24 of the distal half 1 is left protruding beyond the proximal end of the bone of the distal phlange.
[0056] Holding the proximal phalange that contains the proximal half 5 in one hand, the surgeon pulls distal phalange containing the distal half 1 away slightly while rotating the distal phlange counterclockwise so that the proximal end 24 of the distal half 1 is installed over the distal end 25 of the proximal half 5 , making sure that the male peg 29 is aligned with and inserted into the smooth inner bore 11 of the distal half 1 . The distal half 1 may then be tightened and coupled to the proximal half 5 by either using a spanner wrench commonly known in the art interfaced with two opposing wrench flats 16 defined on the external surface of the distal half 1 as shown in FIG. 1 , or by using a hex shaped wrench inserted through the drilled pilot hole at the distal end of the toe and into the distal end 23 of the distal half 1 . In the latter instance the hex wrench is inserted into the internal hexagonally shaped bore 12 and then rotated. As the distal half 1 is being rotated, the external threads 6 on the male peg 29 of the proximal half 5 engage the internal female quick lock thread 10 . The distal half 1 is rotated about the male peg 29 until the male peg 29 makes contact with the shoulder 36 at the proximal end of internal hexagonal bore 12 and further engagement with the internal female quick lock thread 10 is no longer possible. With the distal half 1 and proximal half 5 now firmly coupled together, the bone pin 34 comprised of halves 1 and 5 effectively becomes a single piece. The bone pin 34 is further rotated by the hex wrench in a clockwise direction, which due to the opposing left and right hand orientated threads of the distal half 1 and proximal half 5 as discussed above, cause the separated proximal and distal phalanges to be drawn together and further increase the stability and strength of the coupling of the bone pin 34 . The distance between the phalanges can then be easily adjusted by rotation of the coupled proximal half 5 and distal half 1 in either a clockwise or counterclockwise direction as shown in FIG. 7 .
[0057] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following invention and its various embodiments.
[0058] Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the invention is explicitly contemplated as within the scope of the invention.
[0059] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
[0060] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0061] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0062] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention. | The apparatus and method is directed to a pair of self-tapping, interconnecting, externally and internally threaded devices that, when installed between two separate pieces of material, will draw and hold the material together as a single threaded unit. While the pair of threaded devices are being fastened into the host material, due to the unique design of their threads, no radial outward forces are produced that could cause cracking or splitting of the sections of the material into which they are installed. The external threads are helically defined into the exterior of each half of the device with a right hand thread defined into one half and a left hand thread into the other half. When the two halves are being fastened together, the increased thread pitch on one of the halves continuously draws the halves into each other even when the internal threads have already been maximally tightened. | 0 |
BACKGROUND OF THE INVENTION
[0001] This application is a divisional of U.S. application Ser. No. 12/329,245 filed Dec. 5, 2008 which claims the benefit of U.S. Provisional Patent Application 61/019,354, filed Jan. 7, 2008, the entirety of which is incorporated by reference
[0002] This invention relates to the comminution of lignocellulosic materials (referred to herein as “fibrous material” or “wood fibrous material”) and, particularly, to comminution using refiner plates having bars and grooves to separate fibers from lignocellulosic materials.
[0003] The invention is applicable to bar and groove designs for various types of refiner plates, including but not limited to disk refiners, counter-rotating disk refiners, twin and twin-flow refiners, cylindrical refiners, conical refiners and conical-disk refiners.
[0004] Refiner plates typically are arranged in a refiner to have facing surface separated by a gap. The plates rotate relative to each other. The fibrous material is introduced into the gap between the plates, typically, by flowing through a center inlet in one of the plates. The fibrous material flows in the gap between the plates and, in doing so, moves across the bars on the facing surfaces of the plates. As the fibrous material moves over the bars, the bars apply forces, such as compression pulses and impact forces, to the material. These forces tend to be greatest when the bars on the opposite plates cross over each other. The forces applied to the fibrous material act on the network of fibers in the material to separate individual fibers from the network and further develop these fibers. The separation of individual fibers and repeated compression of the fibrous mass results in the refining of the fibrous material.
[0005] Conventional refiner plates have refining bars separated by grooves arranged on a surface of the plate. The fibrous material, steam, water and other material flow through the grooves and over the bars as the material moves radially outward between the plates. Refining of the fibrous material tends not to occur in the groves. Refining occurs primarily as the fibrous material moves over the top ridges of the bars. The groves may include dams or other obstructions to prevent or restrict the flow of fibers and fluid through the grooves.
[0006] The bars typically include a sharp leading edge along a forward facing top edge of the bar. The conventional sharp leading edge angles of the bars are believed to promote shearing of the fibrous material passing over the bars. As bars on opposing plates pass each other, they impact and shear the fibrous material caught between the bars. The shear impacts of the fibrous material against the bar are a biproduct of the crossing of the bars. The shearing of fibrous material is undesirable.
[0007] Conventional wisdom views sharp leading edge angles as desirable to provide grooves with steep slopes such that the cross-sectional volume of the grooves provides sufficient flow capacity to move the fibrous material between the plates. A dull leading edge and its corresponding sloped leading face, i.e., leading sidewall, would result in conventional grooves having relatively narrow cross-sectional areas that may be insufficient to accommodate the flow of fibrous materials and the accompanying steam and water that should pass through the grooves. Examples of refiner plates with various types of leading edges on bars are shown in U.S. Pat. No. 5,039,022 entitled “Refiner Element Pattern Achieving Successive Compression Before Impact” and U.S. Pat. No. 4,678,127 entitled “Pumped Flow Attrition Disk Zone.”
[0008] The crossing of opposite bars creates compressive pressure pulses that impact the fibrous material between the bars. The compression pulses apply mechanical force to the fibrous material that promote the refining of the fibrous material. The compression pulses are believed to provide desirable refining action by producing high strength fibrous material.
[0009] There is a long felt need for refiner plates that minimize the impact forces and resulting shearing of fibrous material and maximize compression pulses to refine the material.
BRIEF DESCRIPTION OF THE INVENTION
[0010] To reduce the shear impacts of energy transfer into the fibrous material, at least one of a pair of opposite refining elements includes bars having a dull bar edge. To reduce the tendency of sharp edges on the leading edge of bars to shear fibrous material, the leading edge angle of a bar should preferably be dull, e.g., between 150 degrees and 175 degrees. A dull leading edge on a bar should reduce the impacts between the bars and fibrous material that are caused by the sharp leading bar edges of conventional refiner plates. Minimizing the impacts should reduce shearing of fibrous materials and thereby maximize the strength of the fibers separated through repeated compression refining.
[0011] One embodiment of the invention is a refiner plate, such as a stator plate or a rotor plate, for a mechanical refining system, the plate comprising: a refining surface including bars and grooves, wherein the bars have a leading edge defined by an interior angle of between 150 degrees to 175 degrees. The bars may each include a leading face extending from the leading edge to a trailing face of an adjacent bar. The may include leading face having an upper sidewall section forming an angle of between 150 degrees to 175 degrees with respect to an upper ridge of the bar and a lower sidewall section substantially perpendicular to a substrate of the bar. Further, the leading face of the bars may be concave or convex. In addition, the trailing edge of the bars may have an interior angle of between 80 degrees to 140 degrees. The grooves between the bars may each have a groove bottom formed by an intersection of the leading face and a trailing face of a bar.
[0012] Another embodiment of the invention is a refiner plate for a mechanical refining system, the plate comprising: a refining surface including bars and grooves; each of the grooves has a width extending between the upper ridges of adjacent bars; the bars each have a leading face, an upper ridge surface and a leading edge formed by an intersection of the leading face and the upper ridge surface, wherein the leading edge has an interior angle between the leading face and the upper ridge surface of between 150 to 175 degrees, and wherein a width of the upper ridge surface of each bar is in a range of 30 percent to 75 percent of a total width of the ridge surface and the width of a groove.
[0013] A further embodiment of the invention is a method of mechanically refining lignocellulosic material in a refiner having opposing refiner plates, the method comprising: introducing the material to an inlet in one of the opposing refiner plates; rotating at least one of the plates with respect to the other plate, wherein the material moves radially outward through a gap between the plates due to centrifugal forces created by the rotation; as the material moves through the gap, passing the material over bars in a refiner section of a first one the plates, wherein the bars on at least one of the plates has a leading edge defined by an interior angle of between 150 degrees to 175 degrees, and discharging the material from the gap at a periphery of the refiner plates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a cross-sectional view of a portion of a conventional refiner plate, e.g., a rotor and stator plate, showing a conventional geometric cross-sectional shape of bars and grooves.
[0015] FIG. 2 shows a crossing of conventional bars of opposing plates, where the bars are shown in cross-section.
[0016] FIG. 3 is a chart of the force applied to fibrous material between the crossing bars shown in FIG. 2 .
[0017] FIG. 4 is a cross-sectional view of a portion of a refiner plate, e.g., a stator plate, showing a novel geometric cross-sectional shape of bars and grooves.
[0018] FIG. 5 shows a crossing of conventional bar of one refiner plate with a novel bar of an opposing refiner plate, opposing plates, wherein the bars are shown in cross-section.
[0019] FIG. 6 is a chart of the force (solid line) applied to fibrous material between the crossing bars shown in FIG. 5 , as compared to the force (dotted line) applied to fibrous material between the crossing bars shown in FIGS. 2 and 3 .
[0020] FIG. 7 shows the crossing of bars both of which have novel profiles, of opposing plates, where the bars are shown in cross-section.
[0021] FIGS. 8 a and 8 b show in a cross-section bars having a flat leading sidewall ( 8 a ) and a curved leading sidewall ( 8 b ).
[0022] FIG. 9 is an enlarged cross-sectional view of a portion of a refiner plate, e.g., a stator plate, showing a novel geometric cross-sectional shape of bars and grooves.
[0023] FIG. 10 is an enlarged cross-sectional view of a portion of a refiner plate, e.g., a stator plate, showing another novel geometric cross-sectional shape of bars and grooves.
[0024] FIG. 11 is a cross-sectional diagram showing a refiner having a refiner housing for an annular rotor disc and plate assembly and an annular stator disc and plate assembly.
[0025] FIG. 12 is a front view of the annular stator disc shown in FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 is a cross-sectional view of a portion of a conventional refiner plate 10 , e.g., a rotor or stator plate, showing a conventional geometric cross-sectional shape of bars 14 and grooves 12 . The bars have a relatively sharp leading edge 16 formed by the intersection of the leading face 18 of the bar and the ridge 20 at the upper surface of the bar. The leading face 18 is a sidewall of the bar facing the direction of rotation if on a rotor plate and facing the approaching rotor bars if on a stator plate.
[0027] The angle of the leading edge is defined as the interior angle 21 between the leading face and ridge 20 of the bar. A conventional leading edge angle is sharp, such as in a range of 90 degrees to 100 degrees and may include leading edge angles as small as 75 degrees. The sharp leading edges on bars, e.g., having a leading edge angle of 75 to 100 degrees, tend to shear fibrous material caught between opposite bars as the bars on opposite refiner plates cross during rotation of one or both of the refiner plates.
[0028] The sharp leading edge of the conventional bar provides a steep leading face 18 that is nearly perpendicular with respect to the substrate 22 of the refiner plate. The trailing face 24 of a bar is on the opposite side of the bar to the leading face. The trailing face 24 is steep and typically forms an interior angle with the ridge 20 of between 90 to 100 degrees. The steep leading and trailing faces of the bar results in grooves 12 that are relatively wide from the top to the bottom 25 of the groove at the level of the substrate 22 . The grooves typically have a generally flat surface bottom 25 between the lower corners of the leading and trailing faces of adjacent bars. The wide grooves 12 have large cross-sectional areas that allow for relatively large volumes of material flow, e.g., steam and water, through the grooves. The capacity of the wide grooves to pass large volumes of material enhances the capacity of the refiner plate apparatus to handle a large flow of fibrous material moving between the plates.
[0029] FIG. 2 shows a crossing of conventional bars 26 , 30 of opposing plates, where the bars are shown in cross-section. The plates may be a rotor plate 26 moving in a rotational direction (arrow 28 ) with respect to a stationary stator plate 30 . The rotor and stator plates are opposite to each other, such that the ridges 20 of the bars on opposing plates pass each other with a relatively small refining gap 32 , e.g., 0.5 to 4 millimeters, between the ridges. The refining gap 32 between the crossing bars tends to be the region where much of the refining action occurs to separate fibers from the fibrous material. The pressures and forces applied to the fibrous material in the refining gap are greater than the pressures and forces in regions between a groove and a bar, or between opposing grooves. The higher pressures and forces in the refining gap 32 cause the fibers to separate from the network of fibers in the fibrous material.
[0030] Fibrous material 34 being refined by the plates may be sheared in the gap 32 between the plates. The sharp leading edges 16 of the conventional bars can directly impact and shear the fibrous material 34 . The shearing of wood fibrous material is not desired. Shearing may break fibers, reduce the length of the fibers in the pulp produced by refining and reduce the potential strength of fiber based products produced with the pulp. Shearing the fibrous material is believed to be most acute in the gap 32 as the sharp leading edges 16 cross of opposing bars. The sharp leading edge and the steep slope of the leading face of the bar tend to impact fibrous material between the plates. The impacts shear the fibrous material.
[0031] FIG. 3 is a chart 36 depicting the forces (F), as understood by the inventor, applied to fibrous material between the crossing bars shown in FIG. 2 . The horizontal axis 40 of the chart 36 depicts movement of a bar moving through a distance (d) in the direction of the arrow 28 . The trace 38 represents the force applied to the material between the refiner plates. As the ridge of a bar on one plate moves over the groove of an opposite plate (represented by distance d 1 ), a very low force 40 is applied to the fibrous material between the bar and groove.
[0032] As the sharp leading edge and steep leading face of one conventional bar approaches the sharp leading edge and steep leading face of an opposite conventional bar, the force applied to the fibrous material between the bars increases dramatically, as indicated by the rapidly rising portion 42 of the force trace 38 . As the leading edges of the opposing bars cross, the force spikes 46 because the leading bar edges violently impact the fibrous material. The force spike 46 is at an excessive level 48 that can shear the fibrous material, break fibers in the material and otherwise harm the material.
[0033] The ridges of the opposing bars cross during a distance d 2 in FIG. 2 . After the leading edges 16 of opposing bars cross and the bar ridges are opposite to each other, the force quickly reduces to a force level 50 which is relatively high. This high force level 50 results from a compressive pressure pulse applied by the crossing of the bar ridges 20 . The high level of forces 50 is sufficient to refine the fibrous material, such as to cause fibers to be separated from the fiber network of a wood material. The high level of forces 50 is believed to not substantially shear the fibrous material or otherwise damage the material to the same extent that occurs by application of the excessive force level 48 during a force spike 46 . The force spike 46 is an undesirable and unnecessary trait of many conventional refiner plates.
[0034] FIG. 4 is a cross-sectional diagram of a refiner plate 52 having bars 54 and grooves 56 . The bars have a leading face 58 having a slope of approximately 5 to 40 degrees with respect to a plane of the ridges of the bars. The slope may be applied to the entire leading face from the ridge to the substrate. Alternatively, the slope may be applied to an upper section of the leading face adjacent the ridge, while a lower section of the leading face is steeper, such as having a slope of 45 to 90 degrees.
[0035] The leading edge 60 is formed at the intersection of the leading face 58 and the ridge 62 of the bar. The interior angle 61 of the leading edge is dull and may be in a range of 140 degrees to 175 degrees, and preferably in a range of 155 degrees to 175 degrees, and most preferably at 160 degrees.
[0036] The leading face 58 has a shallow slope resulting from the dull leading edge angle. Because of its shallow slope, the leading face of each bar extends substantially the entire width of the groove 56 . Due to its shallow slope and dull leading edge, the leading face 58 gradually applies an increasing compressive pressure to the fibrous material between the plates, as the leading face approaches a bar on an opposing plate. The trailing face 64 of the bars 54 may be substantially parallel, e.g., an interior angle of 90 degrees to 100 degrees, with respect to an axis 66 of the plate. The bar 54 and groove 56 shapes provide a compressive bars and groove pattern.
[0037] The grooves 56 between the bars are formed by the leading face and trailing face of adjacent bars. The slope of the leading face 58 of the bar gradually reduces the depth of the groove in a direction approaching the leading edge 60 of the bar. Due to the slope of the leading face 58 , the groove may have a cross sectional shape of a triangle in which the leading face 58 and trailing face 64 intersect at the bottom 62 of the groove. The cross-sectional area of the groove should be sufficient to allow water, steam and other fluids in the fibrous material to flow through the grooves of the refiner plate without inhibiting the flow of the fibrous material between the opposing plates.
[0038] The grooves 56 are shallow, especially near the leading edge 60 of the bar. The shallow groove promotes smooth movement of the fibrous material through the refining gap between crossing bars. The shallow groove tends to move fibrous material into the refining gap between crossing bars. The dull leading edges and sloped leading faces of the bars shown in FIG. 4 tend to increase the concentration of fibrous material in the compression sites of the refining gap between the ridges of bars and thereby increase the energy applicable in compression refining. In contrast, conventional grooves tend to impact against fibrous material, do not provide a smooth transition over the leading edge and into the gap between opposing ridges of bars and tend to allow fibrous material to gather in the groove.
[0039] The grooves 56 shown in FIG. 4 have a reduced cross-sectional area as compared to conventional grooves, such as shown in FIG. 1 . Due to the limited volume available in the grooves 56 , the refiner plates with the reduced cross-sectional area grooves are most suited to be (but not necessarily) one of the following: (1) a compression bar edge design on one of the refining plates and a conventional bar edge design on the opposite refining plate; (2) a compression bar edge design and a conventional bar edge design alternating between the refining annular zones on opposite refining plates; (3) a compression bar edge design on both refining plates in conjunction, with flow-enhancing design features, such as steam pockets (as shown in U.S. Pat. No. 5,863,000), steam grooves (U.S. Pat. No. 4,676,440), pumping/feeding grooves, or (4) other modifications that enhance the capacity of the refiner plates to fibrous material water and steam.
[0040] FIG. 5 shows, in cross-section, the crossing of bars 54 , 12 , where one of the bars 54 has the dull leading edge shown in FIG. 4 and the opposite bar has a conventional sharp leading edged such as shown in FIG. 1 . In this example, the bar crossing is shown with a rotor plate 26 having bars 12 having a leading face 18 with a sharp leading edge 16 . The bars of the stator plate 52 have a sloped leading face 58 with a dull leading edge 60 . The rotor plate moves in a rotational direction shown by the arrow 68 .
[0041] The fibrous material 70 is refined in the gap between the opposing bars on the rotor and stator plates and, particularly, by the compressive pressure applied to the material as the opposing bars cross. The pressure applied to the fibrous material results from the crossing of the bars 12 , 54 which reduces the gap between the refiner plates and thereby increases the pressure in the gap and applied to the fibrous material 70 in the gap.
[0042] The shallow slope of the leading face 58 of the stator bar 54 gradually increases the pressure applied to the fibrous material 70 as the bar 12 of the rotor passes over the groove 56 in the stator plate and approaches a leading edge 60 of the stator bar 54 . The shallow slope of the leading face 58 of the stator bar reduces the tendency of the fibrous material to be violently impacted by the leading edges of the crossing bars. The gradual pressure increase resulting from the sloped leading face 58 and dull leading edge 60 of the stator bar is less prone to impacting and shearing of the material due to the profile of that bar. The sharp leading edge 16 of the rotor bar 12 in FIG. 5 is believed to be less prone to impacting and shearing the chip material because the fibrous material are not pinched between an opposing sharp leading edges of opposite bars.
[0043] FIG. 6 is a chart 72 depicting the forces (F), as understood by the inventor, applied to fibrous material between a crossing of the opposing bars shown in FIG. 5 and FIG. 2 . The solid line force trace 74 depicts the perceived forces applied to fibrous material 70 , e.g., wood chips, between the rotor and stator plates 26 , 52 shown in FIG. 5 . The dotted line trace 76 shows the perceived forces applied to the fibrous material 34 between the rotor and stator plates 26 , 30 shown in FIG. 2 .
[0044] The dotted line trace 76 is similar to the trace 38 shown in the chart 36 of FIG. 3 . The dotted line trace 76 is presented in FIG. 6 by way of comparison to illustrate the pressure spike resulting from the crossing of bars with conventional sharp leading edges as compared to the pressures (shown by solid line trace 74 ) that result from bar crossings, wherein at least one of the bars has a sloped leading face and dull leading edge, (a “compression bar design.”)
[0045] The solid line force trace 74 shows the gradual increase 78 in forces applied to the fibrous material as the leading edge 16 of the rotor bar 12 passes over the groove 56 of the stator bar 54 . The gradual increase in force is in contrast to the rapid rise in force (see trace portion 42 in FIG. 3 ) that is believed to occur when conventional bars having sharp leading edges approach, as shown by the dotted line trace 76 in FIG. 6 . The shallow slope of the leading face 58 of the stator compression bar 54 is believed to cause the forces to increase gradually to a maximum force, indicated by the crest 90 of the force trace 74 .
[0046] The solid line force trace 74 shows substantially no spike in impact forces being applied to the fibrous material by the crossing of a the dull leading edge of a compression bar and a sharp leading edge of the rotor bar. The spike of impact forces (see spike in dotted line 76 ) as opposing sharp leading edges crossed in conventional bar profiles are believed to be avoided when at least one refiner plate has compression bars, such as bar 54 shown in FIG. 5 .
[0047] The high level of forces 80 applied to the fibrous material in the compression stage of the bar crossing are sufficient to refine the material. The shallow slope of the leading face of the stator bar is believed to avoid a force spike as the leading edges cross of opposing bars. Avoiding the spikes in the forces applied to the fibrous material reduces the shearing of fibrous materials as the leading edges of opposite bars cross. The maximum force level 80 occurs as the ridges of the opposite bars cross. After the bars cross, the forces on the chip material are reduced as the bars pass over an opposing groove. The forces shown in FIG. 6 are repeatedly applied to the fibrous material as the rotor bars cross the stator bars.
[0048] FIG. 7 shows in cross-section a rotor plate 82 and a stator plate 84 which both have bars 86 having leading faces 88 with shallow slopes and dull leading edges. The fibrous material 90 is subjected to repeated compression pulses as the bars cross as the rotor plate moves in the rotation direction indicated by the arrow. The forces applied to the fibrous material by the crossing bars 86 tend to be entirely or at least primarily due to compression forces applied to the material. The crossing bars have a cross-sectional profile, e.g., sloped leading face and dull leading edge, that minimize impact forces applied when the bars cross. The minimization of impact forces should reduce or eliminate the shearing of fibers due to the crossing of the leading edges of opposing bars.
[0049] As shown in FIGS. 4 and 7 , compression bars with a dull leading edge and a leading face having a shallow slope may be arranged on one or both of a pair of opposing plates. Preferably, these bars are arranged on at least the stator plate (see FIG. 5 ), but may be arranged solely on a rotor plate or on both opposing plates, e.g., a rotor-rotor pair of plates and a rotor-stator pair of plates ( FIG. 7 ).
[0050] FIGS. 8A and 8B each show in cross-section a portion of a refiner plate having bars 54 , 92 with dull leading edges and leading faces having a shallow slope. The bar 54 shown in FIG. 8A is substantially the same as the bar 54 shown in FIG. 4 . Particularly, the leading face 58 of the bar 54 is substantially planar and forms a straight line in cross-section. The bar 92 shown in FIG. 8B has a convex leading face 94 that merges into the ridge 98 of the bar without any creases or other abrupt changes at the leading edge 96 of the bar 92 . The planar leading face 58 shown in FIG. 8 a may facilitate fabrication, e.g., molding, of the plate. The convex leading face 94 and curved leading edge 96 section of bar 92 shown in FIG. 8 b may minimize impacts and spikes in the forces applied to the fibrous material due to the crossing of the leading edges of bars in opposite plates.
[0051] FIG. 9 is an enlarged cross-sectional view of a portion of a refiner plate 100 , e.g., a stator plate, showing a novel geometric cross-sectional shape of bars 102 and grooves 104 . The bars have a sloped leading face 106 and a dull leading edge 108 . It is preferable that the width (c) of the bar ridge 110 be substantially equal to the width (b) of the groove 104 . For example, the widths of the grooves and bars may be each in a range of two to eight millimeters (mm) and, preferably, in a range of two to four millimeters. The ratio of bar width to the combined widths (d) of bar and groove should be in a range of 30 percent to 75 percent, and preferably in a range of 40 percent to 60 percent.
[0052] The angle (a) of the leading edge 108 of the bar 102 should be in a range of 150 degrees to 175 degrees. The angle (e) of the trailing bar edge 112 should preferably in approximately 90 degrees, such as between 80 degrees to 100 degrees. A sharp angle on the trailing edge provides a trailing face with a steep slope and allows for deep grooves having a relatively large cross-sectional area. Alternatively, the trailing edge angle (e) may be wide, e.g., 150 degrees to 175 degrees, especially if the refiner plate is to operate in either rotational directions.
[0053] The groove cross-sectional area should be sufficient to allow the fibrous material, steam and water to pass between the refiner plates. In addition, the groove should have a depth sufficient to allow compression relief after the bars have crossed. A groove that is too shallow may be inadequate to provide compression relief after the bars cross. Without sufficient compression relief, the efficiency of the energy transfer to the fibrous may be reduced.
[0054] The shape of the groove and the sidewalls of the bars may be designed to provide sufficient cross-sectional area for the groove and compression relief to the fibrous material. Preferably, the upper portion of the leading sidewall is sloped and the leading edge is dull, as described above, to minimize the impacts by the leading edges on fibrous material as the bars cross. The lower portion of the leading sidewall my be steeply sloped or substantially perpendicular to the substrate to increase the cross-sectional area of the plate.
[0055] FIG. 10 is an enlarged cross-sectional view of a portion of a refiner plate 114 , e.g., a stator plate, showing another novel geometric cross-sectional shape of bars 115 and grooves 116 . The bars include a generally flat upper ridge 117 and a leading sidewall having a sloped upper sidewall section 118 with a curved leading edge 119 as the sidewall merges into the upper ridge. The leading sidewall also includes a substantially straight lower sidewall section 120 to increase the depth and cross-sectional area of the groove.
[0056] The lower sidewall section 120 of the leading sidewall and the trailing sidewall 64 may have draft angles, e.g., angles from a line perpendicular to the substrate 22 of the plate, of less than one or two degrees and be substantially perpendicular to the substrate 22 of the plate 114 . The transition between the upper sidewall section 118 and lower sidewall section 120 may be determined to provide a desired cross-sectional area of a groove and is preferably approximately in the middle of the bar between the upper ridge 117 and substrate 22 .
[0057] FIG. 11 is a cross-sectional diagram showing a refiner 121 having a refiner housing 122 that encloses an annular rotor disc 124 and an annular stator disc 126 . The discs each support, respectively, an annular rotor plates 128 (which may also be an annular assembly of plate segments) and an annular stator plate 130 (which may also be an annular assembly of plate segments). The rotor disc 124 is mounted on a shaft 132 that is rotated (see arrow on a half circle) by a motor 134 . A mechanical adjustment, e.g., a screw, moves the shaft axially (see doubled headed arrow) to move the rotor disc and plate axially relative to the stator disc and plate. The axial adjustment determines the gap 136 between the opposing surfaces of the plates.
[0058] Unrefined fibrous material is introduced through a center inlet 138 of the stator disc and enters the gap 136 between the plates. The material moves radially outward through the gap due to the centrifugal forces imparted by the rotation of the rotor disc. As the material moves between the plates, the material passes between crossing bars of the opposing plates and is thereby refined into a pulp having separated fibers. The refined pulp exits the gap 136 at the peripheries of the refiner plates and is discharged through outlet 140 from the refiner. Each refiner plate 141 may include multiple annular and concentric refining zones 142 , 144 , 146 and 148 . The refining zones each have a pattern of bars and grooves arranged on the surface of the refining plate. Generally, opposing plates have similar annular refining sections that are aligned when placed in the refiner. The stator plate 130 may, for example, include an inner annular section 142 having bars with dull leading edges and shallow leading faces and an outer annular section 144 having bars with sharp leading edges and steep sloped leading faces. The rotor plate 128 may have an inner annular section 148 having bars with sharp leading edges and steep leading faces and an outer annular refining section 146 having bars with dull leading edges and shallow leading faces.
[0059] FIG. 12 is a front view that generically shows a disc 131 , that may be a rotor disc or stator disc. An annular array of refiner plates 141 are arranged on the disc 131 . Refiner plates often include two or more annular refining zones 150 , 152 and 154 . Each refining zone typically has a uniform pattern of bars and grooves.
[0060] It is preferable, that bars with dull leading edges and shallow sloped leading faces be on at least one plate of a pair of opposite plates for each of the annular refining sections. However, pairs of opposite plates may be arranged such that one or more of the annular refining zones 150 , 152 have bars with sharp leading edges and steep leading faces on both plates, and at least one annular refining zone 154 has bars with dull leading edges and shallow sloped leading faces on at least one of the plates.
[0061] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A method of mechanically refining lignocellulosic material in a refiner having opposing refiner plates including: introducing the material to an inlet in one of the opposing refiner plates; rotating at least one of the plates with respect to the other plate, wherein the material moves radially outward through a gap between the plates due to centrifugal forces created by the rotation; as the material moves through the gap, passing the material over bars in a refiner zone of a first one the plates, each bar in the refiner zone having a leading face and an upper ridge, wherein the leading face includes a sidewall of the bar facing a direction of rotation of the opposing plate and the leading edge has an interior angle of between 150 degrees to 175 degrees, and discharging the material from the gap at a periphery of the refiner plates. | 3 |
CROSS REFERENCE TO RELATED APPLICATION[S]
[0001] This application is a continuation of the earlier U.S. patent application Ser. No. 12/469,313 filed on May 20, 2009 and entitled COMPRESSION CONNECTOR FOR COAXIAL CABLE, now pending, which is a continuation-in-part of and claims priority from U.S. patent application Ser. No. 11/743,633 filed on May 2, 2007 and entitled COMPRESSION CONNECTOR FOR COAXIAL CABLE, now pending, the disclosures of which are hereby incorporated entirely herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] This invention relates generally to the field of coaxial cable connectors, and more particularly to a compression connector for smooth walled, corrugated, and spiral corrugated coaxial cable.
[0004] 2. State of the Art
[0005] Coaxial cable is installed on a widespread basis in order to carry signals for communications networks such as cable television (CATV) and computer networks. The coaxial cable must at some point be connected to network equipment ports. In general, it has proven difficult to make such connections without requiring labor intensive effort by highly skilled technicians.
[0006] These generalized installation problems are also encountered with respect to spiral corrugated coaxial cable, sometimes known as “Superflex” cable. Examples of spiral corrugated cable include 50 ohm “Superflex” cable and 75 ohm “coral” cable manufactured by Andrew Corporation (www.andrew.com). Spiral corrugated coaxial cable is a special type of coaxial cable that is used in situations where a solid conductor is necessary for shielding purposes, but it is also necessary for the cable to be highly flexible. Unlike standard coaxial cable, spiral corrugated coaxial cable has an irregular outer surface, which makes it difficult to design connectors or connection techniques in a manner that provides a high degree of mechanical stability, electrical shielding, and environmental sealing, but which does not physically damage the irregular outer surface of the cable. Ordinary corrugated, i.e., non-spiral, coaxial cable also has the advantages of superior mechanical strength, with the ability to be bent around corners without breaking or cracking. In corrugated coaxial cables, the corrugated sheath is also the outer conductor.
[0007] When affixing a cable connector to a coaxial cable, it is necessary to provide good electrical and physical contact between the cable connector and the center and outer conductors of the cable. It is also desirable to connect the center and outer conductors without having to reposition the cable connector within a connecting tool during the connection operation. Compression connectors for coaxial cable are known which require dual stage compression to independently activate both inner conductor and outer conductor mechanisms, thus requiring a complex compression tool to accomplish the compression when installing the compression connector onto the coaxial cable.
SUMMARY
[0008] Often, to minimize the number of contacts in series in a given electrical path, such as the ground path, within a cable connector, it is desirable to have the moveable clamping element which contacts the outer conductor of a coaxial cable make direct contact with the stationary outer housing of the connector. Such a design is shown in FIGS. 1-12 of this and the parent application. However, due to particular considerations necessitating maximizing the actual area of contact between components which undergoes wiping as the parts move relative to one another, or to adapt body cavities within the cable connector, which must be large for impedance matching, to clamps which must be small to accommodate fitting of coaxial cable while maintaining flexibility or resilience, an intermediate connector element (or transition member) is inserted between the connector housing and the clamp.
[0009] Briefly stated, a compression connector for smooth walled, corrugated, and spiral corrugated coaxial cable includes an insulator disposed within the body, wherein the insulator contains a central opening therein which is dimensioned smaller than a collet portion which seizes a center conductor of the coaxial cable. The connector also includes a clamp disposed inside the body as well as a compression sleeve assembly. An intermediate connector element includes a transitional surface which interacts with the clamp. When an axial force is applied to the compression sleeve, the clamp is forced by the transitional surface into the body, causing the clamp to squeeze onto an outer conductor layer of the coaxial cable. At approximately the same time, the collet portion is forced through the central opening of the insulator, causing the collet portion to squeeze onto the center conductor. The collet portion can be designed to be simultaneously squeezed onto the center conductor at the same time the clamp compresses the outer conductor layer, or the engagement of the collet portion with the center conductor can be designed to be delayed.
[0010] According to an embodiment of the invention, a compression connector for a coaxial cable, wherein the coaxial cable includes a center conductor surrounded by a dielectric, which dielectric is surrounded by a conductor layer, includes a connector body having a first end and a second end and a central passageway therethrough; an insulator disposed within the central passageway at the first end of the body; the insulator having an opening therein; a compression sleeve assembly connected to the second end of the body; first clamp means, disposed in the central passageway, for clamping onto the conductor layer; and second clamp means, disposed within the central passageway, for clamping onto the center conductor, whereby upon axial advancement of the compression sleeve assembly from the second end to the first end, the first and second clamp means are radially compressed inwardly.
[0011] According to an embodiment of the invention, a method for installing a compression connector onto a coaxial cable, wherein the coaxial cable includes a center conductor surrounded by a dielectric, which dielectric is surrounded by a conductor layer, includes the steps of (a) forming a connector body having a first end and a second end, and a central passageway therethrough; (b) forming an insulator for placement within the central passageway at the first end of the body, wherein the insulator includes an opening therein; (c) forming a conductive pin having a collet portion at one end thereof, wherein an outer diameter of the collet portion is greater than a diameter of the opening in the insulator, such that forcing the conductive pin in the longitudinally axial direction causes the outer diameter of the collet portion to reduce in size as the collet portion is forced into the opening; (d) forming a compression sleeve assembly for connection to the second end of the body; (e) forming a clamp and disposing the clamp on an inside of the body, the clamp having a first portion and a second portion, wherein the first portion has an outer engagement surface and the second portion has an outer diameter; (f) forming a mandrel for placement between the clamp and the collet portion; (g) forming a transition member and disposing the transition member between the mandrel and the clamp, wherein the transition member includes a transition surface on an inside of the transition member and a smooth surface on an outside of the transition member such that the transition member and the body make good electrical contact; (h) wherein a diameter of the smooth surface of the transition member and the outer diameter of the second portion of the clamp are the same; (i) wherein forcing the clamp in the longitudinally axial direction causes the outer engagement surface to interact with the transition surface such that the first portion of the clamp reduces inwardly in size; and (j) wherein an axial movement of the compression assembly causes both the clamp and the collet portion to clamp inwardly.
[0012] The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A shows a perspective view of a spiral corrugated coaxial cable where an end has been prepared for engagement with a coaxial cable connector.
[0014] FIG. 1B shows a perspective view of the spiral corrugated coaxial cable of FIG. 1A with the dielectric foam removed.
[0015] FIG. 1C shows a perspective view of an annular corrugated coaxial cable where an end has been prepared for engagement with a coaxial cable connector.
[0016] FIG. 1D shows a perspective view of a smooth-walled coaxial cable where an end has been prepared for engagement with a coaxial cable connector.
[0017] FIG. 1E shows a perspective view of the smooth-walled coaxial cable of FIG. 1D with the dielectric foam removed.
[0018] FIG. 2 shows a perspective view with a partial cut-away of a coaxial cable connector in a partially compressed position in accordance with a first embodiment of the present invention.
[0019] FIG. 3 shows a cross-section of the coaxial cable connector of FIG. 2 shown in the installed position.
[0020] FIG. 4 shows an exploded view of the coaxial cable connector of FIG. 2 .
[0021] FIG. 5 shows a perspective view with a partial cut-away of a coaxial cable connector in accordance with a second embodiment of the present invention for use with an annular corrugated coaxial cable.
[0022] FIG. 6 shows a cross sectional view of a coaxial cable connector in accordance with a variation of the second embodiment of the present invention.
[0023] FIG. 7 shows an exploded view of the coaxial cable connector of FIG. 6 .
[0024] FIG. 8 shows a cross-section of a coaxial cable connector taken along the line 8 - 8 in FIG. 9 in accordance with a third embodiment of the present invention shown in the uninstalled position.
[0025] FIG. 9 shows a side elevation view of the coaxial cable connector of FIG. 8 .
[0026] FIG. 10 shows an exploded view of the coaxial cable connector of FIG. 2 .
[0027] FIG. 11 shows a cross-section of a connector body in accordance with an embodiment of the present invention.
[0028] FIG. 11A shows an expanded view of a transitional surface circled in FIG. 11 in accordance with an embodiment the present invention.
[0029] FIG. 11B shows an expanded view of a convex transitional surface circled in FIG. 11 in accordance with an embodiment the present invention.
[0030] FIG. 11C shows an expanded view of a ramped transitional surface circled in FIG. 11 in accordance with an embodiment the present invention.
[0031] FIG. 11D shows an expanded view of a concave transitional surface circled in FIG. 11 in accordance with an embodiment the present invention.
[0032] FIG. 12 shows a cross-section of a coaxial cable connector according to an embodiment of the present invention which is similar to the cable connector of FIG. 8 but intended for installation on a smooth-walled coaxial cable.
[0033] FIG. 13 shows a partial cross sectional view of a coaxial cable connector in accordance with an embodiment of the present invention.
[0034] FIG. 14 shows a partial cross sectional view of a coaxial cable connector at a certain stage of compression in accordance with the embodiment of FIG. 13 .
[0035] FIG. 15 shows a partial cross sectional view of a coaxial cable connector at a compressed stage in accordance with the embodiment of FIG. 13 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0036] Referring to FIG. 1A , a spiral corrugated coaxial cable 10 is shown prepared for installation onto a compression connector 20 ( FIG. 2 ). A jacket 12 is cutaway to expose a portion of a spiral corrugated conductor layer 14 . Layer 14 is also known as the ground or outer conductor layer. Both corrugated conductor layer 14 and a dielectric 16 are cutaway from a center conductor 18 . Preparation of corrugated coaxial cable 10 for installation is well known in the art.
[0037] Referring to FIG. 1B , a spiral corrugated coaxial cable 10 ′ is shown prepared for installation onto a compression connector 60 ( FIG. 6 ). In addition to jacket 12 being cutaway to expose a portion of spiral corrugated conductor layer 14 , dielectric 16 is cored out leaving a hollow 58 after both corrugated conductor layer 14 and dielectric 16 are cutaway from center conductor 18 . Preparation of corrugated coaxial cable 10 ′ for installation is well known in the art.
[0038] Referring to FIG. 1C , a non-spiral corrugated coaxial cable 10 ″ is shown prepared for installation onto a compression connector. The preparation of cable 10 ″ is well known in the art, and is the same as previously described with respect to FIG. 1A . Note that corrugated conductor layer 14 ″ is non-spiral, but still corrugated. The basic steps of preparing a corrugated coaxial cable are known in the prior art, such as removing a portion of the cable jacket or coring the dielectric foam. For example, it is known to cut away the corrugated outer conductor in a “valley” to ensure enough of the “peak” is left for outer conductor seizure. However, the present invention allows the outer conductor to be cut in either the “peak” or a “valley” because of the configuration of the inner surface of the outer conductor clamp.
[0039] Referring to FIG. 1D , a smooth walled coaxial cable 10 ′″ is shown prepared for installation onto a compression connector. The preparation of cable 10 ′″ is well known in the art, and is the same as previously described with respect to FIG. 1A . Note that conductor layer 14 ′″ is non-spiral and non-corrugated, i.e., smooth walled.
[0040] Referring to FIG. 1E , a smooth walled coaxial cable 10 ″″ is shown prepared for installation onto a compression connector. In addition to jacket 12 being cutaway to expose a portion of conductor layer 14 ″, dielectric 16 ( FIG. 1D ) is cored out leaving a hollow 58 after both conductor layer 14 and dielectric 16 are cutaway from center conductor 18 . Preparation of coaxial cable 10 ″″ for installation is well known in the art.
[0041] Referring also to FIG. 2 , compression connector 20 , shown in a partially compressed position, includes a body 22 with a nut 24 connected to body 22 via an annular flange 26 . An insulator 28 positions and holds a conductive pin 30 within body 22 . Conductive pin 30 includes a pin portion 32 at one end and a collet portion 34 at the other end. A drive insulator or mandrel 36 is positioned inside body 22 between and end of collet portion 34 and a clamp 38 . Clamp 38 has an interior annular surface which is geometrically congruent to the spiral of spiral corrugated conductor layer 14 . Clamp 38 preferably includes a plurality of slots 39 ( FIG. 4 ) in an outer annular portion of the clamp, so that clamp 38 can be compressed or squeezed inward. A part of a compression sleeve 40 fits over an end 42 of body 22 . A drive portion 44 of compression sleeve 40 fits against an annular flange 46 of a drive ring 48 . An elastomer seal 50 fits against jacket 12 of corrugated coaxial cable 10 during installation to prevent external environmental influences (moisture, grit, etc.) from entering connector 20 as well as to provide strain relief and increase cable retention.
[0042] When prepared corrugated coaxial cable 10 is inserted into an opening 54 of connector 20 , cable 10 is twisted as it is inserted so that the spirals on conductor layer 14 fit into the spirals in clamp 38 , while center conductor 18 fits into collet portion 34 . When compressive force is applied to compression sleeve 40 in the direction indicated by an arrow a, drive portion 44 of compression sleeve 40 drives drive ring 48 against clamp 38 , forcing clamp 38 against a transition surface 52 of body 22 , which transition surface 52 is configured to radially inwardly squeeze clamp 38 against conductor layer 14 , while continuing to move clamp 38 axially in the direction of arrow a. Clamp 38 thus forces mandrel 36 to move in the direction of arrow a, and mandrel 36 forces collet portion 34 of conductive pin 30 through an opening 56 in insulator 28 . Opening 56 may take various forms, including convex, concave, or radial. Collet portion 34 also has a collet transition surface 35 configured to compress collet portion 34 radially inwardly upon advancement of conductive pin 30 into opening 56 of insulator 28 . Because a diameter of opening 56 is smaller than an outer diameter ramped surface 35 of collet portion 34 , collet portion 34 is squeezed onto and seizes center conductor 18 of corrugated coaxial cable 10 . During the clamping process, it is noted that center conductor 18 , now located within conductive pin 30 , does not move relative to pin 30 during the clamping process. With the transition surface as shown in FIG. 2 , the collet portion 34 is simultaneously compressed radially inwardly at the same time clamp 38 is compressed radially inwardly. The transition surface 35 however, can be designed to have a portion of surface 35 consistent with the diameter of opening 56 . In this instance, the squeezing of collet portion 34 is delayed until a greater advancement of compression sleeve 40 .
[0043] FIG. 3 shows the position of the driven and compressed elements of connector 20 after connector 20 is installed onto corrugated coaxial cable 10 .
[0044] Referring to FIG. 4 , an exploded view is shown of the components of connector 20 . During preferred assembly of the components of connector 20 , conductive pin 30 is inserted into insulator 28 , after which the combination is inserted into body 22 , followed by mandrel 36 , clamp 38 , and drive ring 48 . Seal 50 is positioned inside compression sleeve 40 , after which the combination is slid onto/into body 22 after nut 24 is slid over the outside of body 22 .
[0045] Referring now to FIGS. 5-6 , and referring back to FIG. 1B , a compression connector 60 is similar to compression connector 20 of FIGS. 2-4 , but with a mandrel 76 having an extended portion 98 which fits into hollow 58 of corrugated coaxial cable 10 ′ during installation of connector 60 onto cable 10 ′. Extended portion 98 provides support to the spiral corrugated conductor layer 14 during compression. Another difference between embodiments is that a body 62 of connector 60 is shaped somewhat differently to accommodate an O-ring 100 which provides sealing with a portion 102 of a compression sleeve 80 when connector 60 is installed onto cable 10 ′. The remainder of the components of connector 60 interoperate the same way as the components of the embodiment of connector 20 and are not described further herein.
[0046] Referring to FIG. 7 , an exploded view is shown of the components of connector 60 . During preferred assembly, an O-ring 100 is placed onto body 62 . A conductive pin 70 is inserted into insulator 68 , after which the combination is inserted into body 62 , followed by mandrel 76 , a clamp 78 , and a drive ring 88 . A seal 90 is positioned inside compression sleeve 80 , after which the combination is slid onto/into body 62 after nut 64 is slid over the outside of body 62 . During compression, an inner diameter of seal 90 decreases, thus forming a seal around jacket 12 . This provides strain relief on the cable and also aids in cable retention.
[0047] Referring to FIGS. 8-10 , a compression connector 110 is shown which is similar to the previous embodiments, but which includes a spacer 112 between a mandrel 114 and a clamp 116 . The addition of spacer 112 may assist in better impedance matching. During installation of connector 110 onto corrugated coaxial cable 10 ( FIG. 1A ), clamp 116 forces spacer 112 against mandrel 114 instead of acting directly against mandrel 114 . It should be obvious to one of ordinary skill in the art that such variations are within the scope of the invention. The remainder of the components of this embodiment interact in the same manner as the previous embodiments, so that further description is omitted.
[0048] Referring to FIG. 11 , transition surface 52 may take various forms, including a shoulder, a ramped or tapered surface, or various shapes such as convex, concave or radial. FIG. 11A shows a shoulder, FIG. 11B shows a convex surface, FIG. 11C shows a ramped surface, and FIG. 11D shows a concave surface.
[0049] Referring to FIG. 12 , a coaxial cable connector 110 ′ is shown which is similar to cable connector 110 ( FIG. 8 ) but which is intended for installation on smooth-walled coaxial cable 10 ′″ ( FIG. 1D ). Note that clamp 116 ′, unlike clamp 116 of FIG. 8 , does not contain valleys and ridges corresponding to the valleys and ridges of corrugated coaxial cable in order to provide greater gripping surface.
[0050] Referring to FIG. 13 , a compression connector 150 is shown in a partially compressed position, while FIG. 14 shows the same compression connector 150 in a more fully compressed position, and FIG. 15 shows the same compression connector 150 in a fully compressed position. That is, FIG. 15 shows the position of the driven and compressed elements of connector 150 after connector 150 is installed onto coaxial cable 10 , 10 ′, 10 ″, 10 ′″, 10 ″″.
[0051] Referring to FIGS. 13-15 , compression connector 150 includes a body 152 with a nut 154 connected to body 152 via an annular flange 156 . An insulator 158 positions and holds a conductive pin 160 within body 152 . Conductive pin 160 includes a pin portion 162 at one end and a collet portion 164 at the other end. A drive insulator or mandrel 166 is positioned inside body 152 between and end of collet portion 164 and a clamp 168 . Clamp 168 optionally has an interior annular surface which is geometrically congruent to the spiral of spiral corrugated conductor layer 14 when connector 150 is to be used with spiral corrugated coaxial cable; otherwise the interior annular surface of clamp 168 is generally smooth. Clamp 168 preferably includes a plurality of slots 139 in an outer annular portion of the clamp, so that clamp 168 can be compressed or squeezed inward. A part of a compression sleeve 170 fits over an end 142 of body 152 . A drive portion 144 of compression sleeve 170 fits against an annular flange 146 of a drive ring 178 . An elastomer seal 190 fits against jacket 12 of coaxial cable 10 , 10 ′, 10 ″, 10 ′″, 10 ″″ during installation to prevent external environmental influences (moisture, grit, etc.) from entering connector 150 as well as to provide strain relief and increase cable retention.
[0052] Mandrel 166 preferably includes an extended portion 180 which provides support to conductor layer 14 , 14 ′, 14 ″, 14 ′″ during compression and may assist in better impedance matching than without portion 180 . An annular groove 192 accommodates an O-ring (item 100 in FIG. 5 ) which provides sealing with a portion 194 of compression sleeve 170 when connector 150 is installed onto cable 10 , 10 ′, 10 ″, 10 ′″, 10 ″″.
[0053] Connector 150 preferably includes a transition member 169 which fits inside body 152 , with an outer surface of transition member 169 making good electrical contact with an inner surface of body 152 . The outer surface of transition member 169 is preferably smooth but may be ridged or roughened or otherwise not smooth. A transition surface 196 on an inner surface of transition member 169 cooperates with an outer engagement surface 174 of clamp 168 as connector 150 is fitted onto coaxial cable 10 , 10 ′, 10 ″, 10 ′″, 10 ″″ to drive clamp 168 radially inward.
[0054] When prepared coaxial cable 10 , 10 ′, 10 ″, 10 ′″, 10 ″″ is inserted into an opening 148 of connector 150 , center conductor 18 fits into collet portion 164 . When compressive force is applied to compression sleeve 170 in the direction indicated by an arrow a, drive portion 144 of compression sleeve 170 drives drive ring 178 against clamp 168 , forcing clamp 168 against transition surface 196 of transition member 169 , which transition surface 196 is configured to radially inwardly squeeze clamp 168 against conductor layer 14 , 14 ′, 14 ″, 14 ′″ while continuing to move clamp 168 axially in the direction of arrow a. Clamp 168 thus forces mandrel 166 to move in the direction of arrow a, and mandrel 166 forces collet portion 164 of conductive pin 160 through an opening 172 in insulator 158 . Opening 172 may take various forms, including convex, concave, or radial. Collet portion 164 also has a collet transition surface 135 configured to compress collet portion 164 radially inwardly upon advancement of conductive pin 160 into opening 172 of insulator 158 . Because a diameter of opening 172 is smaller than an outer diameter of ramped collet transition surface 135 of collet portion 164 , collet portion 164 is squeezed onto and seizes center conductor 18 of coaxial cable 10 , 10 ′, 10 ″, 10 ′″, 10 ″″. It should be noted that, during the clamping process, center conductor 18 , now located within conductive pin 160 , does not move relative to pin 160 during the clamping process. With the transition surface as shown in FIGS. 13-15 , collet portion 164 is simultaneously compressed radially inwardly at the same time clamp 168 is compressed radially inwardly. Transition surface 135 however, can be designed to have a portion of surface 135 consistent with the diameter of opening 172 , such that the squeezing of collet portion 164 is delayed until a greater advancement of compression sleeve 170 than is otherwise the case.
[0055] During installation of any of these embodiments onto spiral corrugated coaxial cable 10 ( FIG. 1A ), non-spiral corrugated coaxial cable 10 ′, and smooth walled coaxial cable 10 ′″, connectors 20 , 60 , 110 , 150 have to be relatively immovable while compressive force is applied to the respective compression sleeves in the direction of arrow a ( FIGS. 2 & 13 ). The preferred design of a compression connector tool to accomplish the installation would, while applying the compressive force in the direction of arrow a, stabilize the connector in the opposing direction, thus ensuring that the compressive force was sufficient to squeeze the respective clamps around the conductor layer of the corrugated coaxial cable and squeeze the respective collet portions onto the center conductor. Although the squeezing of the respective clamps begins slightly before the squeezing of the respective collet portions, the squeezing of the respective clamps and collet portions mainly happens simultaneously, unlike with prior art embodiments which require a two-stage operation.
[0056] While the present invention has been described with reference to a particular preferred embodiment and the accompanying drawings, it will be understood by those skilled in the art that the invention is not limited to the preferred embodiment and that various modifications and the like could be made thereto without departing from the scope of the invention as defined in the following claims. | A compression connector for smooth walled, corrugated, and spiral corrugated coaxial cable includes an insulator disposed within the body, wherein the insulator contains a central opening therein which is dimensioned smaller than a collet portion which seizes a center conductor of the coaxial cable. The connector also includes a clamp disposed inside the body as well as a compression sleeve assembly. An intermediate connector element includes a transitional surface which interacts with the clamp. When an axial force is applied to the compression sleeve, the clamp is forced by the transitional surface into the body, causing the clamp to squeeze onto an outer conductor layer of the coaxial cable. At approximately the same time, the collet portion is forced through the central opening of the insulator, causing the collet portion to squeeze onto the center conductor. | 7 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to multifunctional holding devices for toolless attachment to frames, especially ladders, stringers, steps of stepladders or ladder rungs, and for accommodation of working devices without fasteners, for example tools, storage boxes, buckets and the like, with rod-shaped, bar-shaped or plate-shaped holding parts, which have with one another to a frame-shaped article with hook elements for hanging of the holding parts on the frame and for accommodating working devices [sic], the hook-shaped elements coming into contact with the respective parts of the frame, for example stringers, steps or rungs and being supported on these parts.
[0002] Hooks or holding devices of most varied type have become known. The main use of hooks or holding devices consists in hanging an article or attaching it in some way. The simplest and most common execution of a hook is S-shaped, consists of metal, and can be used in a versatile manner for simple purposes.
[0003] In order to perform special tasks however, numerous other hook-shaped articles and holding devices have been developed.
[0004] According to DE 299 10 008 U1 a holding device is placed over the beam on the rung of a ladder. A support arm which proceeds from the holding device is used in this connection as a receiver for a bucket. The disadvantage of this execution is that it can only be used on a limited basis, since both a stringer and also a rung of a ladder are required for hanging. Furthermore the holding receiver on which the bucket can be hung is far from the ladder so that the center of gravity of the bucket is displaced three-dimensionally away from the ladder. The resulting lever action can lead to the construction bending under a greater load, or the position of the ladder becoming unstable. Especially when the device is hung on the side of a ladder facing the user can this constitute a real danger.
[0005] In another type of hanging device as claimed in DE 299 00 960 U1 it is important that the hanging device is adjustable and can be matched to the respective width of the ladder stringer in order to hand a so-called rung cutout on the rung or that the hanging device can be placed on one step. In this connection the decisive feature is considered to be the installation of a pivoting support and blocking lever which in the working position on a connecting joint of a stepladder is used as a support or block against the device possibly sliding out of the stringer region of the stepladder. In this adjustable hanging device what is important is first of all achieving a variable region to which a hanging device can be attached using two stringer enclosures which can be adjusted to one another. In this connection a segment cutout holds another segment insert, and the two parts can be adjusted to one another for matching of the thickness of the stringer. In this hanging device in spite of complex production (cutting, drilling, thread cutting, fitting of segments and rung jaws) a device which may not be unconditionally safe in all applications in its stability and safety is formed.
[0006] Examples of rod-shaped holding devices according to the generic execution of this invention include U.S. Pat. Nos. 5,957,238, 6,131,699, 6,250,595 B1, UK patents 213082 A, 2353064 A, 2375570 A, DE 2121131 OS and U.S. Pat. No. 1,811,065 which relate to rod-shaped holding devices for use in conjunction with ladders and buckets or the corresponding vessels which can be attached to the ladders. These configurations of holding devices are all limited in their possible application to holding devices with a use which does not enable multifunctional uses.
[0007] It is an object of the invention is to devise holding devices for different applications which are as simple and versatile, therefore as multifunctional as possible, in their construction.
SUMMARY OF THE INVENTION
[0008] As claimed in the invention, for generic holding devices it is suggested that two multiple hook arrangements which are made in parallel planes and which are spaced apart from one another consist of one continuous horizontal middle rod each with upper U-shaped hooks and lower U-shaped or L-shaped hooks made on the two rod ends, the multi-hook arrangements each on the side of the planes which is pointed away from the middle rod having an open site between the opposing hook legs for insertion or attachment of the holding device on the frame. Selectively on the face-side ends of the multi-hook arrangements with the middle rods cross connectors are additionally attached which fix the multi-hook arrangements and which on their outer ends each have one L-shaped hook at a time.
[0009] The important advantages of the invention are that in addition to improving the hanging and holding action of a conventional hook, a host of possibilities is created for attaching, fastening or fixing the holding device by a resting, clamping or tilting action on a device which is generally called a frame, especially a ladder or its stringer, step or rung or also on a lashing device. For this purpose the individual component regions or sections of the holding device are made with hooks for achieving the object such that they are arranged symmetrically and/or parallel, or also asymmetrically at a given distance to one another, also in pairs. The type of selected execution ensures that the hook or holding device in addition to its conventional function of a hanger is additionally placed or slipped onto a frame, for example a stringer, a step or a rung of a ladder or the like at a distance which is not defined in detail to the latter, or at least partially surrounds or extends behind this device or parts of it so that twisting around a cross sectional diagonal, for example of a stringer, a step or a rung is prevented by tilting, clamping, positive contact or locking, and on at least one part of the hook device or holding device a working device, for example a tool, a bucket, or the like can be securely hung or attached.
[0010] Another advantage of the invention is that two U-shaped component regions of the hook device or holding device which are located essentially parallel to one another for conventional hanging over a rung in the region of the ladder stringer act to stabilize in all three axes or counteract twisting. Moreover the holding device can be easily and reliably attached without adversely affecting operation and safety on both sides of the ladder, both on the side facing the user and the side facing away from the him.
[0011] Furthermore the invention enables the holding device to be placed or slipped onto a rung or the articulated part which connects the stringers of a stepladder along the lengthwise axis of the connecting region. In this respect it is especially beneficial that a large region at least in two axes comes into contact with them, protected against turning. Furthermore the articulated part is at least partially surrounded; this leads to high stability and outstanding holding capacity. Even larger loads can be easily affixed by this holding capacity, stable execution and closeness to the object.
[0012] When the holding device is slipped or hung on a rung or the step of a stepladder, it is possible to set the tool, for example in the form of a bucket, on the underlying rung or step so that only the handle of the bucket need be hung to protect against tipping. This has the major advantage that the weight of the tool is attached not laterally outside the ladder, but always over the ladder and thus tipping of the ladder even under greater loads can be avoided or at least reduced. If a bucket is hung on the uppermost step of a stepladder, it assumes an ideal and safe working position because it can be optimally reached by the worker when he is standing on the opposite side of the ladder.
[0013] Also in the case of a holding device hung on the top connecting stringer of two lateral stringers of a one-sided stepladder can the tool be optimally positioned for hanging a bucket or for pushing a resting surface into the hook and the bucket or the tool placed on the working surface can always be safely reached.
[0014] With a hose clamp fitting or cable clamp fitting the multifunctional hook itself can be attached quickly and safely and can be used to hang many different devices. Thus the tool for example can likewise be easily hung on a post or a handle. Accordingly a series of tools can be comfortably hung and carried along on a lashing belt or belt using the holding device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention and its practical use are explained below in conjunction with the drawings using embodiments.
[0016] FIG. 1 shows in a perspective of one embodiment of a multifunctional holding device;
[0017] FIG. 2 shows in a side view a one-sided stepladder, on the top intermediate part of the lateral stringers of which a multifunctional holding device, as shown in FIG. 1 is hung;
[0018] FIG. 3 shows a perspective of a combined stepladder in which a stepladder and a rung ladder are movably connected to an articulated region. On the topmost step of the stepladder a multifunctional holding device is hung;
[0019] FIG. 4 shows in a perspective view of the lower rung of a ladder a holding device which is hung vertically offset by 90° to the step of the stepladder as shown in FIG. 3 ;
[0020] The perspective in FIG. 5 shows a holding device 1 which has been slipped on in the articulated region of a stepladder;
[0021] The holding device 1 as shown in FIG. 6 , which is hung with a U-hook on a rung of a ladder;
[0022] FIG. 7 shows in a perspective view a combined stepladder with one section consisting of a stepladder and its other section of a rung ladder;
[0023] FIG. 8 shows a holding device on a rung of a ladder with hooks, which are made flat in an L shape at a connecting site connected to a U-hook;
[0024] FIG. 9 shows one embodiment of a holding device that is fixed on a tubular tool or on which a tool is fixed with a fastener;
[0025] The embodiment as shown in FIG. 10 shows how a holding device can be hung on a lashing belt or a belt;
[0026] FIG. 11 shows a cross sectional diagonal of a rung of a ladder on which the holding device is fixed;
[0027] FIG. 12 shows the cross sectional diagonal of a step of a stepladder;
[0028] FIG. 13 shows the cross sectional diagonal of the articulated region of a ladder;
[0029] FIG. 14 shows a cross sectional diagonal of an intermediate part or of a lateral stringer of a stepladder or a rung ladder; and
[0030] The photographs in FIGS. 15-26 show various practical applications of the holding device of the invention in conjunction with ladder rungs, ladder stringers, etc.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 shows in a perspective of one embodiment of a multifunctional holding device 1 as claimed in the invention. The holding device 1 consists of two holding elements 1 a and 1 b which are located in two parallel planes E 1 and E 2 and which each consist of a frame-like article which is composed of U-shaped hooks 2 a , 2 b on one end and U-shaped hooks 2 c, 2 d on the other end of a horizontal middle support 4 a , 4 b as the top section, and U-shaped hooks 2 e and 2 f on one end and L-shaped hooks 3 a , 3 b on the opposite end. These hook parts 2 , 3 form receiving, attachment and hanging regions 5 which are assembled, for example welded together, by the U-shaped hooks 2 and L-shaped hooks 3 which are located parallel, symmetrically or asymmetrically to one another to form the entire holding device 1 . In addition, as shown in FIG. 1 , there can be cross connectors 4 c , 4 d , which are connected, preferably welded to the holding elements 1 a, 1 b at the height of the middle bars 4 a , 4 b , and which have L-shaped hooks 2 f, 2 g on their ends in order to achieve other hook devices.
[0032] FIG. 2 shows in a side view a one-sided stepladder 6 , on the top intermediate part 7 of the lateral stringers 8 of which a multifunctional holding device 1 as shown in FIG. 1 is hung or slipped, and the handle 9 of a bucket 10 can be hung both on a U-shaped hook 2 and also on an L-shaped hook 3 . Furthermore the tool 11 is inserted under a U-hook 2 in a receiving, attachment or hanging region 5 and is held or supported by an L-hook 3 . At a sufficient height of the bucket 10 the bottom 12 of the bucket can be rested on the platform 13 of the one-sided stepladder 6 . The lower part of FIG. 2 shows a multifunctional holding device 1 which with a U-hook 2 extends around the step of a stepladder 14 of a one-sided stepladder 6 , on another U-hook of the holding device 1 the handle 9 of a bucket 10 being hung, and the bottom 12 of the bucket is placed on the step 14 of the stepladder 6 .
[0033] FIG. 3 shows a perspective of a combined stepladder 15 in which a stepladder 16 and a rung ladder 17 are movably connected to an articulated region 20 . On the topmost step 14 a of the stepladder 16 a multifunctional holding device 1 is hung or slipped. In the receiving, attachment and hanging region 5 a tool 11 in the form of a horizontal resting surface 11 is inserted and fixed on the U-hook 2 . On the second highest step 14 b a multifunctional holding device 1 is hung or slipped, the handle 9 of a bucket 10 being hung in two U-hooks 2 and the bottom 12 of the bucket 10 sitting on the step 14 c underneath. Furthermore, FIG. 3 shows a multifunctional holding device 1 which has been slipped on one rung 18 of the stepladder 15 and which with reference to the holding device 1 slipped on the step 14 b is seated horizontally by 90° to the lengthwise axis 19 of the step 14 b on the rung 18 .
[0034] FIG. 4 shows in a perspective view of the lower rung 18 c of a ladder a holding device 1 which is hung vertically offset by 90° to the step 14 a of the stepladder 16 as shown in FIG. 3 . Furthermore, FIG. 4 shows a holding device 1 which has been slipped onto the topmost rung 18 a; in the receiving, attachment and hanging region 5 of the device the handle 9 of a bucket 10 is hung, and the bottom 12 of the bucket 10 sits underneath on the rung 18 b.
[0035] The perspective in FIG. 5 shows a holding device 1 which has been slipped on in the articulated region 20 of a stepladder 15 and which with its connecting parts 4 rests both on the articulated region 20 and also laterally adjoining, with hooks 2 which form a receiving region 5 , and extend around the stringers 8 , 21 of the stepladder 15 or its articulated region 20 and are supported thereon against twisting. Furthermore, FIG. 5 shows a holding device 1 with the handle 9 of a bucket 10 hung in its receiving region 5 .
[0036] The holding device 1 as shown in FIG. 6 which is hung with a U-hook 2 on a rung 18 of a rung ladder 22 is fixed such that two U-hooks 2 and two L-hooks 3 at a time laterally encompass the stringer 21 of the rung ladder 22 and protect it against twisting by tilting, the connecting parts 4 coming into contact with the stringer 21 in a stabilizing manner. Furthermore FIG. 6 shows that the handle 9 of a bucket 10 is hung in a U-hook 2 of the holding device 1 .
[0037] FIG. 7 shows in a perspective view a combined stepladder 15 with one section consisting of a step ladder 16 and its other section of a rung ladder 17 . On the topmost step 14 a of the stepladder 16 a holding device 1 is hung or slipped. In this regard the connection region 23 is made flat. On the edges 24 of the connecting region 25 U-hooks 2 or L-hooks 3 are attached at any positions. Furthermore FIG. 7 shows on the step 14 c of the stepladder 16 a holding device 1 which has been hung or slipped on, with U-hooks 2 and L-hooks 3 running parallel to one another and with the respective ends connected to a connecting part 4 . On the step 14 e of the stepladder 16 a holding device 1 is shown slipped or hung, in which two U-hooks 2 are connected to only one L-hook 3 at one connecting site 26 at only one point. On the lowermost step 14 f of the stepladder 16 a single (instead of a double) holding device 1 is shown in which only one U-hook 2 and one L-hook 3 at a time without a connecting part 4 are joined to one another. This holding device is made in one piece. Furthermore, FIG. 7 shows on the step 14 d of the stepladder 16 a single holding device 1 in which two U-hooks 2 are joined to one another without a connecting part 4 and which is made in one piece. On one rung 18 e a holding device 1 of U-hooks 2 or L-hooks 3 which are made rod-shaped is shown. The embodiment of the holding device 1 of U-hooks 25 and L-hooks 32 which are made flat is shown on one rung 18 b. On the rung 18 c of FIG. 7 another version of a holding device 1 is shown with U-hooks 2 and L-hooks 3 which are made rod-shaped, while their connecting region 23 is made flat. Another embodiment of a single holding device 1 of rod-shaped material is shown hung on a rung 18 d. Finally, FIG. 7 shows on the articulated region 20 of a combined stepladder 15 a holding device 1 which is hung and which consists of a U-hook 2 , connecting parts 4 and another U-hook 27 which is made selectively flat or rod-shaped.
[0038] FIG. 8 shows a holding device on a rung 18 f of a ladder with hooks 25 which are made flat in an L shape at a connecting site 26 connected to a U-hook. On the flat hook 25 an adjusting or locking device 31 in the form of a thumb screw is attached.
[0039] FIG. 9 shows one embodiment of a holding device 1 which is fixed on a tubular tool 11 or on which a tool 11 is fixed with a fastener 28 .
[0040] The embodiment as shown in FIG. 10 shows how a holding device 1 can be hung on a lashing belt 29 or a belt.
[0041] FIG. 11 shows a cross sectional diagonal 30 of a rung 18 of a ladder on which the holding device 1 is fixed. This holding device 1 is attached relative to the cross sectional diagonal 30 by clamping, tilting, positively, or rigidly and thus protected against twisting, nonpositively or with locking capacity.
[0042] FIG. 12 shows the cross sectional diagonal 30 of a step of a stepladder 14 ,
[0043] FIG. 13 shows the cross sectional diagonal 30 of the articulated region 20 of a ladder,
[0044] FIG. 14 shows a cross sectional diagonal of an intermediate part 7 or of a lateral stringer of a stepladder or a rung ladder 21 .
[0045] The photographs in FIGS. 15-26 show various practical possible applications of the holding device as claimed in the invention in conjunction with ladder rungs, ladder stringers, etc., which can be fixed by tilting, clamping, encompassing, etc. against rotation with a ladder or the like without using a tool. | The invention relates to a single- or multiple- or multifunctional holding device that is designed in such a manner that it can be fastened to a support in different ways and can in turn be used as the support for a second object. Differently shaped receiving sections, produced by the arrangement of the structural units in the form of U-shaped hooks, L-shaped hooks, connecting elements and connecting sections in relation to each other allow for the holding device to be fastened to differently shaped supports in a rotationally fixed manner by jamming, blocking, encompassing, engaging behind or positively resting against them and to be used as a support for other objects. | 4 |
BACKGROUND OF THE INVENTION
Payments for goods and services with data cards, such as credit cards and debit cards, has become increasingly popular in recent years due in part to the ease and speed of performing data card transactions. For example, in retail settings, goods and/or services to be purchased are first entered into a cash register or point-of-sale terminal to determine their total cost. Once the total cost is determined, a consumer or a retail establishment associate swipes the consumer's data card to access consumer financial account information linked to the data card. The consumer provides approval, typically by providing a signature, thereby confirming intent to authorize payment from the consumer financial account for the goods. Following approval, funds are transferred from the consumer financial account to a financial account associated with the retail establishment. Although faster than traditional payment methods, such as payment by check, the time needed to swipe the data card and to approve the transaction contributes to the overall time each consumer spends in the checkout line waiting to purchase goods.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a method of sale. The method of sale includes processing a plurality of purchases to be sold to a consumer, identifying a consumer financial account held by a financial institution, receiving authorization from the financial institution to enable payment for the plurality of purchases from the consumer financial account, and providing the consumer with an option to approve the payment from the consumer financial account. The option is provided during processing of the plurality of purchases. Other features and advantages are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described with respect to the figures, in which like reference numerals denote like elements, and in which:
FIG. 1 is a perspective view illustrating one embodiment of a transaction approval system, according to the present invention.
FIG. 2 is a flow chart illustrating one embodiment of a method of sale, according to the present invention.
FIG. 3 is a top view illustrating a portion of the transaction approval system of FIG. 1 during the method of sale of FIG. 2 .
FIG. 4 is a top view illustrating a portion of the transaction approval system of FIG. 1 during the method of sale of FIG. 2 .
FIG. 5 is a top view illustrating a portion of the transaction approval system of FIG. 1 during the method of sale of FIG. 2 .
FIG. 6 is a top view illustrating a portion of the transaction approval system of FIG. 1 during the method of sale of FIG. 2 .
DETAILED DESCRIPTION
A process and system for approving and confirming financial card transactions, according to embodiments of the present invention, decrease overall consumer time spent in checkout lines. Decreasing the overall time each consumer spends in the checkout line provides a more attractive shopping environment and experience, increases overall efficiency of the retail establishment, decreases the labor necessary to handle consumer purchases, and improves the bottom line of the retail establishment or other entity from which goods and services are purchased.
FIG. 1 illustrates one embodiment of a transaction approval system 10 including a cash register or point-of-sale terminal 12 , a financial transaction terminal 14 , and a stylus 16 . In one embodiment, point-of-sale terminal 12 is electrically coupled with financial transaction terminal 14 via a cord 18 or wireless connection, and stylus 16 is coupled with financial transaction terminal 14 via a cord 20 . Alternatively, stylus 16 is not mechanically coupled with financial transaction terminal 14 . Purchases by a consumer are processed or entered into point-of-sale terminal 12 to arrive at a total cost to be charged to the consumer for the entered purchases. Purchases include goods and/or services being sold to the consumer.
Financial transaction terminal 14 is configured to receive a financial transaction card 22 to access a related consumer financial account or source of funding and to charge the total cost of the purchases to the financial account by way of financial transaction card 22 . Financial transaction card 22 is one of a credit card, a debit card, or a stored-value card such as a gift card, to name several examples. Stylus 16 allows a user to enter a user signature and/or other confirmation indicator into financial transaction terminal 14 , to approve or confirm the transfer of funds from the financial account to complete the purchase and ultimately perform the associated financial transaction or withdrawal.
Point-of-sale terminal 12 includes a keyboard 30 , a scanner 32 , a monitor 34 , and a printer 36 . Item barcodes or other product information can be entered into point-of-sale terminal 12 via keyboard 30 or scanner 32 , which, in one embodiment, is capable of reading UPC or bar codes off of the purchases. Alternatively, point-of-sale terminal 12 includes a radio frequency identification (RFID) device capable of reading and/or registering cost data and other purchase data. The information entered into point-of-sale terminal 12 can be viewed by a worker or associate of the retail establishment and/or a consumer via monitor 34 . Finally, upon completion of the financial transaction or upon each addition of a new purchase or item to the point-of-sale terminal 12 , printer 36 prints transaction details to a receipt 38 including a list of the purchases processed as well as the cash or amounts charged to the consumer's financial account to pay for the registered purchases. In one embodiment, receipt 38 includes a printout of a digitally captured signature, as will be further described below.
Financial transaction terminal 14 is a financial transaction card reader in communication with at least one financial institution network. As such, in one embodiment, financial transaction terminal 14 includes a financial transaction card reception slot 40 for at least partially receiving financial transaction card 22 . In particular, financial transaction card 22 includes a magnetic strip 24 along one side of financial transaction card 22 including a magnetic representation of the information necessary to access the consumer financial account linked to or associated with financial transaction card 22 . Accordingly, reception slot 40 extends along a side of financial transaction terminal 14 and includes a reading mechanism capable of accessing magnetic strip 24 to obtain necessary information from financial transaction card 22 . Financial transaction terminal 14 is configured to selectively receive financial transaction card 22 as financial transaction card 22 is slid from a first end 42 of reception slot 40 to a second end 44 of reception slot 40 . As financial transaction card 22 is slid from first end 42 to second end 44 of reception slot 40 , the information on magnetic strip 24 is read by financial transaction terminal 14 and the associated financial account is electronically accessed based upon the information from the magnetic strip 24 .
Alternatively, in one embodiment, financial transaction terminal 14 includes an alternative financial transaction card reception slot 46 instead of financial transaction card reception slot 40 . Financial transaction card reception slot 46 is positioned at one end of financial transaction terminal 14 and is configured to receive financial transaction card 22 and to pull financial transaction card 22 fully within financial transaction terminal 14 for reading information from magnetic strip 24 of financial transaction card 22 to access the associated financial account.
Financial transaction terminal 14 additionally includes a user interface, monitor, or touch screen 48 on a top surface 45 of financial transaction terminal 14 . Touch screen 48 is configured to relay information to the consumer or to the worker or associate of the retail establishment utilizing financial transaction terminal 14 . In one embodiment, touch screen 48 also is configured to be contacted by stylus 16 to enter information into financial transaction terminal 14 . In particular, financial transaction terminal 14 may exhibit buttons such as button 62 in FIG. 3 on touch screen 48 that can be pressed or otherwise selected with stylus 16 . In one embodiment, stylus 16 is an elongated, pencil-like member including a pointed end configured to contact touch screen 48 . In addition, touch screen 48 may display boxes for receiving written information or signatures. Touch screen 48 is capable of presenting different touch buttons and messages to a user throughout the transaction approval process.
One embodiment of a method of sale 50 is generally illustrated with reference to FIG. 2 . At 52 , the purchases to be sold to the consumer begin to be processed. In particular, in one embodiment, at 52 , the product codes of the purchases are entered into point-of-sale terminal 12 by the worker of the retail establishment or the consumer via scanner 32 , manually via keyboard 30 , RFID device, or other entry device or system.
While purchases are being processed for sale at 52 , touch screen 48 displays a message giving the consumer an option to initiate the financial transaction. In one embodiment, the message notifying the consumer that they may initiate the transaction is a message such as “PLEASE INSERT CARD” as illustrated in FIG. 1 . If, at 54 , the consumer decides to initiate the transaction, the consumer slides financial transaction card 22 through reception slot 40 or inserts financial transaction card 22 into reception slot 46 of financial transaction terminal 14 at 56 . In one embodiment, only one financial transaction card reception slot 40 or 46 exists and, therefore, financial transaction card 22 must be inserted into or slide through the financial transaction card reception slot 40 or 46 existing in the particular financial transaction terminal 14 of transaction approval system 10 .
Once the financial transaction card 22 is inserted, financial transaction terminal 14 interfaces with magnetic strip 24 to read information from magnetic strip 24 . More specifically, financial transaction terminal 14 reads the information from magnetic strip 24 to remotely identify the financial institution or a financial network associated with the consumer financial account linked to financial transaction card 22 . In one embodiment, transaction approval system 10 uses the information to determine the type of financial transaction card 22 that has been inserted, more specifically, whether the financial transaction card 22 is a debit card, a credit card, stored-value card, etc. Alternatively, upon insertion of financial transaction card 22 , in one embodiment, transaction approval system 10 prompts the consumer to identify the type of financial transaction card 22 that has been inserted.
Accordingly, following insertion of financial transaction card 22 into financial transaction terminal 14 , at 58 the consumer decides whether he or she wishes to begin the transaction approval process. In particular, at 58 , touch screen 48 presents the consumer with confirmation approval page or graphical interface 59 indicating that upon approval by the consumer, the consumer agrees to pay for all charges incurred in accordance with the cardholder agreement with the financial institution holding the financial account linked to financial transaction card 22 , as illustrated in FIG. 3 . In one embodiment, graphical interface 59 on touch screen 48 includes a signature block 60 , for receiving a consumer signature, and/or a transaction confirmation button 62 .
In one embodiment, graphical user interface 59 additionally includes a charge box 64 for indicating whether the total charges or cost of purchases have been determined and, if so, what the total charges are. At 58 , charge box 64 is empty, indicating that the total charges for the purchases have not yet been determined (i.e. purchases are still being processed and a final, total charge has not yet been determined). In one embodiment, the empty charge box 64 is yellow or another bright color to draw consumer attention to the fact that the total charges are not yet determined. In one embodiment, once the total charges are computed, the color of charge box 64 is changed or removed. Alternatively, in one embodiment, charge box 64 remains a consistent color when empty and when displaying the total cost. Graphical interface 59 displayed by financial transaction terminal 14 as illustrated in FIG. 3 allows the consumer to determine whether or not they wish to continue approving the transaction at 58 .
More specifically, the objects displayed on touch screen 48 at this point allow the consumer to decide whether or not to provide a consumer signature within signature block 60 immediately or to wait until a subsequent time in the method of sale 50 . In particular, if the consumer chooses to continue approving the transaction, then at 70 the consumer provides and transaction approval system 10 receives a signature 72 within signature block 60 as illustrated with reference to FIG. 4 . If the consumer chooses not to continue approving the transaction at this time, the method 50 continues to 78 where processing of the purchases is completed, as will be further described below. Once signature 72 of the consumer is provided, the consumer determines whether or not they wish to finalize approval of the transaction at 74 .
If the consumer decides to continue the transaction approval process, then at 76 the consumer provides and the transaction approval system 10 receives final transaction approval or confirmation. If the consumer decides not to continue the transaction approval process, method 50 continues to 78 to complete processing of the purchases, as will be further described below. In one embodiment, the consumer provides final transaction approval by contacting confirmation button 62 of graphical user interface 59 with stylus 16 . Contacting confirmation button 62 also signifies to financial transaction terminal 14 that the consumer has finished providing signature 72 . At 78 , following receipt of the final transaction approval, processing of the purchases is completed and the total cost of the processed goods is displayed in charge box 64 as illustrated in FIG. 5 . In one embodiment, display box 64 , once colored to indicate that total charges had not yet been determined, optionally changes or removes the color once the cost is displayed in box 64 . In other embodiments, box 64 remains yellow or otherwise highlighted.
Following calculation of the total cost of purchases, the financial transaction terminal 14 uses the information from magnetic strip 24 of financial transaction card 22 to access the financial institution or network associated with the inserted financial transaction card 22 at 79 . The financial institution or network provides the financial transaction terminal 14 with an indication of whether the financial account is sufficiently funded or authorized to support the current transaction. In particular, the financial institution or network provides an authorization to use the financial account or an indication that use of the financial account is declined. If the financial institution or network authorizes the current transaction the method of sale 50 continues.
At 80 , data terminal 14 determines whether transaction approval is complete. If transaction approval is determined to be complete, then at 82 the transaction is completed by transferring funds, or at least an electronic representation of funds, or by authorizing such a transfer, from the consumer financial account linked to financial transaction card 22 to a financial account associated with the retail establishment. Upon conclusion of the financial transaction printed receipt 38 is created or finished and provided to the consumer detailing the purchases and the financial transaction. In one embodiment, printed receipt 38 includes a printed form of signature 72 digitally provided to financial transaction terminal 14 . Upon completion of the financial transaction, the consumer is free to take the purchases from the retail establishment to their car or other desired location outside of or away from the retail setting.
If, at 54 , the consumer decided not to begin the authorization process 50 or if at 58 or 74 the consumer decided not to continue the transaction approval process, the method of sale 50 continues directly to step 78 in which, as described above, processing of the purchases is completed and the total cost of the processed purchases is provided to the consumer, for example, by display of the cost within cost display box 64 as illustrated in FIG. 6 . At 80 , transaction approval system 10 determines if transaction approval is complete.
If, at 80 , transaction approval system 10 determines that the transaction authorization is not complete (as it will if the consumer chose not to begin or finish the transaction or approval process at 54 , 58 , or 74 ), the method of sale 50 continues to 84 . At 84 , transaction approval system 10 determines whether financial transaction card 22 has or has not yet been inserted into financial transaction terminal 14 to initiate the transaction. If financial transaction card 22 has not yet been inserted into financial transaction terminal 14 , transaction approval system 10 will continue to prompt the consumer to enter financial transaction card 22 into financial transaction terminal 14 via touch screen 48 . At 86 , a consumer eventually inserts financial transaction card 22 into financial transaction terminal 14 .
As described above, upon insertion of financial transaction card 22 , financial transaction terminal 14 interfaces with magnetic strip 24 to read the information from magnetic strip 24 to remotely identify the financial institution or at least a financial network associated with the financial account linked to financial transaction card 22 . In one embodiment, transaction approval system 10 uses the information to determine the type of financial transaction card 22 that has been inserted, and more specifically, whether the financial transaction card 22 is a debit card, a credit card, a stored-value card, etc. Alternatively, upon insertion of financial transaction card 22 , in one embodiment, transaction approval system 10 prompts the consumer to identify the type of financial transaction card 22 that has been inserted.
At 88 , following insertion of financial transaction card 22 into card terminal 14 , the consumer is prompted to provide consumer signature 72 via graphical interface 59 in a similar manner as described above with respect to receiving consumer signature 72 at 70 . Following 88 , in one embodiment, the consumer is presented with graphical interface 59 on touch screen 48 , such as that illustrated in FIG. 5 . At 90 , the consumer provides and transaction approval system 10 receives final transaction approval, and the consumer acknowledges consumer signature 72 is complete by contacting touch screen 48 , more particularly, by interaction with final approval button 62 via stylus 16 . At 82 , the funds are transferred or authorized to be transferred and receipt 38 is printed to complete the transaction. Once the transaction is complete, the consumer is free to leave the retail establishment with the purchases and receipt 38 in hand.
Alternatively, if at 84 it is determined that financial transaction card 22 has already been inserted into financial transaction terminal 14 , transaction approval system 10 determines, at 92 , whether consumer signature 72 has yet been received. If the consumer signature has not yet been provided, the method of sale 50 continues to 88 where consumer signature 72 is provided in signature box 60 . Continuing once again to 90 , final transaction approval is provided for receipt by transaction approval system 10 via consumer contact with approval button 62 via stylus 16 , and the transaction is completed at 82 as described above.
If, at 92 , transaction approval system 10 determines that a consumer signature 72 has already been received, the method of sale 50 continues directly to 90 where final transaction approval is provided by the consumer as described above. Once again, following final transaction approval, the transaction is completed at 82 , and a consumer is provided with receipt 38 , thereby leaving the consumer free to leave the retail establishment with the purchases and receipt 38 in hand.
A transaction approval system and method of sale, according to embodiments of the present invention, allow the consumer to decide when to start and finish consumer approval of a financial transaction. In particular, in order to speed the transaction process, a consumer can provide a signature and final transaction approval prior to the final processing of all the purchases. However, in other instances, a consumer may provide a signature while the purchases are being processed, but wait to provide final transaction approval until the total charges have been determined. In yet another instance, a consumer may wait until the total charge for the purchases is determined before providing a signature and a final transaction approval.
Although the invention has been described with respect to particular embodiments, such embodiments are for illustrative purposes only and should not be considered to limit the invention. Various alternatives and changes will be apparent to those of ordinary skill in the art. For example, other display screens or buttons may be presented to a consumer in order to provide the consumer with a two or three point transaction approval process that can be entered into at a time chosen by the consumer. In addition, one or more retail employees can prompt the consumer to complete one or more tasks in the process. Additional modifications and changes will be apparent to those of ordinary skill in the art. | A method of sale including processing a plurality of purchases to be sold to a consumer, identifying a consumer financial account held by a financial institution, receiving authorization from the financial institution to enable payment for the plurality of purchases from the consumer financial account, and providing the consumer with an option to approve the payment from the consumer financial account. The option is provided during processing of the plurality of purchases. Transaction approval systems provide additional advantages. | 6 |
TECHNICAL FIELD OF THE INVENTION
[0001] The invention relates to a control device for lights, for example passenger vehicle lights, and particularly LED lights, having at least one input, wherein a coded resistor for the nominal power, the nominal current, and/or the nominal voltage of a light or of a lamp can be connected to said input, and having at least one input, wherein a passive temperature sensor, particularly a PTC or an NTC, can be connected to the same. The invention also relates to an arrangement of such a control device and at least one light.
BACKGROUND OF THE INVENTION
[0002] Lights which have, or are for, light-emitting diode lamps are increasingly being used in motor vehicles. Resistor components are frequently included in the lights or in the light equipped with the light-emitting diodes. One or more information sets for the lights or the light-emitting diodes used therein has been assigned to the ohmic resistance of such a resistor component. In principle, the assignment is arbitrary. If the classification is known, it is possible to figure out, using the resistance of the resistor component, what the light is suitable for and configured for, and/or how or to what it must be electrically connected.
[0003] Therefore, information is coded into the resistor components. For this reason, they are called coded resistors.
[0004] Light-emitting diodes and/or light-emitting diode means which are used in motor vehicles are classified into normed, so-called light classes, e.g., wherein certain electrical connector sizes of the light-emitting diodes and/or light-emitting diode lamps are assigned to each light class. In addition, information on the light class of a light can be saved in this light by means of coded resistors.
SUMMARY OF THE INVENTION
[0005] In the case of the control devices developed by the applicant, said control devices have inputs via which it is possible to determine the ohmic resistance of coded resistors of light-emitting diodes or light-emitting diode lamps, or lights having light-emitting diodes or light-emitting diode lamps, in order to acquire information on the light class of the lights controlled by the control device. The control device can then control the lights according to the light classes.
[0006] The same control devices have inputs to which passive temperature sensors (for example NTC resistors or PTC resistors) can be connected, by means of which it is possible to monitor the temperature in a light controlled by the control device.
[0007] The control device is conceived in such a manner that it can be used in different motor vehicles. Each motor vehicle for which the control device is suitable renders a number of inputs for coded resistors and a number of inputs for temperature sensors necessary, and these can be different from one motor vehicle to the next. In order to be suitable for the largest possible number of different types of vehicles, it is advantageous if numerous inputs for temperature sensors and numerous inputs for coded resistors are present. This requires a plurality of components and devices in the control device.
[0008] The invention therefore addresses the problem of improving a control device in the named class in such a manner that fewer components and devices are required in order to make it possible to use the control device in various different types of vehicles.
[0009] This problem is addressed according to the invention in that the inputs of the control device can be configured for both the connection of a coded resistor and for the connection of a passive temperature sensor. In the control device according to the invention, coded resistors alone, passive temperature sensors alone, or both of these can be connected to the control device.
[0010] A light in the context of the invention can be a module of a headlight.
[0011] The control device can have a microcontroller which is connected via analog to digital converters to the inputs. The inputs can be connected to a reference potential connector in the control device via pull-up resistors. It is likewise possible that a reference potential is tapped at the control device to which the coded resistor or the passive temperature sensor is connected. The coded resistor or the passive temperature sensor can then be connected to ground via an input of the control device and a pull-down resistor in the control device. During operation of the control device, a current can flow via the pull-up resistor or the pull-down resistor, and either the coded resistor or the passive temperature sensor, wherein the strength of said current is composed of the sum of the resistance values of the pull-up resistor and/or the pull-down resistor and the coded resistor and/or the passive temperature sensor. A voltage is created at the input, said voltage being created according to the voltage divider composed of the resistance values. According to the configuration of the input, the voltage can either be interpreted by the microcontroller as a light class, according to the coded resistor, or as a temperature, according to the resistance of the passive sensor.
[0012] The values for the coded resistors can be from 100 Ohm to 100 kOhm. However, a 0 Ohm resistor can also be contemplated, the same being implemented as a bridge. However, an infinite Ohm resistor can also be contemplated, the same being implemented as a line disconnection. The values for the passive resistors can be 100 Ohm to 200 kOhm, according to the sensor and the temperature.
[0013] The microcontroller can be suitable and configured for the purpose of further processing the voltage created at the input and received via an analog to digital converter, according to the configuration of the input, and of undertaking a control of the lights according to a program.
[0014] The control device can be programmable in order to determine a configuration of the input. The control device can have a storage device in which one or multiple configurations for the inputs can be saved, or is/are saved.
[0015] The control device can have an interface via which it is possible to read in and/or input a configuration of the inputs and/or an instruction to select a saved configuration of the inputs.
[0016] An arrangement according to the invention of a control device according to the invention and at least one light, for example a passenger vehicle light, and particularly an LED light, can be designed in such a manner that the at least one light has at least one coded resistor, in which the nominal power, the nominal voltage and/or the nominal current of one or multiple lamps for the light is/are coded. The at least one coded resistor can be connected to a first input of the inputs of the control device, and this first input can be configured for the connection of a coded resistor.
[0017] The at least one light, or a further light of the arrangement, can have a temperature sensor, and the at least one temperature sensor can be connected to a second input of the inputs of the control device, wherein the second input is configured for connection to a temperature sensor.
[0018] These aspects are merely illustrative of the innumerable aspects associated with the present invention and should not be deemed as limiting in any manner. These and other aspects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the referenced drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out the invention and wherein similar reference characters indicate the same parts throughout the views.
[0020] FIG. 1 shows a schematic illustration of an arrangement according to the invention, having a control device according to the invention.
DETAILED DESCRIPTION
[0021] In the following detailed description numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. For example, the invention is not limited in scope to the particular type of industry application depicted in the figures. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
[0022] The illustrated arrangement according to the invention has a control device 1 and two headlights 2 a , 2 c of a motor vehicle connected to the control device. Only the connections between the control device 1 e [sic] and the headlights 2 a , 2 c are illustrated, these being of interest in the context of the invention. Additional connections between the control device 1 and the headlights 2 a , 2 c , for example for the purpose of controlling the headlights 2 a , 2 c , are not illustrated.
[0023] The control device can be included centrally in the vehicle for multiple lights. However, it is also possible to functionally assign the control device to one or several lights of the vehicle. In this case, multiple control devices according to the invention can be configured in the vehicle.
[0024] In addition, the components of the control device 1 and of the headlights 2 a , 2 c are illustrated which are of interest in the context of the invention.
[0025] The control device 1 has a microcontroller 10 . The microcontroller 10 has four inputs 100 a , 100 b , 110 c , 100 d , which are connected via analog to digital converters to inputs 13 a , 13 b , 13 c , 13 d of the control device. The inputs 13 a , 13 b , 13 c , 13 d are connected to a positive reference potential V + of the control device 1 via resistors 12 a , 12 b , 12 c , 12 d . In addition, the control device 1 has a storage device 14 .
[0026] The analog to digital converters could also be arranged outside of the control device. The analog to digital converters could also be a part of the microcontroller.
[0027] The inputs 13 a , 13 b are connected via connectors 22 a , 22 b of the upper of the two illustrated headlights 2 a , 2 c . The connector 22 a is connected via an NTC resistor 20 a to ground. The NTC resistor 20 a is used as a temperature sensor in the headlight 2 a . The electrical resistance of the NTC resistor 20 a varies as the temperature of the headlights 2 a changes.
[0028] The connector 22 b is likewise connected via a resistor 21 a to ground. The resistor 21 a has a resistance value which represents one light class of the headlight. The resistor 21 a is therefore also termed a coded resistor.
[0029] The inputs 13 c , 13 c [sic] are connected via connectors 22 c , 22 d of the lower of the two illustrated headlights 2 a , 2 c . The headlight 2 c is constructed exactly as the uppermost of the illustrated headlights 2 a in the context of the invention. The connector 22 c is connected via an NTC resistor 20 c to ground. The NTC resistor 20 a is used as a temperature sensor in the headlight 2 c . The connector 22 d is likewise connected via a resistor 21 c to ground. The resistor 21 c is likewise a coded resistor.
[0030] The voltage divider consisting of the pull-up resistors 12 a to d and the temperature sensors 20 a , 20 c and/or the coded resistors 21 a , 21 b regulates the electrical potential at the inputs 13 a , 13 b , 13 c , 13 d of the control device 1 , said potential being created by a flow of current via this voltage divider from the positive reference potential V+ of the control device to the ground potential of the headlights, and being supplied to the microcontroller 10 via the analog to digital converters 11 a to d . By utilizing this potential and the configuration of the inputs 13 a to d saved in the control device 1 , the microcontroller either determines the temperature or obtains information on the light class, these being required for the further processing in the control device.
[0031] Each of the inputs 13 a to 13 d of the control device can be connected [sic: configured] as an input for connection to a coded resistor or to a passive temperature sensor. The configuration is programmed in a software application in the microcontroller 10 . The programming can be modified so that the control device 1 can be used in an arrangement according to the invention which has another topology. Various configurations of the inputs 13 a to 13 d are saved in the storage device 14 , and can be loaded from there into the microcontroller.
[0032] The preferred embodiments of the invention have been described above to explain the principles of the invention and its practical application to thereby enable others skilled in the art to utilize the invention in the best mode known to the inventors. However, as various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by the above-described exemplary embodiment, but should be defined only in accordance with the following claims appended hereto and their equivalents.
LIST OF REFERENCE NUMBERS
[0000]
1 control device
10 microcontroller
100 a bis 100 d inputs of the microcontroller
11 a bis 11 b analog to digital converter
12 a bis 12 d pull-up resistor
13 a bis 13 d inputs of the control device
14 storage device
2 a , 2 c headlights
20 a , 20 c passive temperature sensors
21 a , 21 c coded resistors
22 a bis 22 d connectors of the headlights | A control device for lights having at least one input wherein a coded resistor can be connected to the input, and having at least one input wherein a passive temperature sensor 20 a, 20 c , particularly a PTC or an NTC, can be connected to the same. The invention also relates to an arrangement of such a control device and at least one light. | 7 |
RELATED U.S. APPLICATION DATA
This application is a division of non-provisional patent application Ser. No. 13/428,543, filed Mar. 23, 2012, which claims the benefit of provisional application No. 61/466,872, filed Mar. 23, 2011, hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a mine device which will deploy a non-lethal chemical marker on an intruder to easily identify the intruder.
BACKGROUND OF THE INVENTION
Illegal immigration into the United States is massive in scale. The growing number of illegal aliens is a sign of how dangerously open the US borders are. The presence of millions of undocumented migrants distorts the law, distracts resources, and can effectively create a cover for terrorists and criminals. Immigrants can be classified as illegal for one of three reasons: entering without authorization or inspection, staying beyond the authorized period after legal entry, or violating the terms of legal entry. The consequences of illegally entering the US provides for a fine, imprisonment, or both for any immigrant. Stricter enforcement of the border in cities has failed to significantly curb illegal immigration. Once undocumented migrants enter the US, they can easily blend in with legal US citizens.
SUMMARY OF THE INVENTION
The present invention provides a customized mine device which will deploy a chemical marker such as a dye on escapees, immigrants, criminals and perpetrators providing an identification system for authorities.
An aspect of an embodiment of the invention provides various colors and types of chemical markers, where the color or type of the marker can identify a type of illegal action committed by the perpetrator.
A further aspect of an embodiment of the invention provides the device being connected together in a daisy chain fashion such that the devices can be ignited in a series.
A further aspect of an embodiment of the invention provides the device functioning above ground in the form of a fence, below ground just below the surface as a non-lethal landmine and subterranean and several feet below ground as an anti-tunneling device.
Additional aspects, objectives, 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 perspective view of the mine device designed to prevent underground tunneling.
FIG. 2 is a perspective view of a mine device in an active state.
FIG. 3 is a perspective view of the mine device below the surface in a first stage.
FIG. 4 is a perspective view of the mine device below the surface in a second stage.
FIG. 5 is a perspective view of the mine device in a third stage.
FIG. 6 a illustrates the inner housing unit of the main housing unit.
FIG. 6 b illustrates the outer and inner housing unit of the main housing unit.
FIG. 6 c illustrates the main housing unit with full components.
FIG. 7 a illustrates the CPU protective door in a closed position on the inner housing unit.
FIG. 7 b illustrates the CPU protective door in an open position on the inner housing unit.
FIG. 7 c illustrates a door flap on the main housing unit.
FIG. 8 is a cut away section of a deployment of mine devices in the ground.
FIG. 9 is an illustration of the device in the form of a fence.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 is a perspective view of the Human Identification Detection (HID) mine device 100 . The device material features poly-carbon or plastic to avoid detection by metal detectors. The device is weather resistant. The device 100 is a two part cylinder 101 , 102 about a foot and a half long. The main housing cylinder is 101 and the inner housing unit is 102 . The inner housing unit 102 fits inside of the main housing cylinder 101 and makes up the bottom half of the device. The size of the device may vary depending on the volume of chemicals house and the size of the targeted area. The main housing unit 101 features an open top and open bottom to receive the inner housing unit 102 . The bottom half 102 of the device rests in the ground 105 below the surface of the earth at about four inches. The main housing cylinder 100 has four electronic leads 299 , shown in FIG. 3 that extend outward from it and are hidden beneath the surface of the ground. Additional or less leads 299 can be added to the device depending on the location of the device or the need to secure an area. The leads 299 are the contacts which allows current to travel through the device. The contacts for the device are disguised as small rocks to camouflage it further. The entire device 100 will be camouflaged to avoid detection by the intruder. FIG. 3 is a perspective view of the mine device below the surface in a first stage. The leads can be various lengths to avoid anticipating when the device will explode. On the end of these leads are electronic sensors 300 that measure weight when stepped upon. The sensors 300 can be designed to trigger the device to an active state. The sensors 300 can be set to trigger the device when a predetermined weight/load is in the vicinity of the sensor or on the sensor. The contacts can be programmed to be weight sensitive to prevent the triggering of the device by animals.
Also contained in the base unit 100 is a processing unit featuring a small electronic motherboard/CPU that is connected to the leads. That motherboard interprets the signals from the contacts. For example, the weight sensor will send signals to the motherboard to activate the device. The motherboard will send signals to the homing units to notify that the mines have been activated. The homing unit can be located at a separate area and monitored so the status of the device may be monitored at all times. The base unit also contains a GPS, radio transponder, and battery to power the unit. The GPS can provide the exact location of the device to monitor the location of the device at all times. The motherboard takes the information from the contacts and interprets it and ignites the charge in the insert tube. The motherboard also sends a signal to a nearby transponder or homing unit that alerts the monitoring station that the device has been triggered. The motherboard is also connected a GPS unit in the device that notifies the transponder and the monitoring station which unit has been triggered. The base unit also has a trigger to ignite the insert unit 102 that is propelled out of the outer housing by an explosive charge. The trigger may also be controlled remotely by the homing unit or activated by the sensors, as discussed above.
The inner housing unit 102 acts as a lid for the cylinder. The inner housing unit 102 is disposable and can be recharged with a new engine or power source, explosive charge or chemical bag. The insert lid 500 fits snuggly over the top of the main housing unit 101 . The center of the lid has a long tube 301 attached to the center that extends into the center of the housing cylinder 101 . In the center of the tube 301 is a propellant that fires the inner housing unit out of the housing cylinder several feet into the air when ignited by the trigger in the base unit, as shown in FIG. 5 . The propellant deploys or propels the insert to a predetermined height for maximum effective as shown in FIG. 4 . FIG. 4 is a perspective view of the mine device below the surface in a second stage. The inner housing unit 102 has a center tube that will hold the explosive charge or propellant. The first charge will propel the unit at least four feet into the air from beneath four inches of the ground. The second charge will be ignited by the primary charge at the insert's apex of flight. The second charge will explode pushing the concussive force out through slits in the insert center tube impacting and rupturing the plastic pouch, as shown in FIG. 5 . As the inserts spins in a counter-clockwise or clockwise fashion, the chemicals contained in the bag will be thrown several feet in all directions, tagging the intruders, escapees or targets. FIG. 5 is a perspective view of the mine device in a second stage. The explosive charge detonates the dye/chemical pack and the chemicals 555 can mark an area of 25 feet in diameter with luminescent biodegradable dyes.
A plastic bag or chemical bag 570 is wrapped around the center tube of the inner housing unit 102 . The plastic bag houses a variety of chemical agents. The chemical bag can contain several different chemicals for different missions. The chemicals may be a biodegradable dye that cannot be washed off by soap and water and can only be removed by an engineered compatible chemical key. The dye will contain RFID tags so that individuals can be detected by compatible electronic devices even when concealed or covered by clothing, for example. The tags use a technology that uses radio waves to identify the infraction of the target. The dye will also contain some metallic elements so that it can be detected under clothing by metal detectors. The plastic pouches can also contain pepper spray of tear gas. The pouches will be designed so that they can carry one chemical or a combination of several chemicals. The agent features a chemical marker. The chemical marker contains RFID and metallic elements which allow the dye to be scanned underneath clothing. To remove the dye, a chemical key is required. This may be in the form of an engineered soap or a wipe. The RFID chips when scanned will hold a message based on the location of the device and infraction such as PRISON ESCAPE, FUGITIVE or BORDER VIOLATION, for example. Also, if desired, the dye can be mixed with a pepper spray. The chemical marker will allow easy identification of the perpetrator being in an unwarranted area. When the inner housing cylinder 102 is propelled into the air out of the housing cylinder 101 , a second explosion is triggered within the insert tube and is expelled through vents in the insert tube. The tube features vents or openings along its body that allow the chemicals to escape the tube. The small blast ruptures the bag, sending the chemicals in all directions marking the intruders and or escapees. The insert bag is designed to rupture with a minimal amount of force. The chemicals may be color coded such that the colors represent the type of trespass or crime committed. For example, a red dye may represent a PRISON ESCAPE, a blue dye may represent FUGITIVE, etc.
The HIDS devices can be triggered individually or in tandem. The devices can be daisy chained together by trading the contacts for electronic connections between two adjoining devices. When one adjoining device is triggered, all attached devices in that series are ignited. FIG. 8 is a cut away section of a deployment of mine devices 100 in the ground which are designed to trigger in tandem or individually.
The device can also be trigged by remote control. An operator can manually trigger the device by a hand held remote that ignites the device. The devices can also be controlled by a central control panel and software. An operator can activate or disable a whole perimeter of HIDS by use of a directly connected panel. Aside from the contacts, the HIDS can be triggered by being connected to a sensor net. The net can replace the individual contacts for each device. The net contains preinstalled contacts. It is then rolled out over a given area and the HIDS are placed into the ground as desired and connected to the net. The net can be connected to a control board or act independently. The net is used for protecting larger areas.
FIG. 1 is a perspective view of the mine device 900 designed to prevent underground tunneling. This unit 900 is designed to prevent tunneling underground into or from out of protected facilities or areas. The device is constructed of non-metallic poly-carbon or plastic. The design is completely watertight and weatherproof. It is designed to be buried deep underground, up to about twenty feet. This unit is designed in a similar fashion to the device shown in FIG. 3 but the principle is inverted and will operate several feet underground. The device is in a cylinder shape housing cylinder 901 about one and a half feet long. The top of the unit has a flat base 800 which can be pushed out from the housing cylinder by a spring concealed in the closed top. The base is contracted and held in place by a pin mechanism that is released inside of the housing cylinder 901 . The top plate 800 of the device is spring-loaded. The plate is released by a latch that is controlled electronically or mechanically from within the base unit.
The bottom of the housing cylinder 901 is open. The unit has a motherboard within the housing cylinder as well as a GPS, which is used to locate the device at all times, as discussed in the device of FIG. 3 . The GPS receives the signal from the motherboard that it has been activated and fired and relays that information and location to the antenna that extends above ground, that in turns sends it to the monitoring station via a field transponder. The antenna extends from the unit to the ground above. The base unit has an ignition system that is triggered by a sensor 903 in the nose of the inner housing cylinder 902 . The motherboard receives signals from the sensor at the bottom of the device and relays it to the release latch for the compression spring and it also ignites the propellant and charge in the insert tube.
The second part of the unit is the inner housing unit 902 . The inner housing unit is the bottom of the unit. The bottom is curved and has a button sensor 903 extending from it. The bottom fits across the entire diameter of the cylinder. The unit 902 has a long hollow tube 905 attached to its center. That tube contains a propulsion engine and explosive charge. This engine and charge are activated by the motherboard and sensor in the nose of the device. The center of the insert tube is surrounded by a plastic bag that is filled with chemicals whose use and purpose are described above.
A deep cylinder like hole is dug into the ground 906 . The device 900 is then placed into the ground at the bottom of the hole with the sensor down 903 . The wire antenna is run from the device to the topsoil leaving it exposed. The top of the device which has the pressure plate is still compressed. The hole is then filled with dirt and the weight of the dirt is on top of the device.
When a tunnel is being dug by an intruder or escapee, the intruder loosens the dirt under the HIDS device. The sensor in the bottom of the device is extended and triggers the device. The sensor is pressure sensitive. The motherboard then removes the pin or latch that is keeping the spring compressed at the top of the device. Once pressure is removed from the bottom of the device, the sensor is extended and triggers the actions of the device. The spring is then uncompressed and pushes the device into the tunnel cavity. At the same time, the motherboard then ignites the trigger on the propellant that is attached to the insert.
The propellant then fires the insert 902 into the tunnel cavity as shown in FIG. 2 . FIG. 2 is a perspective view of the mine device in an active state. The insert contains a bag of chemicals 905 that is fired at the targets in the tunnel cavity. The second ignition to the explosive then ignites sending a concussive force through the support tube of the insert and through the plastic pouch or chemical bag containing the chemicals. The chemicals are dispersed throughout the tunnel marking the targets and possibly collapsing the tunnel. The chemical bag and components are described above. The insert unit has a center tube that will hold the explosive charge or repellant. The first charge will propel the unit at through about a foot of soil into the tunnel. Gravity will assist in moving the unit through a tunnel. The second charge will be ignited by the primary charge at the insert's apex of flight. The second charge will explode pushing the concussive force out through slits in the insert center tube impacting and rupturing the plastic pouch. As the inserts spins in a counter-clockwise or clockwise fashion the chemicals contained in the bag will be thrown several feet in all directions, tagging the intruders, escapees or targets.
FIG. 9 is an illustration of the device in the form of a fence 1800 . The fence 1800 has sensors 810 that detects someone climbing onto it. A sensor system is provided and senses weight or pressure on the links, top and support poles of the fence. The sensors cause the release of a spray of chemicals to mark or disable the intruder or escapee. The chemicals are described above. The fence can be activated or disabled by an operator. The fence is also connected to a security network via software. The fence can also act autonomously. When the intruder climbs the fence, his weight will activate pumps underground that will pump a chemical solution through apertures in the fence poles and on top and cover the escapee/intruder with the chemical solution. The fence will have apertures in the support poles and top rail that will allow the chemicals to flow through and mark anyone that climbs onto it or is in an unwarranted area.
The mix of the chemical solution depends on the facility and mission. Only the section of the fence that is violated will be activated. The fence can be passive or active. It can be triggered manually and it will be connected to the facility security network via software. The fence will notify the facility of intrusion or escape via software at the monitoring station. The fence can be deactivated for maintenance and upkeep or retrieval of an intruder or escapee. When the fence is active, an alarm system activates and notifies the facility of a breach. The devices 100 may be positioned along the fence in the ground and they can activate if the intruder 855 comes within its vicinity. The intruder 855 is shown with chemical markers 857 .
FIG. 6 a illustrates the inner housing unit 102 of the main housing unit 101 . The inner housing unit 102 features the insert 500 . The insert acts as a lid for the main housing unit cylinder 101 . The lid 500 features a central stabilizer tube 301 extending downward. A separation plate 610 fits on the tube 301 and separates the tube 301 and secured dye pack 700 from the A8-5 rocket 710 designed to launch and ignite the explosive 711 . The insert unit is disposable and can be recharged with a new engine or power source, explosive charge or chemical bag. The insert lid 500 fits snuggly over the top of the base. The center of the lid has a long tube 301 that extends into the center of the base unit. A detonator 721 such as a mechanical or electrical explosive device or a small amount of explosive is used to initiate the release of the dye.
FIG. 6 b illustrates the outer 101 and inner housing unit 102 of the main housing unit. The inner housing unit 102 is fitted inside of the outer housing 101 . A CPU 621 is positioned between the inner and outer housing units. The processing unit (CPU) controls the device 100 , as discussed above. It allows the device to be remotely activated or deactivated. The CPU 621 processes all of the data for the device.
FIG. 6 c illustrates the main housing unit with full components. The dye pack 700 is wrapped around the tube 301 . The rocket 710 is shown underneath the separator plate 610 with the detonator 721 underneath the rocket 710 .
FIG. 7 a illustrates the CPU protective door 622 in a closed position on an inside surface of the main housing unit 101 . The CPU 621 is protected by the door 622 . The door conceals the CPU from the elements including weather, dust and debris. The door 622 features a screw 623 that functions as a lock. When turned, the screw 623 locks and unlocks the door 622 . The door 622 provides access to the CPU 621 . The door 622 features an interior seal 624 that adds an extra layer of protection as well as provides a secure fit to ensure the door is sealed and closed. FIG. 7 b illustrates the CPU protective door in an open position on the main housing unit. FIG. 7 c illustrates a door flap on the main housing unit.
The device can be used and positioned near nuclear plants, military bases, national borders or any government secured facility, for example.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | The invention provides a system, device and method designed to detect, alert and identify unwanted entry into areas by intruders. The invention is also designed to prevent escape from secured facilities. If escape from such a secured facility is realized, the system will identify and mark the intruder or escapee for immediate or later capture by local and or federal law enforcement authorities. The system will accomplish this by mechanical, electronic and chemical means. The system is also designed to be a territory denial system. Although the system will accomplish its means by clandestine deployment, the unseen but known presence of the device will cause a profound psychological block to any would be intruder to a given area that it is deployed in. The devices are deployed below ground just below the surface as a non-lethal landmine and subterranean several feet below ground as an anti-tunneling device. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS (CLAIMING BENEFIT UNDER 35 U.S.C. 120)
This application is a divisional application related U.S. patent Ser. No. 09/496,145, now U.S. Pat. 6,551,639, entitled, “Container for Storage and Serving of Breastmilk, filed on Feb. 1, 2000 by Rebecca R. Nye.
INCORPORATION BY REFERENCE
This applications incorporates by reference the related parent application, U.S. patent Ser. No. 09/496,145, now U.S. Pat. 6,551,639, entitled, “Container for Storage and Serving of Breastmilk”, filed on Feb. 1, 2000, by Rebecca R. Nye.
TECHNICAL FIELD OF THE INVENTION
This invention pertains to the art of food containers for perishable beverages, especially human breast milk, baby formula, nutritional supplements, and fruit juices. In particular, this invention relates to aseptic containers in which perishable beverages can be stored at ambient temperature, and from which perishable beverages can be served.
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT STATEMENT
This invention was not developed in conjunction with any Federally-sponsored contract.
MICROFICHE APPENDIX
Not applicable.
BACKGROUND OF THE INVENTION
The need to store, transport, and serve perishable beverages has been answered in part by several available well-known containers. However, many of these containers are not suitable for storage of human breast milk and baby formula.
One well-known package is the “Brick Pack” by Tetra Laval Holding & Finance, S. A., of Pully, Switzerland. This aseptic package is commonly used for storage and serving of juice products and long-term storage milk. The package includes a coated paperboard outer carton, which is folded into a generally cubical or rectangular shape, and sealed with an internal coated foil liner. The package is sterilized prior to filling with the beverage, and then hermetically sealed. The product can then be stored at ambient temperature, and is served by inserting a pointed straw through an aperture provided in the carton paperboard. The straw punctures the inner foil seal, and allows for the beverage to be consumed via the straw. Some other variants of this package include a re-sealable pouring spout, but after the initial aseptic seal is broken, the remaining product contents must be refrigerated. Tetra Laval holds several U.S. patents to similar packages and related manufacturing methods, including U.S. Pat. No. 5,704,541 to Mogard; U.S. Pat. No. 5,639,432 to Carlson; U.S. Pat. No. 5,893,477 to Kaneko, et al; U.S. Pat. No. 5,927,046 to Martin; and U.S. Pat. No. 5,938,107 to Anchor, et al. However, these packages are not particularly suitable for directly serving perishable beverages such as human breast milk to an infant, as infants are unable to drink from a straw. Alternatively, breast milk stored in such as package with a pouring spout is undesirable in that it requires a care giver to pour the liquid into another container, such as a baby bottle. This requires the care giver to keep on hand and/or travel with one or more clean serving containers, and to prepare the serving in an environment conducive to pouring. This excludes this scheme from use in moving vehicles, windy outdoors, crowded conditions, etc. It also provides an opportunity for the beverage to become contaminated by the unsterilized serving container or from the nearby environment. Finally, when the serving is completely consumed, the serving container generally must be kept for washing later.
Another common serving package for baby formula and breast milk is a bottle and liner system manufactured by Playtex Products, Inc., of Dover, Del. The Playtex bottle consists of a generally cylindrical holder, in which a plastic liner bag is placed and filled with liquid. In one variant, the liner bag top is stretched over the top of the holder. In another variant, the liner bag is provided with a semi-rigid ring around the top to facilitate installation of the bag in just one hand. In either case, a soft plastic nipple and retainer ring are installed over the top of the holder, forming a liquid-tight seal between the liner bag and the nipple. As the beverage is consumed by an infant, the liner bag collapses. This system, however, does not provide for sterile and aseptic storage of the breast milk, and thus requires refrigeration after being filled.
A similar system is described in U.S. Pat. No. 5,424,086 to Walker. In the Walker patent, a disposable plastic bag is disclosed which may be filled and sealed prior to consumption. When the serving is prepared, the contents of the bag are poured into another serving vessel, or the bag is dropped down into another vessel such as a baby bottle, and the top is cut off and stretched over the rim of the bottle. This system shares similar disadvantages as the Playtex system and as the paperboard containers discussed supra.
An alternative packaging solution was described in U.S. Pat. No. 5,664,705 to Stolper. The Stolper package includes a container, a valve arrangement, and a nipple for serving. The package is defined as two reservoirs, a storage portion and a dispensing portion. Pressure on the sides of the storage reservoir forces the beverage through the valve arrangement and into the dispensing reservoir, and the beverage in the dispensing portion may be consumed. Back flow from the dispensing portion into the storage reservoir is prevented, allowing a measured amount of the beverage to be dispensed and keeping the beverage in the storage reservoir from contamination. However, the complexity of this package may prohibit production at very low costs, and the need for pressure to cause distribution of the beverage is a disadvantage.
Therefore, there is a need in the art for an aseptic package and method for manufacture of the package suitable for storage of perishable beverages such as breast milk. Further, there is a need in the art for this package to allow serving directly from the package to minimize the possibility of contamination of the contents, and the maximize the usefulness and convenience of the product. Additionally, there is a need in the art for this package to be realizable in materials which allow it to be disposable and affordable.
SUMMARY OF THE INVENTION
The present invention employs a disposable, aseptic package for storage and serving of perishable beverages, such as human breast milk. The package is generally cylindrical in shape. The top of the package is provided with a circular flange about the circumference of the package, such that the filled package can be dropped down into a cylindrical outer holder. The package is held with its top surface near the top of the holder by the flange. A dispensing assembly, such as a nipple assembly or straw assembly, is then mounted atop the holder. As the dispensing assembly is mounted on the holder, a penetrating conduit engages the top surface of the package and punctures it, thereby providing a via for the beverage to flow freely from the package to the dispensing assembly, such as through a nipple or through a straw.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures presented herein when taken in conjunction with the disclosure form a complete description of the invention.
FIG. 1 presents a view of the disposable, aseptic package.
FIG. 2 shows a top view of the disposable, aseptic package.
FIG. 3 depicts a typical bottle for baby formula.
FIG. 4 a illustrates a nipple-type dispensing assembly, including the puncturing conduit. FIG. 4 b shows an alternate embodiment of the nipple assembly.
FIG. 5 shows straw-type dispensing assembly.
FIG. 6 illustrates the details of the puncturing conduit.
FIG. 7 shows an entire serving assembly with bottle, package, and dispensing assembly.
FIG. 8 shows a nipple assembly wrapped in a plastic or cellophane envelope for storage until ready to use.
DETAILED DESCRIPTION OF THE INVENTION
The objects, features and advantages of the invention will be apparent from the following detailed description of a preferred embodiment of the invention, which illustrated in the accompanying drawings in which like reference numbers indicate like parts of the invention.
Turning to FIG. 1 a , an aseptic drop-in package ( 1 ), for perishable beverages and other liquids is shown. The drop-in ( 1 ) package preferably has a generally cylindrical shape, but it could take a substantially rectangular shape as well without adverse effect on functionality. This container portion ( 2 ) of the package is preferably constructed of molded or heat formed semi-rigid plastic using similar materials and methods used to manufacture crushable, disposable plastic cups. An annular flange ( 5 ) is formed around the top circumference of the container portion ( 2 ) to add reinforcement to the round shape of the container portion, and to provide a mechanical detente when the drop-in package is installed in a bottle or holder. The annular flange is shown wider than necessary in FIGS. 1 a and 1 b for illustrative purposes, and must only be of suitable width to hold the filled drop-in package in place as described infra.
The lid portion ( 7 ) of the drop-in package is preferably a two-ply design. The first ply is a thin hermetically sealed film which is stretched taut across the top of the container portion ( 2 ), and glued or heat sealed to the annular flange ( 5 ) so as to form a hermetically sealed reservoir ( 6 ) within the drop-in package. The first ply film is preferably constructed of a material which has high tensile strength, but is easily punctured through the thickness of the film. Such materials include mylar film and aluminum foil. The second ply of the lid portion ( 7 ) is a thicker material less susceptible to puncture than the first ply, such as 3 or 4 mil plastic or coated paperboard. A circular puncture port ( 8 ) is provided in the center of the second ply. The second ply is continuously bonded atop the first ply using glue, heat seal, or any other suitable bonding method. The first ply film is exposed to puncture through the circular puncture port ( 8 ), while the remaining area of the first ply film is protected from puncture by the second ply.
Finally in FIG. 1, the container portion ( 2 ) may have a generally flat bottom ( 4 ), or an angled bottom ( 3 ). The flat bottom ( 4 ) allows the drop-in package to be placed upright on a level surface, while the angle bottom ( 3 ) may promote better flow of the beverage with minimized air gaps when the package is tilted.
Turning to FIG. 2, a top view of the lid portion ( 7 ) is shown, with the exposed first ply film through the puncture port ( 8 ).
FIG. 3 shows a holder ( 30 ) for the drop-in package, which is a generally cylindrical open-mouth bottle ( 31 ) having a threaded portion ( 33 ) around the top of the open-mouth for receiving a dispensing assembly. A cavity ( 32 ) for receiving the drop-in package is of sufficient diameter to allow the container portion ( 2 ) of the drop-in package to freely move in and out of the holder ( 30 ) without mechanical interference, but of small enough diameter to intercept the flange ( 5 ) of the drop-in package around the lip of the holder ( 30 ) just above the threaded portion ( 33 ). This allows the drop-in package ( 2 ) to be easily installed in the holder ( 30 ), with it coming to rest along the flange and the lip of the holder. Conversely, the diameter of the drop-in package may be set to an appropriate value so as to allow use of a particular prior art baby bottle as the holder.
FIG. 4 a shows the preferred embodiment ( 40 ) of the dispensing assembly. This embodiment is a nipple-type dispensing assembly for use with serving infants and toddlers. It consists of a threaded plastic ring ( 41 ), through which a soft plastic formed nipple ( 42 ) is installed. The threads in the plastic ring ( 41 ) are mating threads to the threaded portion ( 33 ) of the holder. The nipple is provided with one or more orifices through which the liquid beverage may flow when a suction is applied by the nursing infant or toddler. The basic nipple and ring arrangement is well known in the art. Added to the well-known arrangement is a puncturing conduit ( 43 ) which punctures the first ply film of the lid portion ( 7 ) of the drop-in package through the puncture port ( 8 ) when the dispensing assembly is screwed onto the top of the holder. In the preferred embodiment of the nipple assembly, puncturing conduit ( 43 ) is shorter than the thread length. This allows the nipple assembly to be placed on the top of the holder, and for the threads to engage prior to the puncturing conduit breaking the package seal. FIG. 4 b shows an alternate embodiment of the nipple assembly, in which the puncturing conduit ( 43 ′) is longer than the depth of the threaded ring depth, which allows the user to puncture the seal on the beverage container prior to threading the nipple assembly onto the holder.
The puncturing conduit ( 43 ) is shown in more detail in FIG. 6 . The puncturing conduit ( 43 ) is preferably a single-piece molded rigid plastic device, having a circular disk ( 62 ) with a pointed conduit ( 61 ) centered on the disk ( 62 ) as shown. The length of the pointed conduit ( 61 ) should exceed the diameter of the puncture port ( 8 ) so that when a circular flap of the film is pressed through by the conduit, the flap does not extend far enough towards the pointed end of the conduit so as to be drawn back into the conduit by the liquid flow. The diameter of the pointed conduit must be slightly less than the diameter of the puncture port ( 8 ) to allow it to pass without interference through the port. The puncturing conduit ( 43 ) is installed into the threaded ring ( 41 ) following the nipple ( 42 ). So, the diameter of the circular disk ( 62 ) is preferably set to a value slightly less than the inside diameter of the threads of the threaded ring ( 41 ) so as to allow easy installation and removal of the puncturing conduit but to allow a light friction fit to retain the puncturing conduit in the threaded ring.
FIG. 5 shows a straw-type dispensing assembly in which a straw is formed in the assembly rather than a nipple. A single-piece molded plastic device may include a threaded ring ( 51 ) and a flexible straw portion ( 52 ), or this may be constructed of 2 molded plastic pieces. The puncturing conduit ( 43 ”) is installed in the threaded ring ( 51 ) similarly to the nipple-type dispensing assembly, but is much longer to allow access to fluids in the container when the container is held upright instead of inverted. This straw-type assembly is useful for serving perishable fluids to non-infants, such as nutritional supplements to bedridden patients and elderly persons.
In FIG. 7, the entire assembly is shown ready for serving, with hidden features shown by dashed lines. The nipple-type dispensing assembly ( 40 ) is installed atop the holder ( 30 ) and engaged at the threaded portion of the holder and the threaded ring. The drop-in package ( 1 ) is captured securely in the assembly, held in place by the flange pinched between the lip of the holder ( 30 ) and the disk of puncturing conduit ( 43 ). The pointed conduit ( 61 ) has punctured the inner seal (the first ply film), providing a fluid flow path from the reservoir of the drop-in package ( 1 ) to the nipple of the dispensing assembly.
In production, the container portion ( 2 ) of the drop-in package is preferably sterilized using one of many well-known methods, such as the use of hot air. Then, a fluid, such as human breast milk or nutritional supplement formula, is poured into the sterilized container portion. The first ply film is then applied and hermetically sealed to the top of the container portion along the flange. The second protective ply of the lid portion ( 7 ) is affixed to the drop-in package. A peel-away protective tab or label may be placed over the circular puncture port. The nipple and straw assemblies may be sterilized and packaged in a plastic or cellophane envelope, as shown in FIG. 8 . This completes the product packaging, and may be followed by appropriate labeling or marking with information such as fluid type, nutritional analysis, production lot trace indicators, directions for use and storage, and an expiration date.
While the disclosure contained herein has set forth a preferred embodiment of the invention, and the fundamental mechanical components used within the invention are well known within the art, it will be appreciated by those who are skilled in the art that variations to the combination of elements, materials and steps disclosed can be made without departing from the scope and spirit of the invention. | A disposable, aseptic package for storage and serving of perishable beverages, such as human breast milk. The package is generally cylindrical in shape, the top of which is provided with a circular flange about the circumference of the package, such that the filled package can be dropped down into a cylindrical outer holder. The package is held with its top surface near the top of a holder by the flange. A dispensing assembly, such as a nipple assembly or straw assembly, is mounted atop the holder. As the dispensing assembly is mounted on the holder, a penetrating conduit engages the top surface of the package and punctures it, thereby providing a via for the beverage to flow freely from the package to the dispensing assembly, such as through a nipple or through a straw. | 0 |
BACKGROUND OF THE INVENTION
A linearly operating side-locked padlock of U.S. Pat. No. 4,742,700 was disclosed by the same applicant of this application, in which the dials 3 are rotated to their opening numbers as predetermined to drive the clutch wheels 4 to their opening position, and the button 221 is depressed downwardly to lower the movable shackle fastener 23 to unlock the upper shackle 21 so that the opening or closing of the shackle is linearly operated by a user's single hand. It is really quick to operate the lock. However, when depressing the button 221 for opening the lock, one user's hand should hold the rectangular casing 1 to allow his (her) thumb to depress the button 221 and his (her) other fingers may not firmly clasp the movable shackle 23 to allow an opening stroke of the movable shackle 23, resulting in an unstable holding of the padlock. The opening movement of the movable shackle 23 may possibly injure the user's fingers as jammed between the shielding plate 232 and the right side wall 103 of the casing 1. So, the applicant's prior invention of U.S. Pat. No. 4,742,700 still has some drawbacks on an ergonomics point of view. It is therefore expected to invent a combination padlock to overcome the aforesaid ergonomic drawbacks.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a pushertype combination padlock having a movable shackle provided with a pusher plate thereon so that the shackle may be directly pushed outwardly to open the padlock in an easy and comfortable way to enhance its ergonomic effect.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration showing all elements in construction of the present invention.
FIG. 2 is an illustration showing a locking condition of the present invention.
FIG. 3 shows an opening padlock of the present invention.
FIG. 4 is a cross sectional drawing of the present invention when viewed from 4--4 direction of FIG. 3.
FIG. 5 is a sectional drawing of the present invention when viewed from 5--5 direction of FIG. 3.
FIG. 6 is a perspective view of the present invention as assembled, by reversing the padlock as shown in foregoing drawings.
DETAILED DESCRIPTION
As shown in the figures, the present invention comprises: a first cover 1, a second cover 2 in combination with the first cover 1 to form a casing of the padlock, a plurality of dials 3, a plurality of sleeves 4, a longitudinal slide member 5, a movable shackle means 6, and a lateral detent means 7. The integral casing of the padlock may be made to be a very thin, compact rectangular structure.
The first cover 1 includes: a fixed shackle portion 11 protruding outwardly from a first longitudinal side wall 1a, an elongate slot 12 formed on an upper side wall 1c (opposite to a bottom wall 1d) of the cover 1 proximate to a second longitudinal side wall 1b (opposite to the first longitudinal side wall 1a), a plurality of pivots 13 formed on a base surface 19 of the cover 1 proximate to the first side wall 1a for pivotally mounting the plurality of dials 3, a plurality of protrusions 14 formed on the base surface radially disposed around each pivot 13, a plurality of stems 15 formed on the base surface engageable with a plurality of sockets 22 formed in the second cover 2 for combining the two covers 1, 2, a plurality of notches 16 recessed from the first side wall 1a for revealing any one numeral 33 formed on each dial 3, a lateral extension 17 protruding inwardly from a middle portion of the second side wall 1b for retaining a restoring spring 68 of the movable shackle means 6, and an elongate extension 18 formed on the base surface proximate and parallel to the second side wall 1b for guiding a sliding movement of a rear portion of the shackle means 6.
The second cover 2, having plurality of side walls corresponding to all side walls 1a, 1b, 1c, 1dof the first cover 1, is formed with a through hole 20 in its one corner to form a chain opening 10, 20 in commensuration with another through hole 10 formed in the first cover so that the casing 1,2 can be held by a chain passing through the holes 20, 10. A bottom socket 21 is formed in the cover 2 for storing a rear spring plate 52 of the slide member 5 normally tensioning the slide member 5 towards a bottom side wall 1d of the casing 1, 2. Two transverse extensions 23 are formed proximate to an upper side wall 1c of the casing to movably define the detent means 7 in the two extensions. An opening 121 is formed on a corner of the casing 1,2 for reciprocatively moving the shackle means 6. A corrugate surface 24 may be formed on a back surface of the cover 2 adapted for a frictional holding by a user.
Each dial 3 includes: a central hole 31 for pivotally securing each dial 3 on each pivot 13, a plurality of recesses 32 radially disposed in a bottom surface of the dial 3 to resiliently engage each protrusion 14 formed on the cover 1 (as retained by spring 45 on each sleeve 4) to allow each dial 3 to be clickingly rotated in the casing, and a plurality of protrusions 34 formed on an upper surface of the dial 3 each resiliently engaging each recess 44 formed on a bottom surface of each sleeve 4.
Each sleeve 4 includes a central hole 41 for pivotally securing each sleeve 4 in the pivot 13 and superimposing each sleeve 4 on each dial 3, a central spring socket 42 for storing each tensioning spring 45 retained between the sleeve 4 and the second cover 2, a divergent notch 43 radially formed in an upper surface of the sleeve 4 through each spring socket 42 operatively engaging each tapered extension 50 formed on the slide member 5. After combining the covers 1, 2, the spring 45 will tension the sleeve 4 and the dial 3 for resiliently coupling the same.
The longitudinal slide member 5 is generally formed as a rectangular plate having a plurality of sleeve openings 51 longitudinally formed therein, each sleeve opening 51 having a length larger than a diameter of each sleeve 4 and a tapered extension 50 protruding downwardly towards a bottom side wall 1d from each opening 51 to operatively engage each divergent notch 43 of the sleeve 4, a rear spring plate 52 embedded in a socket 21 of the second cover 2 to normally tension the slide member 5 towards the bottom side wall 1d, a side notch 53 recessed in a longitudinal side wall of the slide member 5 facing the second side wall 1b for operatively engaging a wedge portion 72 of the lateral detent means 7. The rear opening 51a of the slide member 5 can be cut through its rear portion to form the spring plate 52 as shown in FIG. 1. Each tapered extension 50 is formed an arcuate surface 50a on its lower circumference to smoothly engage a perimeter of each sleeve 4 as shown in FIG. 2.
The movable shackle means 6 includes: a movable shackle portion 61 generally formed as C shape having an opening end 611 operatively closing the fixed shackle portion 11 formed on the cover 1 for locking the present padlock, a pusher plate 62 having corrugate or anti-slipping surface 621 formed thereon secured to a middle portion of the shackle means by a connecting plate 63 movably engaged with the slot 12 of the first cover 1 and slidably overlain outside the cover 1, an intermediate flat plate 60 formed on a middle portion thereof slidably laid on the base surface 19 of the cover 1 having a recess portion 64 recessed in a direction towards the second side wall 1b opposite to the first side wall 1a and having an extension portion 65 protruding towards the first side wall 1a from the recess portion 64, and a rear shank portion 67 protruding towards a bottom side wall 1d from the flat plate 60 having a bottom hook portion 66 formed on its rear end. The rear shank portion 67 may be inserted therein a restoring spring 68 to be held between the lateral extension 17 of cover 1 and the hook portion 66 to normally resiliently tension the shackle means 6 rearwardly towards the bottom side wall 1d for closing the movable shackle portion 61 on the fixed shackle portion 11 as shown in FIG. 2.
The lateral detent means 7 as shown in FIGS. 1, 4, 2 and 3 includes: a slide plate 71 slidable retained between the flat plate 60 of shackle means 6 and the second cover 2, a wedge portion 72 tapered towards the first side wall 1a and protruding from the slide plate 71 to operatively engage the side notch 53 of the longitudinal slide member 5 as shown in FIG. 3, a base block 73 formed under the slide plate 71 slidably laid on the base surface 19 and operatively obstructing the recess portion 64 of the shackle means 6 as shown in FIG. 2, and a tensioning spring 74 resiliently tensioning the slide plate 71 and wedge portion 72 towards the first side wall 1a. The spring 74 is retained against the second longitudinal side wall 2b of the second cover 2 as shown in FIG. 4 to tension the detent means 7 towards the longitudinal slide member 5.
When using the present invention for locking purpose (from FIG. 3 to FIG. 2), the dials 3 have already been rotated to their locking state so as to allow the divergent notch 43 of each sleeve 4 to leftwardly thrust the tapered extension 50 of the longitudinal slide member 5 (the arcuate surface 50a of the extension 50 being resiliently engaged with a perimeter of the sleeve 4 as shown in FIG. 2), bearing the resilience of the spring plate 52 embedded in the socket 21, towards the upper side wall 1c or the shackle portion 61. Simultaneously, the side notch 53 formed in the side wall 54 will also thrust and retract the wedge portion 72 of the detent means 7 from the position shown in FIG. 3 to that as shown in FIG. 2 to allow the base block 73 to engage the recess portion 64 to obstruct the shackle means 6 to prevent from its leftward opening action when pushing the pusher plate 62 to open the shackle 61, thereby locking the present padlock as shown in FIG. 2.
When it is intended to open the lock, the dials are rotated to their opening combination and the extensions 50 of the slide member 5 are engaged with the notches 43 of the sleeves 4 as shown in FIG. 3 and 5 since the slide member 5 is always retained towards the bottom side wall by the spring plate 52. Meanwhile, the side notch 53 is engaged with the wedge portion 72 of the detent means 7 which is tensioned towards the first side wall 1a by the spring 74 and the base block 73 is no longer obstructing the recess portion 64 of the shackle means 6 so that upon a leftward pushing of the pusher plate 62, the shackle portion 61 will be opened to open the present lock.
If for resetting a new combination of the present invention, the pusher plate 62 is firmly depressed by a user's hand when opening the lock as shown in FIG. 3. Since the base block 73 is backwardly retarded by the extension portion 65 of the shackle means 6, the wedge portion 72 as engaged with the notch 53 will "lock" the slide member 5 to allow its extensions 50 engaged with sleeve notches 43 to brake the rotation of all sleeves 4, thereby providing a free rotation of any one dial 3 for resetting a new combination of the present invention.
The present invention is superior to the applicant's previous U.S. Pat. No. 4,742,700 with the following advantages:
1. It is ergonomically comfortable to push the movable shackle to open the present lock, while still holding the casing of the lock very stably.
2. Since a thumb, for instance, may be used to outwardly push the pusher plate 62 of the shackle 6, the remaining fingers and hand portion of a user may firmly hold the lock casing 1, 2 without being injured by the moving parts (for example, the shackle portion 61) of the present lock.
3. The elements are integrated to form a compact unit having a smoother appearance and better aesthetic meaning than the U.S. Pat. No. 4,742,700 which is formed with a side locked shackle structure.
The numerals 33 disposed on the bottom surface of the dial 3 are separated from the base surface 19 of the first cover 1 to prevent from their wearing since the dial is rotatively engageable with the plural protrusions 14 formed on the base surface 19 having the bottom surface of the dial positioned slightly higher above the base surface 19 of the first cover.
The longitudinal slide member 5 is integrally formed with the spring plate 52 by an integrated molding process well known in plastic processing.
The fixed shackle portion 11 is formed with an angled extension inclined upwardly outwardly to retard a lateral outward pulling of the opening end 611 of the shackle means 6, of which the opening end 611 is formed as a sloping surface inclined inwardly downwardly, engageable with the angled extension of the fixed shackle portion 11. | A pusher-type combination padlock includes a movable shackle reciprocatively formed in a longitudinal side portion of the padlock having a pusher plate secured to the movable shackle slidably overlain on a cover of a padlock casing so that when rotating the dials and sleeves to their opening combination, the pusher plate can be pushed upwardly to open the movable shackle for opening the lock in an easier and comfortable way, especially for a better ergonomic effect. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. application Ser. No. 12/004,170, filed Dec. 19, 2007 which claims the benefit of Provisional Application No. 60/875,921 filed Dec. 19, 2006, the disclosures of which are hereby incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
This invention relates to prosthetic heart valves, and more particularly to the type of prosthetic heart valves that use tissue material for the leaflets of the valve. The invention also relates to methods of making such valves.
There is increasing interest in artificial, prosthetic heart valves that use tissue material for the leaflets of the valve. Such valves tend to be less thrombogenic than mechanical prosthetic heart valves. This can reduce or eliminate the need for a patient who has received such a prosthesis to take anti-coagulant medication on a long-term basis. Tissue-based heart valves may also have other advantages, such as quieter operation. Because of the interest in such valves, improvements to them are greatly desired. Improved methods of making such valves are also sought.
SUMMARY OF THE INVENTION
In accordance with certain aspects of the invention, a prosthetic heart valve includes an annular stent having a plurality of annularly spaced commissure portions, each of which has a tip. A fabric cover may be provided over each tip. An additional fabric covering may be provided over the fabric tip covers and the remainder of the stent. Tissue may be provided over the fabric covering. Additional tissue is provided around the outside of the previously mentioned components. This additional tissue includes leaflet portions that extend inwardly between annularly adjacent ones of the commissure portions.
In accordance with certain other aspects of the invention, a method of making a prosthetic heart valve includes providing an annular stent having a plurality of annularly spaced commissure portions, each of which has a tip. The method may further include covering each of the tips with a fabric tip cover. The method may still further include covering the tip covers and the remainder of the stent with an additional fabric cover. The method may further include covering the fabric cover with a tissue cover. The method may still further include wrapping additional tissue around the radially outer surface of the tissue cover, the additional tissue including leaflet portions that extend inwardly between annularly adjacent ones of the commissure portions.
Further features of the invention, its nature and various advantages, will be more apparent from the accompanying drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified perspective view of a component of an illustrative embodiment of a prosthetic heart valve in accordance with the invention;
FIG. 2 is a simplified perspective view of a representative portion of FIG. 1 with another representative component added in accordance with the invention;
FIG. 3 is a simplified elevational view of another component prior to assembly with other components in accordance with the invention;
FIG. 4 is a simplified elevational view of yet another component prior to assembly with other components in accordance with the invention;
FIG. 5 is a simplified perspective view of an assembly of the components from FIGS. 1-4 in accordance with the invention;
FIGS. 6 and 7 are respectively simplified perspective top and bottom views of the FIG. 5 assembly with another component added in accordance with the invention;
FIG. 8 is a simplified perspective view of another component prior to assembly with the other components in accordance with the invention;
FIG. 9 is a simplified perspective view of a tool that is useful at a certain stage in the manufacture of heart valves in accordance with the invention;
FIG. 10 is a simplified elevational view of a representative portion of an assembly of components in accordance with the invention;
FIG. 11 is a simplified perspective view of an assembly in accordance with the invention on a tool like that shown in FIG. 9 ; and
FIG. 12 is a simplified perspective of an illustrative embodiment of a completed prosthetic heart valve in accordance with the invention.
DETAILED DESCRIPTION
An illustrative embodiment of a first component 100 of an artificial heart valve in accordance with the invention is shown in FIG. 1 . Component 100 is a hollow, annular, stent-like structure (sometimes referred to for convenience herein simply as a stent). Stent 100 is referred to as “hollow” because the interior that is bounded by its annular structure is open. Stent 100 is typically made of metal such as titanium (e.g., Ti 6Al-4V ELI Grade 5). A typical technique for making stent 100 is to cut it from a tube using a laser. Stent 100 is then typically electro-polished.
Because the valve of the illustrative embodiment being discussed is a tricuspid valve (e.g., for use in replacing a patient's aortic valve), stent 100 has three commissure portions or regions 110 a , 110 b , and 110 c that are equally spaced from one another around the circumference of the stent. Each commissure portion stands up from the annularly continuous base portion of the stent. The base portion includes a lower-most, blood-inflow edge portion 120 . This blood-inflow edge portion is scalloped as one proceeds around the stent to approximately match the natural scallop of the native valve annulus. In particular, this scallop rises in the vicinity of each commissure region, and it falls between each annularly adjacent pair of commissures.
Stent 100 also includes an annularly continuous blood-outflow edge portion 130 (which merges with and becomes part of each commissure region 110 at the commissures). Outflow edge portion 130 is much more deeply scalloped than the inflow edge portion. In particular, outflow edge portion 130 rises adjacent each commissure 110 (actually merging into each commissure as noted above), and falls between each annularly adjacent pair of commissures.
The inflow edge 120 , outflow edge 130 , and flexibility of stent 100 are designed to help ensure proper opening and coaptation of the finished valve in use. (Coaptation is the coming together of the outflow portions of the valve leaflets when the valve is closed.) Stent 120 is further designed to decrease maximum stresses in the stent in use, which gives the finished valve an increased safety factor.
Although titanium is mentioned above as a typical material from which stent 100 can be made, other materials are also possible. Some examples of other materials that may be suitable for use in making stent 100 include Elgiloy MP35N or polymers such as PEEK or acetal.
FIG. 2 illustrates a subsequent possible step in the manufacture of the illustrative embodiment being described. This is the addition of a sleeve-like fabric covering 200 over the top of each commissure post. Fabric commissure tip covers 200 help reduce the possibility that the stent commissure tips may poke through subsequently added components. An illustrative fabric that is suitable for use in making coverings 200 is reemay fabric, which is a spun form of polyester. Each tip cover 200 may be secured to the associated commissure tip with sutures.
FIGS. 3-5 illustrate further possible components and steps in the manufacture of the illustrative embodiment being described. FIG. 3 shows an illustrative embodiment of a polyester fabric tube 300 ; FIG. 4 shows an illustrative embodiment of a silicone cuff filler ring 400 ; and FIG. 5 shows an assembly 500 that includes stent 100 (with post tip coverings 200 ) and silicone cuff filler ring 400 covered inside and out by fabric tube 300 . For example, stent 100 (with coverings 200 ) and ring 400 may be placed coaxially around the outside of a lower portion of fabric tube 300 . Ring 400 may be located outside inflow edge portion 120 . The upper portion of sleeve 300 may then be pulled down over the outside of components 100 and 400 and pulled tightly enough to conform to outflow edge portion 130 as shown in FIG. 5 . Sutures may be used to hold the above-described components together in the condition shown in FIG. 5 . In particular, all of components 100 , 200 , and 400 are completely covered inside and out by fabric 300 . Ring 400 is located adjacent inflow edge portion 120 and follows the scalloping of inflow edge portion 120 all the way around assembly 500 . The upper portion of fabric 300 conforms closely to stent 100 above ring 400 , and in particular, the upper portion of the fabric follows the scalloped outflow edge portion 130 all the way around assembly 500 .
FIGS. 6 and 7 illustrate still further possible components and steps in the manufacture of the illustrative embodiment being described. In particular, these FIGS. illustrate the addition of porcine pericardium tissue 600 over assembly 500 , both inside and out, to produce assembly 700 . One of the purposes of this is to enhance durability of the finished valve. Another purpose is to reduce thrombogenicity of the finished valve. Sutures may be used to secure tissue 600 to assembly 500 as shown in FIGS. 6 and 7 . Apart from somewhat thickening assembly 700 as compared to assembly 500 , the addition of tissue 600 does not significantly change the shape of any portion of the structure.
Although porcine pericardium is mentioned above for component 600 , other types of tissue may be used instead if desired. Examples of such other possible tissue for component 600 include any mammalian pericardium (e.g., equine or bovine pericardium).
FIG. 8 illustrates a further possible component and steps in the manufacture of the illustrative embodiment being described. As shown in FIG. 8 , component 800 is a sheet of bovine pericardium that has been die cut to a shape that can be used to form all three leaflets of a finished valve. Note that the lower edge of sheet 800 (as viewed in FIG. 8 ) is scalloped to conform to the blood-inflow edge (like 120 in FIG. 1 ) of the finished valve. The upper portion of sheet 800 (as viewed in FIG. 8 ) will form the three leaflets of the valve. There are shallow downward cuts 802 between the individual leaflet portions adjacent the upper edge of sheet 800 , but sheet 800 remains intact so that this single sheet of tissue can be used to form all three leaflets in the finished valve.
Although bovine pericardium is mentioned above for component 800 , other types of tissue may be used instead if desired. Examples of such other possible tissue for component 800 include any mammalian pericardium (e.g., equine or porcine pericardium).
FIG. 9 illustrates a tool 900 that can be used in further steps in manufacturing the illustrative embodiment being described. Tool 900 is a mounting mandrel which can be inserted coaxially into assembly 700 . In particular, this is done so that each of the commissure portions 910 a - c of mandrel 900 is angularly or rotationally aligned with a respective one of the commissure portions 710 of assembly 700 . In addition, each of the scalloped edge portions 930 of mandrel 900 is adjacent a corresponding scalloped outflow edge portion 730 of assembly 700 .
With mandrel 900 positioned inside assembly 700 as described in the preceding paragraph, tissue 800 is wrapped around the outside of assembly 700 above the sewing cuff portion of assembly 700 . The sewing cuff portion is the portion that includes ring 400 in its interior. This wrapping is done with the scalloped lower edge ( FIG. 8 ) of tissue 800 just above and conformed to the scalloped sewing cuff of assembly 700 . In addition, each of cuts 802 is adjacent a respective one of two of commissures 710 , and the extreme left and right edges of tissue 800 come together adjacent the third one of commissures 710 . The portion of tissue 800 above each of outflow edge scallops 730 / 930 is pressed radially inwardly so that it resets on the adjacent concave surface 940 of mandrel 900 . Tissue 800 is stitched to assembly 700 (but not to mandrel 900 ) in this condition. For example, FIG. 10 shows stitching 1002 that is used to hold the initially free, left and right edges of tissue 800 together adjacent one of the commissures 710 of assembly 700 . Other stitching 1004 in FIG. 10 is used to stitch tissue 800 to assembly 700 annularly all the way around assembly 700 just above the sewing ring portion of assembly 700 . The valve structure shown in FIG. 10 may be referred to as assembly 1000 .
FIG. 11 illustrates a possible further step in manufacturing the illustrative embodiment being described. FIG. 11 shows an assembly 1000 still on a mandrel 900 as described in the immediately preceding paragraphs. Note in particular that the portion of tissue 800 above each of outflow edge scallops 730 remains pressed in against the adjacent concave surface 940 of mandrel 900 . With assembly 1000 in this condition on mandrel 900 , assembly is subject to fixation of the tissue. Such fixation of the tissue may be by any conventional and suitable means and may include cross-linking of the tissue by exposing it to cross-linking agents such as glutaraldehyde or epoxides such as TGA triglcidyl amine). Such fixation of the tissue stabilizes the tissue and renders it substantially biologically inert and bio-compatible. Such fixation of the tissue in contact with shaped surfaces 940 also gives the tissue a bias to return to that shape when it is not subjected to external forces. On the other hand, the fixation still leaves the tissue sufficiently flexible that the leaflet portions of tissue 800 above outflow edge scallops 730 can deflect outwardly to open the valve and let blood flow out when a ventricular contraction pressurizes the blood in the ventricle below the valve. When that ventricular pressure ceases, however, the leaflet portions above outflow edge scallops 730 come together again (coapt) and close the valve.
After the tissue of assembly 1000 has been subjected to fixation as described above, assembly 1000 can be removed from mandrel 900 . The result is a finished valve 1200 as shown in FIG. 12 . In use, valve 1200 has the operating characteristics described in the preceding paragraphs.
It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. For example, the shapes and/or sizes of various components can be different from the shapes and sizes shown herein. As another example, the materials used for various components can be different from those mentioned specifically herein. | A method of making a prosthetic heart valve may include providing an annular stent having a plurality of annularly spaced commissure portions having tips, covering each of the tips with a first fabric cover, covering the first fabric covers and the remainder of the stent with a second fabric cover, covering the second fabric cover with a first tissue membrane, and covering the outside of the first tissue membrane with a second tissue membrane, the second tissue membrane forming leaflet portions that extend inwardly between the commissure portions. | 0 |
REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Patent Application No. 60/290,735 filed May 14, 2001 under 35 U.S.C. §119(e).
BACKGROUND OF THE INVENTION
Automatic CNC machine tools, known as machining centers or as machine tool centers, are used to machine various materials. A rotating cutting tool ordinarily accomplishes the machining. The cutting tool is held in a spindle and rotated. Moving the cutting tool through the material under pre-programmed control allows for precise and complex machining to be accomplished. The machining operation, also may include the use of different tools which the machining center may be programmed to select from a magazine of the machining center, and mount it sequentially in the spindle. The tools used by the machining center may be of various lengths and configurations.
The cutting operation by the machining center may produce excess heat by the action of the cutting tool against the material. This heat adversely influences the cutting tool and/or the material being machined. Application of a stream of fluid coolant to the interface of the tool and the material where the cutting action is occurring must be employed to extend the life of the cutting tool and retain the properties of the material. The coolant fluid may be of a liquid or gaseous form. Current practice involves positioning static or manually adjusted nozzles mounted to the head of the machining center. This practice is problematic due to the fact that tools of various lengths are used throughout the machining process, and a stationary nozzle can only project coolant at one point on the extended centerline of the cutting tool. Operator intervention to manually adjust the nozzle might involve interrupting the operation, slowing the process, and subjecting the operator to a hazardous environment.
One known improvement to manual adjustment of the coolant nozzle is described in U.S. Pat. No. 5,444,634. This patent is directed to a nozzle that is mounted in a housing or the like that can be controlled to move in a manner commensurate with the programmed movement of a particular tool in the spindle. The nozzle is programmed by a “teach” mode that follows step-wise “jog” movements of the tool prior to actual machining of a work piece. The patent does not describe how the nozzle program keeps track of the changing tools, especially in an arm-type automatic tool changer. Furthermore, the nozzle described in this patent is not suitable for handling high-pressure discharge of coolant, nor is it readily adaptable as a back-fit for upgrading existing machining centers.
SUMMARY OF THE INVENTION
The present invention is directed to a remotely controlled coolant nozzle system for mounting to a machine tool center. The nozzle system is mounted to the machine tool such that the coolant stream intersects the tool and work surface interface or a point selected by the operator. The system includes at least one coolant nozzle mounted at right angles to the center axis of a rotating fluid handling manifold block. This allows the nozzle to rotatably direct coolant fluid to the interface of the working tool and the material, as the working tool moves along its perpendicular axis. The manifold block is rotated by electromechanical means (stepping motor or servo actuator) which receives electronic control signals.
The pathway of the coolant fluid is from a coolant fluid source to a coolant fluid input port of a rotating coolant union. The coolant fluid travels through the rotating coolant union to the manifold block. The pathway through the manifold block is coincident with that of the block centerline. The fluid passage through the block extends to a point where it intersects a fluid pathway from the nozzle. The fluid pathway through the nozzle, the nozzle bore, is formed around the centerline axis of the nozzle. Because the nozzle bore is formed around the centerline axis of the nozzle, the nozzle bore intersects the centerline axis of the manifold block around which the fluid pathway is formed, and the manifold block rotates around this center line axis, the torque required for rotating the block, is unaffected by coolant flow or pressure through the fluid pathway and out the nozzle. This allows for the use of a commercially available servo actuator or stepping motor that does not have to withstand high tortional forces and thus achieves high resolution at low cost even when handling great pressures and volumes of cooling fluid. The rotating coolant union allows for the manifold block to be attached to a fixed incoming coolant line and to be rotatable while maintaining a fluid communication with the coolant line. The manifold block rotates around its center axis when acted on by the electromechanical actuator. The actuator and the block may be connected in a variety of ways. A few examples are direct connections, connections utilizing gears, connections using flexible shafts or connections to thrusting and contracting piston assemblies.
The invention also includes a method for controlling a coolant fluid nozzle assembly mounted to the machine tool center. The location of the tool and material interface is determined and signals are sent based on that determination to an electronic control system. The electronic control system processes the sensor signals and then sends control signals to the electromechanical actuator. The electromechanical actuator rotates the manifold block to which the nozzle is connected in response to the control signals. The stream of coolant coming out of the nozzle is thus rotatably directed to the interface in a manner that is commensurate with change in location of the tool along its perpendicular axis.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the accompanying drawing in which:
FIG. 1 is front view of a machine tool center.
FIG. 2 is a view of the nozzle assembly.
FIG. 3 is a schematic of the electronic control system.
FIG. 4 is a figure of the carousel type software.
FIG. 5 is a schematic for the arm-type software.
FIG. 6 is a view of a machine tool center with an arm-type automatic tool changer.
DESCRIPTION OF PREFERRED EMBODIMENT
With reference to FIGS. 1-6 wherein like reference numbers refer to like parts throughout the Figures, a remotely controlled coolant fluid nozzle system 1 in accordance with the present invention includes a base plate or other structure 17 fixed in relation to the support on which the head 10 is mounted on the machine tool center, an electromechanical actuator, EMA, 12 mounted on the base plate, a rotatable output shaft 13 from the EMA that can be rotated through an angle of at least about 60 degrees, and preferably 90 degrees, a rotating coolant union, RCU, 16 the RCU having a rotation axis in line with the output shaft of the EMA, a manifold block 14 fixed to and driven by the EMA at one end and rotatably connected to the other end by the RCU, the manifold block having a fluid passage from the rotating input port 18 of the RCU to a nozzle 15 , the nozzle being fixed to the manifold block and being perpendicular to the centerline axis of the block. Fluid entering the input port of the RCU passes through the RCU, the manifold block, the nozzle bore and out through the nozzle end. The RCU is preferably a Deublin pn. 1116-607-064 or of a similar design which allows passage of high-pressure fluids from a fixed part to a rotating part with minimal leakage and minimal rotational friction. The EMA is preferably a Futaba S3801 servo actuator or an actuator of similar design, which causes rotation of the manifold block, and thus rotatable movement of the nozzle. The EMA receives control signals from a controller 2 through a nozzle control cable 5 . Because the centerline of the nozzle intersects the centerline of the rotating union and the rotational output shaft of the actuator, that the torque required of the actuator is unaffected by coolant flow or pressure through the nozzle. Whereas conventional coolant pressure is in the range of about 30-75 psi, the inventive configuration can accommodate coolant pressure in the range of about 30-1000 psi.
The controller generates control signals for the EMA. In a preferred embodiment the electromechanical actuator is moved as programmed into memory by the operator, and as retrieved via automatic operation. A plurality of programs can be stored, which correspond to different tools used by the machine center. A Microprocessor-based control logic in the control unit 2 is interfaced to the Machine tool center control system 9 via an electrical cable 6 and is connected via an electrical cable 4 to an external operator input device 3 that allows the nozzle angle to be set by the operator for each tool length and for these settings to be retained and recalled with each automatic change of tools.
In a preferred embodiment a controller as shown in FIG. 3 has a means of receiving electrical power, a micro controller unit (MCU) 9 , a non-volatile random access memory (NVRAM) 19 , several optical isolators 20 A, 20 B, 20 C, and 23 a multi-digit display 21 , and a signal amplifier 22 for the output to the EMA, an operator input 3 for teaching the system to follow the pre-programmed movement of the machine tools, with the operator input consisting of a detented optical encoder or other device to convert manual rotation to a suitable electrical input, or a momentary switch may be included at the input shaft or next to it for modal control. A preferred method of control is where the electronic control produces an output to the EMA that is dependent on a value stored in a particular address in the NVRAM. This value may be adjusted (increased or decreased) within predetermined limits by rotating the operator input. The MCU interprets the output of the operator input (OI) through a software algorithm and then alters the value stored in the NVRAM. The software then passes the new value to the output for controlling the EMA. This results in the nozzle angle “following” the operator input in real time, acting as visual feedback to aid in programming.
Execution of a tool 8 replacement in the spindle 7 of the machine center can be detected through the use of a plurality of sensors mounted externally to the machine center. These sensors are of a nature and have the placement to allow the sensor to detect when a tool change event has taken place, and to further allow differentiation between tools in machine centers, which have a plurality of tools in the magazine. The sensors to detect mechanical activity such as tool change and movement are well known in the art. Alternatively or in addition to external sensors the execution of a tool change in the machine center can be detected by utilization of sensors existing as per the original equipment manufacturer's design of the machine center. While manufacturers have designed a variety of automatic tool changers (ATCs), certain events and conditions need to be sensed and controlled by all of them. Furthermore, the nature of the available signals is consistent with standard industry practices and available sensing and switching devices. Therefore, it is possible, in most cases, to read and interpret these signals and events in such a way as to derive the number of the tool placed in the spindle as the result of an automatic tool change. This tool number does not have to be consistent with the numbering used by the machine center, but only for the purpose of uniquely and consistently identifying tools for the purpose of aiming the coolant nozzle.
The signals of interest usually consist of a contact closure or a D.C. voltage in the range of 5 to 24 volts. By use of an optical isolator 20 A, 20 B, 20 C, 23 of sufficient impedance and, optionally an available D.C. supply, both types of signals may be read without interfering with the normal operation of the machine center.
The signals required are as follows:
1. Index—this signal indicates the movement of a tool magazine 11 by one tool position past a reference point. This Index signal can be generated by an external sensor 30 .
2. Direction—this signal will be asserted or absent depending on the direction of the magazine (forward, backward or clockwise, counterclockwise). This Direction signal can be generated by an external sensor 31 .
3. Arm—Certain ATC systems that use an arm 32 or other device to exchange the tool in the spindle with the tool in the magazine. This signal indicates that the exchange has taken place.
The connection points for placement of the external sensors or to determine the points to access the existing machine center signals may usually be discovered by studying the machine center service and technical documents, and using instruments and techniques common to the industry.
A preferred method of control in a carousel-style ATC is shown in FIG. 4 . The tool in spindle corresponds directly to the position of the tool magazine. The signals of interest are Index and Direction. These two signals are coupled to an up/down counter of modulo n, where n is the tool capacity of the ATC magazine. Such a counter will count from 1 to n when indexed in the positive direction, then restart at 1. Counting in the negative direction results in n being the count following 1. This counter is implemented in software running on the MCU. The Index signal from the machine center is connected to the count input of the counter 24 and the Direction signal is connected to the up/down input of the counter. In this way, the count or content of the counter will reflect the current tool number of the tool in spindle. Note that no allowance is made for determining a “home” position or absolute reference to the actual tool number. The present preferred system only needs to consistently identify a physical tool position. The content of the counter is maintained in NVRAM so that the current count will be maintained should the machine center lose power.
The contents of the counter are used as an address pointer to a pre-defined area of the NVRAM, such that when count equals n, the memory location TOOL n is selected. The value contained in this location is then periodically transferred to the EMA output device, in this case a Pulse Width Modulation algorithm generator 26 in software using methods common to the art. From here the signal is transmitted to the EMA, thus effecting positioning of the nozzle. Further, when the Operator input 3 is adjusted, another counter 25 is incremented or deincremented by a proportional amount, and the value of that counter is added to the selected NVRAM location. Upper and lower bounds are set by software to limit the range of this value, and thus the PWM signal and resultant travel of the nozzle. When a tool change occurs, the value of the counter 24 reflects that event, pointing to a different NVRAM address. The operator input and EMA output now act on the new NVRAM address
The preferred method of operation of electronic control when used with an arm-style ATC is shown in FIG. 5 . This method is similar to that of the carousel style ATC method, and is identical with respect to the handling of the operator input and EMA output. Counter 24 is a modulo n counter where n represents a number of tool pockets 33 in the magazine. The inputs to the counter are interfaced to the ATC in the same manner as with the carousel ATC, so that the output count represents the pocket number available for change. The NVRAM memory area 19 is preloaded consecutively with the numbers 1 through n stored at locations Pocket 1 through Pocket n, respectively. An additional NVRAM location TIS 27 is pre-loaded with the number zero. The value in TIS is used as an address pointer for another NVRAM area 28 which stores the nozzle settings for tools numbered zero through n.
When the magazine advances, the counter 24 selects the appropriate pocket number in 19 but TIS remains unchanged. When the ATC exchanges the tool from the spindle with that in the current magazine position, the signal ARM is asserted, initiating a swap 29 of the value stored in TIS with the value stored in the selected location of NVRAM 19 . The new value of TIS is used to select the active memory of NVRAM 28 enabling operator input and EMA output to act on it. In this way, counter 24 , NVRAM 19 and TIS location 27 behave as a numerical model of the ATC magazine and spindle, with each stored value having a direct and consistent correlation to the tools in the various magazine pockets and spindle. Further, study will show that the numbers stored initially in NVRAM 19 and TIS location 27 need not be identical to the tool numbers as known by the machine center, nor even that they be consecutive at the start of operation. In fact, the only conditions that must be met for the initial contents of the NVRAM area 19 and 28 are as follows:
1. No two values may be the same
2. Each value must be capable of being used as or resolved to an address in NVRAM 28 .
This method provides a system by which each tool in the magazine 11 and the tool in the spindle 7 are associated with a corresponding value stored in NVRAM 28 and the value presented to the EMA will always represent the correct nozzle setting for the tool in the spindle as previously programmed by the operator input.
While a preferred embodiment of the foregoing invention has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations, and alternatives may be employed by those skilled in the art without departing from the spirit and scope of the present invention. | A programmable coolant nozzle system includes a coolant fluid nozzle fixed to a manifold so that the centerline of the nozzle and the centerline of the manifold block are perpendicular. This feature allows coolant fluid to be rotatably directed from the nozzle at great pressure and/or volume with an actuator that does not have to withstand severe tortional force. The invention includes a method which allows coolant fluid to be rotatably directed from a nozzle assembly and to be commensurate with any change in position of the working tool of a machine tool center. | 1 |
RELATED APPLICATION
The present application is a continuation of application Ser. No. 08/499,616, filed Jun. 7, 1995, a now U.S. Pat. No. 5,638,555, which was a continuation-in-part of PCT/US94/03350, filed Mar. 29, 1994, which was a continuation-in-part of application Ser. No. 08/038,924, filed Mar. 29, 1993, and now abandoned.
FIELD OF THE INVENTION
The present invention relates to portable commodes having a removable waste container. More specifically, the invention relates to products such as a child's potty, medical commodes and bed pans which use waste containers to receive body waste. The removable container has a portable support which may be moved to afford dumping of the contents of the container into residential or institutional fixed commodes and rinsed with fresh water until clean. After cleaning, the container is returned to its operative position and fresh water may be deposited into the container to limit sticking of body waste to the container when reused.
BACKGROUND OF THE INVENTION
Known prior art devices include portable supports having removable waste containers. The portable supports are designed to accommodate infants or toddlers or medical patients who cannot use conventional fixed commodes because of their immaturity or their physical limitations. The prior portable commodes vary in size and design. For example, U.S. Pat. No. 5,083,325 discloses a portable commode in the form of a simulation of an automobile. The Lumex Company of Bayshore, N.Y., markets a portable commode in the form of a chair having a cushion which comes off to access the commode. In practically all cases, the body waste container is independent of the seat portion of the support and either slides into position under the seat or is dropped into position under the seat on the support structure. With prior art portable commodes, water is usually deposited in the bottom of the waste container prior to use, and this water along with the waste is dumped into a fixed commode. The emptied container is then rinsed at a separate facility, such as an institutional or commercial sink, or a tub or shower, or similar source of fresh water. Depending upon the nature of the waste, the rinsing and dumping process is sometimes repeated frequently for cleaning satisfaction. In transferring the waste container from the commode for dumping to the water supply for rinsing, spillage may occur leading to unsanitary conditions.
Repeated rinsing of the waste container is wasteful of resources, and the present invention is designed to eliminate the necessity for repeated rinsing and dumping and transferring of the waste container from the water source to the fixed commode.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide an improved portable commode having a removable and reusable body waste container which may be cleaned by setting the portable commode on top of the waste-receiving bowl of a flush toilet and using fresh toilet water from the flushed toilet to rinse the waste container. The rinse water is dumped into the bowl.
The illustrated embodiment of the present invention provides a support for the waste container which rinses it and dumps it while positioned on top of the fixed commode. The container has a horizontal rest position which renders the container in an operative waste-receiving condition and an inverted position which renders the container in a dumping condition.
Specifically, the present invention enables the use of fresh water from the fixed commode to rinse the container as it is dumped into the bowl.
In an illustrated embodiment, the use of water from the fixed commode permits the discharge of the waste material from the waste container with a single flushing of the fixed commode after the waste container is dumped by operating the container from its operative condition to its dumping condition.
The present invention provides a flushing nozzle for the waste container which eliminates the need to remove the waste container from the portable support for cleaning and rinsing.
The present invention provides for automatic cleaning of the waste container by toilet water without need for special plumbing to supply additional water to the cleaning station.
The present invention enables a portable commode to incorporate the advantages of known prior art commodes with the additional advantage of ease of cleaning provided by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
All of the objects of the invention are more fully set forth hereinafter with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a portable commode embodying the present invention as seen from the front of the portable commode with portions broken away to shown interior parts;
FIG. 2 is a rear perspective view of the portable commode shown in FIG. 1;
FIG. 3 is a sectional view taken on the line 3--3 showing the unit positioned on a fixed commode with its front facing the rear of the fixed commode (shown in broken lines);
FIG. 4 is a horizontal sectional view taken on the line 4--4 of FIG. 3;
FIGS. 5, 6 and 7 are vertical sectional views taken on the lines 5--5, 6--6 and 7--7, respectively, of FIG. 3;
FIGS. 8A-8E are diagrammatic views illustrating the sequence of operation of the operating lever;
FIGS. 9A-9E are diagrammatic views showing the sequence of operation of the pump handle; and
FIGS. 10A-10E are diagrammatic views showing the sequence of movement of the waste container.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1, 2 and 3, a portable toilet embodying the present invention is illustrated, having a hollow support structure 14 with an upwardly-facing seat 15 for a human positioned on it. As shown in FIG. 1, the seat 15 is accessible from the front of the hollow support structure 14 so that when the support structure 14 is resting on the floor, the child may straddle the support structure 14 and sit on the seat 15. Behind the seat 15, there is a pump housing 18 having a handle 17 for carrying purposes and for stabilizing the portable toilet when it is resting on the fixed commode. As shown in FIGS. 3 and 4, the fixed commode is a regular household toilet whose bowl contains clean toilet water to receive waste for flushing into a sewer pipe or other drain, but the present invention may be used with any regular toilet having clean water for flushing. The bottom of the housing support structure 14 is open and is configured to be supported on a regular toilet, as shown in FIG. 3.
A bellows-type pump 170 having a pump operator handle 128 is positioned within the pump housing 18 which is defined between a front wall 200 and a rear wall 400. A spring-powered hose control lever 162 is pivoted to the rear wall 400 and has an operator 163 projecting through an arcuate slot 165 in the wall 400. Pivotal movement of the lever 162 by the operator 163 causes the lever to pivot to the lower position past a latch actuator 167 and to engage behind a latching device 169 adjacent the bottom of the slot. As shown in FIG. 3, the lever 162 has a pivot shaft 160 which is journaled in the walls 200 and 400 and has a hose arm 69 which extends radially from the shaft and has a hose holder 168 which engages the open end of an intake hose 172 of the pump 170. Preferably the intake end of the hose is a flexible conduit which incorporates a check valve to maintain the intake hose filled with toilet water, regardless of whether it is immersed in water or removed from water. When the lever 162 is in the upper position, the free end of the hose 172 is elevated into the interior of the housing 14. In the illustrated embodiment, when the lever is actuated to the bottom of the slot 165, the free end of the hose passes down through the bottom opening of the housing and dips into the fresh toilet water in the bowl B of the fixed commode shown in broken lines in FIG. 3. The lever has a spring bias tending to return the lever to the top of the arcuate slot, but is latched in the lower position against the bias by a suitable latch 169 coupled to the pump handle 128 by a connection not shown in the drawing.
With the hose 172 dipped into the water in the bowl B, the pump 170 is actuated by rotating the handle 128 on an axle to fill the bellows of the pump with water from the bowl B. Preferably, the pump handle 128 is lowered prior to or concurrently with the displacement of the lever 162 to evacuate the bellows so that the bellows may be filled with water from the bowl B by elevating the handle 128 to the position shown in FIG. 1. At that position, the bellows is filled with fresh toilet water from the bowl. The bellows of the pump 170 constitutes a pump chamber which enables retention of the water drawn through the hose 172. Upon completion of the upward stroke of the pump handle 128, the latch which holds the lever 162 in the lower position is released to allow the lever to return to its upright position and thereby raise the end of the inlet hose 172 out of the toilet water and into the interior of the housing 14. The check valve in the outlet end of the hose maintains the hose 172 filled as it is elevated.
Within the housing 14, a waste container 100 is positioned in its waste-receiving condition shown in full lines in FIG. 3. In the illustrated embodiment, the waste container 100 is journaled on pivots in the housing so that it may be rotated from the waste-receiving condition shown in FIG. 3 to a dumping condition shown in full lines in FIG. 10D. In its waste-dumping condition, the waste in the container is discharged directly into the toilet bowl B through the bottom opening of the hollow support structure 14.
In the present instance, the container 100 is mounted in journals 16 for rotary movement between a horizontal rest position shown diagrammatically in FIG. 10A and an inverted dumping position shown in FIG. 10D. The container has a return spring (not shown) associated with the journals to bias the container to the rest position. The container 100 may be operated by a cable 154 attached to the bottom of the container 100 and extending through the pump housing 18. The end of the cable 154 is connected to a slider, shown diagrammatically at 152 in FIGS. 8A to 8E, which slides in an arcuate track 150 concentric with the arcuate slot 165. The container 100 is biased toward in its horizontal waste-receiving condition shown in full lines FIG. 3 so that when the slider is displaced to the top of its track 150, the container 100 is inverted against the bias of the spring-loaded journals to the dumping position shown in FIG. 10D by the cable 154. Suitable guides in the form of pulleys and conduits (not shown) permit freedom of movement of the cable to actuate the container 100 between its two positions. Displacement of the cable operates against the bias of the spring-loaded journals to afford tilting of the container 100 to dump its contents directly into the bowl B through the open bottom of the hollow structure 14. It is noted that the inside dimension of the bottom opening of the hollow housing 14 is larger than the outside dimensions of the container 100, and the container 100 is mounted in vertical registry with the open bottom of the housing 14, so that when the waste in the container is discharged by tilting the container, the waste passes through the open bottom directly into the bowl B without fouling the interior walls of the hollow housing 14.
The operation of the device is diagrammed in FIGS. 8A-10E. After use of the portable toilet away from the regular toilet bowl, it is prepared for cleaning by placing the support 14 on the bowl B with its forward end facing the back of the fixed bowl. Preferably, the conventional toilet seat on the bowl is raised so that the hollow support 14 rests directly on the bowl as shown in broken lines in FIG. 3. The handle 17 is used to stabilize the portable toilet as the device is operated. At this point, the lever 162 is upright as shown in FIG. 8A; the pump handle 128 is down to collapse the bellows 170 as shown in FIG. 9A, and the container 100 is in its horizontal loading position shown in FIG. 10A. In the first operation, the lever 163 is displaced to the bottom of the arcuate slot 165 as diagrammed in FIG. 8B so as to displace the free end of the hose 172 into the toilet water in the bowl B. The lever 162 has a spring bias tending to return the lever to the vertical position so that the displacement of the handle from the position shown in FIG. 8A to the position shown in FIG. 8B is effected against the bias of the spring. The lever is latched in its lower position, for example by the latch mechanism 169. When latched, the lever 162 also interlocks the end of the lever 162 with a slider 152 which rides in a track 150 behind the slot 165 shown diagrammatically in FIGS. 8A-8E.
With the lever 162 latched in the lower position, the pump handle 128 may be raised as indicated in broken lines in FIG. 9B to expand the bellows chamber in the pump 170 and draw toilet water into the chamber through the hose 172 whose end is immersed in the bowl. At the top of its stroke, the pump 170 actuates the latch mechanism 169 to release the lever 162 and permit it to return to its upright position shown in FIG. 8C, under the spring bias of the lever. Upward movement of the lever 162 lets the hose arm 69 raise the hose end 172 out of the bowl B.
Since the lever is interlocked with the slider 152 at the end of the cable, the slider 152 is displaced to the upper end of its arcuate track 150 when the lever is moved to the top of its slot 165. The movement of the slider 152 extends the cable and tilts the container 100 as shown in FIG. 10C against the bias of the spring return mechanism in the journal 16. The displacement of the pump handle 128 operates the pump 170 to discharge the toilet water from the pump chamber through a check valve (not shown) in the outlet hose 174 and through the jets of a flushing outlet nozzle 102 at the rear of the container 100. The discharge of the toilet water through the hose 174 sprays the interior of the container to rinse any waste material which has not been dumped during the inversion of the container and discharges the rinse water along the rear wall of the container 100 and into the bowl.
Before the pump chamber in the bellows pump is fully collapsed, for example when the chamber is 90% discharged, the downward movement of the handle 128 actuates the return mechanism for the container 100 so that the container is free to return to its horizontal position as shown in FIG. 10E under the action of the spring return mechanism in the journals 16. The pivotal return of the container 100 to the horizontal position extends the cable 154 to return its slide 152 to its normal position at the bottom of its track 150 where it is available to be engaged by the lever 162. Upon return of the container to its horizontal position, the final traverse of the pump handle to its bottom position discharges the toilet water remaining in the bellows compartment of the pump into the bottom of the container 100 to provide a residual amount of water to maintain the inside of the container sufficiently wet to avoid sticking of waste material to the bottom of the container during subsequent use. The portable potty may then be removed from the bowl B and the bowl may be flushed in the usual way.
If it is found that the container 100 required additional rinsing, the cycle may be repeated after flushing the bowl B.
The particular mechanisms described in connection with the illustrated embodiment are not critical to the operation of the invention and different mechanical movements and operating parts may be employed to achieved the desired results. For example the illustrated embodiment of the invention draws water from the same part of the regular toilet which later receives the waste discharged from the container. Where the design of the regular toilet permits, the water may be drawn from a different part of the regular toilet, or from a separate source of water. | An apparatus for disposing of body waste in a portable toilet is comprised of a container (100) and an associated hollow housing structure (14) which are adapted to be seated on a conventional toilet (B). Waste in container (100) is dumped into the toilet via a cable mechanism (154) on the intake stroke of a hand pump (170). A water intake hose (172) is manually lowered into the toilet water via a hose control handle (162) prior to the operation of the pump. While the container (100) is in a vertical dumping position, the exhaust stroke of pump (170) forces water siphoned from the toilet through a jet outlet (180) to clean the interior of the container (100). The waste and toilet water in the container (100) is discharged directly into the bowl without impinging the hollow housing structure. The container (100) automatically returns to its rest, or horizontal, position due to the action of a return spring. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a coordinate inputting system; more particularly the present invention relates to a coordinate inputting system which is suitable for being incorporated into a so called digitizer for inputting hand written letters and/or graphics, as for example into a computer system; and even more particularly the present invention relates to a coordinate inputting system, in which each coordinate position of a special pen such as a stylus type pen is inputted, as said special pen touches the surface of a coordinate inputting sheet. This point of contact of the special pen upon the coordinate inputting sheet will hereinafter be referred to as the "input point".
The present inventors wish hereby to attract the attention of the examining authorities to copending patent application Ser. No. 055,946, filed June 1, 1987 which may be considered to be material to the examination of the present patent application.
In the prior art, there have been proposed various types of coordinate inputting systems. One such prior art type coordinate inputting system is illustrated in FIG. 7 of the accompanying drawings in exploded perspective view. In this figure, the reference symbol 1A denotes a X coordinate inputting sheet, which has a resistive surface 4A on its one side and a pair of electrodes 2A and 3A laid along its opposite edges and in contact with opposite edges of said resistive surface 4A And, similarly, the reference symbol 1B denotes a Y coordinate inputting sheet, which has a similar resistive surface 4B on its one side and a similar pair of electrodes 2B and 3B laid along its opposite edges and in contact with opposite edges of said resistive surface 4B. These two X and Y coordinate inputting sheets 1A and 1B are laid together in a mutually parallel relationship with their electrodes 2A, 2B and 3A, 3B extending in a mutually skew perpendicular relationship.
With such a coordinate inputting system, when a tip of a special pen touches the upper or outside surface of the X coordinate inputting sheet 1A and presses on it, while at the same time certain voltages are applied between the electrodes 2A and 3A of the X coordinate inputting sheet 1A and 3A and 3B of the Y coordinate inputting sheet 1B, then divided voltages will be produced respectively from said X coordinate inputting sheet 1A and said Y coordinate inputting sheet 1B as X and Y coordinate information.
There is however a problem with such a coordinate inputting system, in that, when a part of the hand or the arm of the operator, such as his or her wrist or elbow, inadvertently touches the upper or outside surface of the X coordinate inputting sheet 1A and presses on it, then this may produce an erroneous reading from this coordinate inputting system. In such a case, the obtained X and Y coordinate information will be a combination of the positional information generated by the tip of the pen, i.e. the correct and desired positional information, and of the positional information generated by this inadvertent user arm pressure, i.e. incorrect and spurious positional information. In such a case, an erroneous input indication may well be produced.
SUMMARY OF THE INVENTION
The inventors of the present invention have considered the various problems detailed above.
Accordingly, it is the primary object of the present invention to provide a coordinate inputting system, which avoids the problems detailed above.
It is a further object of the present invention to provide such a coordinate inputting system, which prevents the production of a spurious or erroneous input indication, if and when the user should inadvertently press upon said coordinate inputting system with an object other than a special pen intended for such pressing, such as by inadvertently resting a part of his or her arm upon said coordinate inputting system.
It is a further object of the present invention to provide such a coordinate inputting system, which can improve the accuracy of positional identification and detection, by detecting when a contact upon said coordinate inputting system other than by the tip of the pen is being produced.
It is further object of the present invention to provide such a coordinate inputting system, which can detect the validity of positional information which is produced.
According to the most general aspect of the present invention, these and other objects are attained by a coordinate inputting system, comprising: a coordinate inputting sheet for detecting an axial coordinate, comprising a sheet body with a resistive surface laid over one of its sides, a pair of mutually substantially parallel edge electrodes extending along opposite edges of said resistive surface and for having voltage applied between them, and a plurality of intermediate electrodes, substantially mutually parallel and substantially parallel to said pair of edge electrodes, and extending along said resistive surface between said pair of edge electrodes in a mutually spaced relationship; a means for processing information by obtaining voltage divided at an input point selected by pen contact against said coordinate inputting sheet as axial coordinate information; a means for storing in advance reference information relating to the voltages on said electrodes when said voltage is applied between said edge electrodes; a means for detecting which of said electrodes straddle the input point by comparing said axial coordinate information obtained from said information processing means with said reference information; and: a means for determining the validity of input operation according to the result of comparison between the voltages upon said electrodes which straddle the input point and said reference information. And, more particularly, said reference information may include the voltages on said electrodes when said voltage is applied between said edge electrodes, and the voltage differences between neighboring ones of said electrodes.
According to such a coordinate inputting system as specified above, in a stage preliminary to the actual operation of inputting coordinates of the input point, a voltage is applied between the edge electrodes, and the voltage levels of said edge electrodes as well as the voltage levels upon the intermediate electrodes are all measured and are stored in the storage means as reference information. Then, when the input point is specified upon the coordinate inputting sheet as for example by the pressure of a special pen thereupon, the means for processing information obtains the voltage divided at said input point as coordinate information. Then, this positional information is compared by the detecting means with the reference information stored in the storage means, and it is detected which of said electrodes straddle the input point. Further, the validity determining means checks the validity of the input operation according to the result of comparison between the voltages upon said electrodes which straddle the input point and said reference information, so as to ensure that, if invalid input such as produced by the pressure of the hand or elbow of the operator is being produced, this circumstance is detected, and an indication of erroneous operation is provided. Thereby, loss of measurement accuracy due to invalid input operation can be prevented, and the production of a spurious or erroneous input indication, if and when the user should inadvertently press upon said coordinate inputting system with an object other than a special pen intended for such pressing, is positively prohibited.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described with respect to the preferred embodiment thereof, and with reference to the illustrative drawings appended hereto, which however are provided for the purposes of explanation and exemplification only, and are not intended to be limitative of the scope of the present invention in any way, since this scope is to be delimited solely by the accompanying claims. With relation to the figures, spatial terms are to be understood as referring only to the orientation on the drawing paper of the illustrations of the relevant parts, unless otherwise specified; like reference numerals, unless otherwise so specified, denote the same parts and gaps and spaces and flow chart steps and so on in the various figures; and:
FIG. 1 is an exploded perspective view showing the physical construction of the preferred embodiment of the coordinate inputting system of the present invention;
FIG. 2 is an equivalent circuit diagram for a pair of switchover circuits constituted by portions of the FIG. 1 construction, in the case that no point upon said construction whose X and Y coordinates are required to be inputted is being pressed, either legitimately by a special pen adapted for doing so or illegitimately by the hand or the elbow (for example) of the user;
FIG. 3 is an equivalent circuit diagram for said pair of switchover circuits constituted by portions of the FIG. 1 construction, similar to FIG. 2, but showing the equivalent circuit in the case that a well defined point upon said construction whose X and Y coordinates are truly required to be inputted is being legitimately pressed as for example by a special pen adapted for doing so;
FIG. 4 is a plan view of the surface of this preferred embodiment of the coordinate inputting system of the present invention, in the case in which both a legitimate contact point P1 between X and Y coordinate inputting sheets thereof whose X and Y coordinates are truly required to be inputted is being pressed by a pen, and also another similar but illegitimate contact point P2 is being pressed, for example inadvertently by the pressure of a hand or elbow of an operator;
FIG. 5 is an equivalent circuit diagram for said pair of switchover circuits constituted by portions of the FIG. 1 construction, similar to FIGS. 2 and 3, but relating to this alternative case that such an additional illegitimate point upon said construction (whose X and Y coordinates are not in fact truly required to be inputted) is being illegitimately pressed, for example by the hand or the elbow of an operator;
FIG. 6 is a partial flow chart for illustrating a portion of a program stored in and obeyed by a micro computer incorporated in said coordinate inputting system, to realize the operation of the preferred embodiment of the coordinate inputting system of the present invention, said program portion being executed at regular and appropriate intervals; and:
FIG. 7, which relates to the prior art and is similar to FIG. 1 relating to the preferred embodiment of the coordinate inputting system of the present invention, shows a prior art type coordinate inputting system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described with reference to the preferred embodiment thereof, and with reference to the figures.
FIGS. 1 through 6 relate to this preferred embodiment of the coordinate inputting system of the present invention, and, as best shown in the exploded perspective view of FIG. 1 and the plan view of FIG. 4, this preferred embodiment comprises an X coordinate inputting sheet 10A for detecting the X coordinate of a point the coordinates of which it is desired to input, and a Y coordinate inputting sheet 10B for detecting the Y coordinate of a point the coordinates of which it is desired to input. The X coordinate inputting sheet 10A comprises a rectangular insulating sheet which is provided with a pair of linear electrodes 12A and 13A laid along two of its opposite edges, and further comprises a resistive surface (not particulary shown) formed on the surface of said rectangular insulating sheet. Similarly, the Y coordinate inputting sheet 10B comprises a rectangular insulating sheet which is provided with a pair of linear electrodes 12B and 13B laid along two of its opposite edges, and further comprises a resistive surface (not particularly shown) formed on the surface of said rectangular insulating sheet. And this X coordinate inputting sheet 10A and this Y coordinate inputting sheet 10B are laid together with their said resistive surfaces confronting one another, and with the pair of linear electrodes 12A and 13A of the X coordinate inputting sheet 10A extending skew perpendicular to the pair of linear electrodes 12B and 13B of the Y coordinate inputting sheet 10B. Further, on the rectangular insulting sheet of the X coordinate inputting sheet 10A there are provided a number of linear intermediate electrodes, nine in number in the shown preferred embodiment although this number thereof is not intended to be limiting, and designated as 11aA, 11bA, . . . 11iA, extending substantially parallel to and between the linear electrodes 12A and 13A thereof at a substantially uniform pitch, thereby dividing the area of said X coordinate inputting sheet 10A which is covered with said resistive surface into ten, in this shown preferred embodiment, strip portions of uniform width. Similarly, on the rectangular insulating sheet of the Y coordinate inputting sheet 10B there are provided a number of linear intermediate electrodes, again nine in number in the shown preferred embodiment although this number thereof is not intended to be limiting, and designated as 11aB, 11bB, . . . 11iB, extending substantially parallel to and between the linear electrodes 12B and 13B thereof at a substantially uniform pitch, thereby similarly dividing the area of said Y coordinate inputting sheet 10B which is covered with said resistive surface into ten, in this shown preferred embodiment, strip portions of uniform width.
During the use of this preferred embodiment of the coordinate inputting system of the present invention, as illustrated in FIG. 1, a voltage E, which conveniently may be approximately 5 volts, is selectively applied either between the linear electrodes 12A and 13A of the X coordinate inputting sheet 10A or between the linear electrodes 12B and 13B of the Y coordinate inputting sheet 10B, according to the selective operation of switches 15 and 16. The two linear electrodes 12A and 13A of the X coordinate inputting sheet 10A and the nine linear intermediate electrodes 11aA, 11bA, . . . 11iA therebetween are terminated in terminals denoted as X0, X1, . . . X10, and similary the two linear electrodes 12B and 13B of the Y coordinate inputting sheet 10B and the nine linear intermediate electrodes 11aB, 11bB, . . . 11iB therebetween are terminated in terminals denoted as Y0, Y1, . . . Y10. These terminals X0 . . . X10 and Y0 . . . Y10 and the other portions of the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B constitute a pair of switchover circuits 17 and 18, an equivalent circuit diagram for which is shown in FIG. 2 together with a schematic block diagram of an information processing circuit unit 19 to which said switchover circuits 17 and 18 are connected. It should be understood that the equivalent circuit diagram shown in FIG. 2 relates to the case that no point upon the preferred embodiment of the coordinate inputting system of the present invention is being pressed in order to indicate a point thereon whose X and Y coordinates are required to be inputted, either legitimately as for example by a special pen adapted for doing so or illegitimately by the hand or the elbow (for example) of the user.
This information processing circuit unit 19 is for producing positional information in terms of an X coordinate and a Y coordinate from voltages divided by an input point on the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B, said input point being defined by the pressure of a pen to said X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B. The information processing circuit unit 19 comprises an A/D converter (analog -digital converter) 20 for converting the thus divided voltages, which are analog quantities, into digital signals, and further comprises a CPU (central processing unit) 21 which receives said digital signals and computes the above defined X coordinate and Y coordinate of the input point according to certain arithmetic processes. This CPU 21 is connected to a memory unit 22 and to an input circuit 23 via a bus, thus constituting a micro computer system of a per se conventional type, further description of which will therefore be omitted. And said micro computer system provides the function of controlling the actions of the switches 15 and 16 and of the switching circuits 17 and 18, the function of detecting the ones for both the X and the Y coordinates of the electrodes 12, 13, and 11a through 11i which bracket the input point, the function of detecting the validity of the input operation, and the function of computing the coordinates.
The memory means 22 comprises a quantity of read only memory (ROM) which permanently stores the programs for the coordinate inputting process and reference information, and also comprises a quantity of RAM (random acess memory) which is used for storing various data which are read as well as various intermediate results. Further, reference information for detecting the ones for both the X and the Y coordinates of the electrodes 12, 13, and 11a through 11i which bracket the input point, and for detecting the validity of the input operation, is stored in this RAM prior to the coordinate inputting operation.
This reference information relates to the voltages on the electrodes 12, 13 and 11a through 11i for both the X and the Y coordinates, i.e. for said X coordinate inputting sheet 10A and said Y coordinate inputting sheet 10B, and FIG. 2, which is illustrates how this reference information for said X coordinate inputting sheet 10A and said Y coordinate inputting sheet 10B is generated. That is, as shown in FIG. 2, first (for example) the switches 15 and 16 are thrown to the "A" side, and then the voltage E is applied across the opposing electrodes 12A and 13A of the X coordinate inputting sheet 10A. In this condition, the electrodes 11aA, 11bA, . . . 11iA are sequentially accessed, and the voltage levels upon all of these electrodes 12A and 13A and these electrodes 11aA, 11bA, . . . 11iA are measured. And, after the voltage differences between the neighboring electrodes are computed by the CPU 21 from the data detected, the voltage levels upon all of these electrodes 12A and 13A and these electrodes 11aA, 11 bA, . . . 11iA and the voltage differences between the neighboring electrodes are stored in the memory means 22. Then next (for example) the switches 15 and 16 are thrown to the "B" side, and then the voltage E is applied across the opposing electrodes 12B and 13B of the Y coordinate inputting sheet 10B. In this condition, the electrodes 11aB, 11bB, . . . 11iB are similarly sequentially accessed, and the voltage levels upon all of these electrodes 12B and 13B and these electrodes 11aB, 11bB, . . . 11iB are measured. And, after the voltage differences between the neighboring electrodes are computed by the CPU 21 from the data detected, the voltage levels upon all of these electrodes 12B and 13B and these electrodes 11aB, 11bB, . . . 11iB and the voltage differences between the neighboring electrodes are again stored in the memory means 22.
FIG. 3 is an equivalent circuit diagram for said pair of switchover circuits constituted by portions of the FIG. 1 construction, similar to FIG. 2, but showing the equivalent circuit in the case that a well defined point upon said construction whose X and Y coordinates are truly required to be inputted is being legitimately pressed as for example by a special pen adapted for doing so. At this time the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B are being brought into mutual contact at certain definite points thereof. In particular, in FIG. 3, the reference numerals 14A and 14B denote the resistive surfaces of the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B respectively, and the points thereof which are in mutual contact are respectively denoted as PA and PB. And the contact resistance between these contact points PA and PB is denoted as 24, while the current value flowing through the resistive surfaces 14A and 14B is denoted as i. In the particular illustrative case shown in FIG. 3, the ones 11dA and 11eA of the intermediate electrodes 11aA . . . 11iA on the X coordinate inputting sheet 10A, which are respectively connected to the terminals X4 and X5, are the ones which bracket the point PA of contact of said X coordinate inputting sheet 10A against the Y coordinate inputting sheet 10B. Similarly, the ones 11fB and 11gB of the intermediate electrodes 11aB . . . 11iB on the Y coordinate inputting sheet 10B, which are respectively connected to the terminals Y6 and Y7, are the ones which bracket the point PB of contact of said Y coordinate inputting sheet 10B against the X coordinate inputting sheet 10A. Thus, when the switches 15 and 16 are selected to their A sides as shown in FIG. 3, the voltage E which is being applied between the electrodes 12A and 13A of the X coordinate inputting sheet 10A is divided by this input point PA, and this voltage is brought out from the intermediate electrode 11gB when the switching circuit 18 selects the terminal Y7 which is connected to said intermediate electrode 11gB. If there are altogether a number n of parts into which the resistive surface of the Y coordinate inputting sheet 10B is divided by the intermediate electrodes 11aB . . . 11iB, then the resistance between the point PB of contact of said Y coordinate inputting sheet 10B against the X coordinate inputting sheet 10A and the closest one of said intermediate electrodes 11aB . . . 11iB is at most 1/2n of the total resistance of said resistive surface of the Y coordinate inputting sheet 10B. Thereby, the input resistance of the A/D converter 20 is kept low, and the margin of error in the A/D conversion process performed thereby can be minimized.
In the particular illustrative case shown in FIG. 3, the ones 11dA and 11eA of the intermediate electrodes 11aA . . . 11iA on the X coordinate inputting sheet 10A, which are respectively connected to the terminals X4 and X5, are the ones which bracket the point PA of contact of said X coordinate inputting sheet 10A against the Y coordinate inputting sheet 10B. And the switching circuit 17 sequentially selects the ones X4 and X5 of the terminals which are connected to said intermediate electrodes 11dA and 11eA so that the voltage levels upon said intermediate electrodes 11dA and 11eA can be read out by the A/D converter 20, as will be described hereinafter in greater detail. Since the point of contact between the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B occurs at the point PA, the same current I flows through the resistive surface 14A before and after the pen contact, and therefore there are no changes in the voltages at the terminals X4 and X5. Here, it is assumed that the input impedance of the A/D converter 20 is sufficiently higher than the resistance of the resistive surface 14A, and that the current flowing into or out of the A/D converter 20 is negligibly small, as compared with the current i which flows through the resistive surfaces 14A and 14B.
Now, in FIG. 4, there is shown the surface of this preferred embodiment of the coordinate inputting system of the present invention in the case in which not only is there a legitimate contact point P1 between the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B which is being caused by the pressure of the pen for inputting X and Y coordinates as before, but also, additionally, there is another illegitimate contact point P2 between said X coordinate inputting sheet 10A and said Y coordinate inputting sheet 10B which is being caused for example by the pressure of a hand or elbow of an operator. And FIG. 5 shows an equivalent circuit diagram for the pair of switchover circuits. This figure is similar to FIGS. 2 and 3, but relates to this alternative case that such an additional illegitimate point upon said construction, whose X and Y coordinates are not in fact truly required to be inputted, is being illegitimately pressed. In this case, the two separated points of said resistive surfaces 14A and 14B of said X coordinate inputting sheet 10A and said Y coordinate inputting sheet 10B which are in mutual contact are respectively denoted as P1A and P2A, and P1B and P2B.
In the illustrated state, the current i' which flows into the resistive surface 14A of the X coordinate inputting sheet 10A additionally flows to the Y coordinate inputting sheet 10B from the input point P1A, and between the two input points P1A and P2A a current designated as i2 flows into the X coordinate inputting sheet 10A, while a current designated as i1 flows into the Y coordinate inputting sheet 10B. In other words, the resistance between the two input points P1A and P2A becomes lower than it was before the contacts took place, and the current i' through the X coordinate inputting sheet 10A is greater than when there is no contact, or when there is only one point of contact.
Thus, when there are two points of contact between the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B, an intermediate point P3 between the two points of contact P1A and P2A appears to be the actual point of contact, and the divided voltage at this apparent point of contact P3 is given as a combination of the voltages at the two actual points of contact P1A and P2A. In the illustrated example, the apparent input point P3 is interposed between the intermediate electrodes P1A and P2A (the terminals X3 and X4), and then the voltage difference between the intermediate electrodes 11cA and 11dA becomes less than when there is no contact or when there is only one point of contact between the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B, because the current i' is divided into the two currents i1 and i2 between the input points P1A and P2A.
Thus, according to the present invention, by measuring the voltage difference between these electrodes, and by comparing the measured voltage with a voltage difference value included in the reference information, the existence of two separate points of contact on the surface of the preferred embodiment of the coordinate inputting system of the present invention, in other words the illegitimacy of the current inputting operation, is detected.
Now, in FIG. 6, a fragmentary flow chart is shown for a portion of the control program which directs the operation of the micro computer incorporating the CPU 21, according to the preferred embodiment of the coordinate inputting system of the present invention, so as to realize its function. The flow chart of FIG. 6 only shows a portion of the control program of the micro computer, and is executed at suitably spaced regular intervals. The intimate programming details relating to this FIG. 6 flow chart will not be particularly described herein in detail, because the details thereof can be easily supplemented by one of ordinary skill in the programming art based upon the functional disclosures set out in this specification. This flow chart will now be explained.
First, before the START block of the FIG. 6 flow chart, the switching circuits 17 and 18 sequentially access the terminals X0 through X10 and Y0 through Y10, while the voltage E is applied alternately across the electrodes 12A and 13A of the X coordinate inputting sheet 10A, and across the electrodes 12B and 13B of the Y coordinate inputting sheet 10B. And during this process the voltages upon the opposing electrodes 12B and 13B, and 12A and 13A, as well as the voltages upon the terminals X0 through X10 and Y0 through Y10, are read out; and the voltage differences between the neighboring pairs of electrodes are computed by the CPU 21. Since the positions of the intermediate electrodes 11aA through 11iA between the electrodes 12A and 13A on the X coordinate inputting sheet 10A, and of the intermediate electrodes 11aB through 11iB between the electrodes 12B and 13B on the Y coordinate inputting sheet 10B, are known, these voltages and voltage differences can be stored in the memory 22 as reference information, using the positions, for example, as addresses.
Now, when upon the completion of the above described preliminary process an input point is indicated to this preferred embodiment of the coordinate inputting system of the present invention by a special pen being used to press upon the surface thereof, for the first time the results of the decisions in the decision steps ST1 and ST2 of the FIG. 6 flow chart both are YES, and the flow of control passes to the step ST3. In this step ST3, the CPU 21 turns both of the switches 15 and 16 to their A positions, and causes the switching circuit 18 to select the terminal Y5; and then the flow of control passes next to the step ST4. As a result of this step, the divided voltage of the input point PA on the X coordinate inputting sheet 10A is produced from the intermediate electrode 11eB which is located in the middle of the Y coordinate inputting sheet 10B, as X coordinate positional information. Then, as the switches 15 and 16 are thrown to their B positions, and the switching circuit 18 is caused to select the terminal X5, the divided voltage of the input point PB on the Y coordinate inputting sheet 10B is produced from the intermediate electrode 11eA which is located in the middle of the X coordinate inputting sheet 10A, as Y coordinate positional information.
These divided voltages are converted into digital signals by the A/D converter 20, and are supplied to the CPU 21. This CPU 21 then, in the step ST4, determines which of the electrodes it is that straddle the input point, for each of the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B, by comparing the obtained data with the voltages on the intermediate electrodes 11a through 11i of that inputting sheet which are stored in the memory means 22. Further, by controlling the switching circuits 17 and 18 sequentially to select the terminals corresponding to the respective electrodes, the CPU 21 detects the voltage on each of the electrodes and the voltage differences between each pair of neighboring electrodes, and stores the measured results in the memory means 22. Then the flow of control passes next to the step ST5.
In the next step ST5, the CPU 21 compares the voltage difference between the pairs of the electrodes which straddle the input point, obtained in the step ST4, with the corresponding voltage difference included in the memorized information stored in the memory means 22, and then the flow of control passes next to the decision step ST6. When the difference is less than a certain threshold level, then in this decision step ST6 a decision is made that the input point is a valid input point due to a single point contact of the pen, and in this case the flow of control passes next to the step ST7. On the other hand, if this difference is greater than said certain threshold level, then in this decision step ST6 a decision is made that the input point is not a valid input point, being due to a two or more point contact, and is therefore due to, for example, the pressure of the arm or elbow of the user as well as perhaps being due to a single point contact of the pen, and in this erroneous case the flow of control passes next to the step ST11. In this step ST11, the system emits a warning to the user as for example by sounding a buzzer or the like, so as to notify said user that his or her input is invalid, and in this case the CPU 21 either terminates the input coordinate measuring process or suspends the output of the measurement results of coordinate measurement.
However, if the result of the decision in this step ST6 is in fact YES, so that it is decided that the input operation is currently a valid one, then in the next step ST7 the CPU 21 determines, both for the X coordinate inputting sheet 10A and for the Y coordinate inputting sheet 10B, which of the intermediate electrodes 11a through 11i of said sheet is the closest to the input point, by comparing the divided voltage data obtained in the step ST3 with the voltages of the intermediate electrodes 11a through 11i that are stored in the memory means 22; and these determined upon electrodes are designated as so called divided voltage tapping electrodes. In the following, it will be assumed that the one of the electrodes for the X coordinate inputting sheet 10A which is the determined upon divided voltage tapping electrode is 11dA and the one of the electrodes for the Y coordinate inputting sheet 10B which is the determined upon divided voltage tapping electrode is 11gB. The CPU 21 throws the switches 15 and 16 to their A positions, and accesses the terminal Y7 of the switching circuit 17, which corresponds to the intermediate electrode 11gB. And, thus, the divided voltage of the input point B on the Y coordinate inputting sheet 10B is tapped from the intermediate electrode 11dA of the X coordinate inputting sheet 10A as X coordinate positional information. These divided voltages are converted into digital signals by the A/D converter 20 and are supplied to the CPU 21. Then the flow of control passes next to the decision step ST8.
In this decision step ST8, the CPU 21 finds the difference between the read out data and the data determined in the step ST3, and makes a decision as to the validity of said read out data by evaluating if this difference is greater than a certain threshold value or not. If the result of this decision is YES, so that the read out data is in fact valid, then the flow of control passes next to the step ST9; but, if the result of this decision is NO, so that the read out data is not in fact valid, then the flow of control passes next to the decision step ST10. In other words, in this step it is determined as to whether or not the point of the pen is in a stationary stable state, during pen input operation.
In the step ST9, the CPU 21 computes the X and the Y coordinates of the input point from the voltages on those of the intermediate electrodes which straddle said input point and which were determined in the step ST4, and from the divided voltage as determined in the step ST7. Then these X and Y coordinates are output as the final coordinate positional information for the input point, and then the flow of control passes next to leave this program portion, without doing anything further. On the other hand, in the decision step ST10, a decision is made as to whether or not the pen is still in contact with the surface of the preferred embodiment of the coordinate inputting system of the present invention. If the result of this decision is YES, so that indeed the pen is still in contact, then the flow of control passes next to the step ST7 again, to repeat the previous determination of the divided voltage tapping electrode; but, if the result of this decision is NO, so that the pen is no longer in contact, then the flow of control passes next to the decision step ST1 again, i.e. repeats this entire program fragment once again. Thus, this flow of control transfer occurs if the pen point has been moved away from the surface of the preferred embodiment of the coordinate inputting system of the present invention, without any affirmative decision result having occurred in the step ST8, and then the flow of control returns to the step ST1 and the system waits for a resumption of input operation.
According to the above operation, since the resistance of the resistive surfaces of the X coordinate inputting sheet 10A and the Y coordinate inputting sheet 10B between the input point and the divided voltage tapping electrodes is relatively small, and the input resistance of the A/D converter 20 is relatively small, the change in the input resistance due to changes in the location of the input point and the conversion error due to the operation of the A/D converter 20 are thereby minimized.
Thus, according to such a coordinate inputting system as described above, in a stage preliminary to the actual operation of inputting coordinates of the input point, a voltage is applied between the edge electrodes, and the voltage levels of said edge electrodes as well as the voltage levels upon the intermediate electrodes are all measured and are stored in the storage means as reference information. Then, when the input point is specified upon the coordinate inputting sheet as for example by the pressure of a special pen thereupon, the means for processing information obtains the voltage divided at said input point as coordinate information. Then, this positional information is compared by the detecting means with the reference information stored in the storage means, and it is detected which of said electrodes straddle the input point. Further, the validity determining means checks the validity of the input operation according to the result of comparison between the voltages upon said electrodes which straddle the input point and said reference information, so as to ensure that, if invalid input such as produced by the pressure of the hand or elbow of the operator is being produced, this circumstance is detected, and an indication of erroneous operation is provided. Thereby, loss of measurement accuracy due to invalid input operation can be prevented, and the production of a spurious or erroneous input indication, if and when the user should inadvertently press upon said coordinate inputting system with an object other than a special pen intended for such pressing, is positively prohibited.
Conclusion
Although the present invention has been shown and described in terms of the preferred embodiment thereof, and with reference to the appended drawings, it should not be considered as being particulary limited thereby, since the details of any particular embodiment, or of the drawings, could be varied without, in many cases, departing from the ambit of the present invention. Accordingly, the scope of the present invention is to be considered as being delimited, not by any particular perhaps entirely fortuitous details of the disclosed preferred embodiment, or of the drawings, but solely by the scope of the accompanying claims, which follow. | In this coordinate inputting system, a coordinate inputting sheet is provided for detecting an axial coordinate, and this includes a sheet body with a resistive surface laid over one of its sides, a pair of mutually substantially parallel edge electrodes extending along opposite edges of this resistive surface which are for having voltage applied between them, and several intermediate electrodes, substantially mutually parallel and substantially parallel to the pair of edge electrodes, and extending along the resistive surface bewteen the pair of edge electrodes in a mutually spaced relationship. Also, there are provided a device for processing information by obtaining voltage divided at an input point selected by pen contact against the coordinate inputting sheet as axial coordinate information, a device for storing in advance reference information relating to the voltages on the electrodes when the voltage is applied between the edge electrodes, a device for detecting which of the electrodes straddle the input point by comparing the axial coordinate information obtained from the information processing device with the reference information, and a device for determining the validity of input operation according to the result of comparison between the voltages upon the electrodes which straddle the input point and the reference information. Optionally, the reference information may include the voltages on the electrodes when the voltage is applied between the edge electrodes, and the voltage differences between neighboring ones of the electrodes. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. Application Ser. No. 10/273,430, filed Oct. 18, 2002, now abandoned, which is a continuation application of U.S. application Ser. No. 09/542,999, filed Apr. 4, 2000, now U.S. Pat. No. 6,514,084, which is a continuation application of U.S. application Ser. No. 09/253,851, filed Feb. 22, 1999, now U.S. Pat. No. 6,086,382, which is a continuation application of U.S. application Ser. No. 08/810,547, filed on Mar. 3, 1997, now U.S. Pat. No. 5,885,087, which is a continuation application of U.S. application Ser. No. 08/315,976, filed on Sep. 30, 1994 and now U.S. Pat. No. 5,618,182, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a computerized learning approach, and more particularly, to a method and apparatus for improving performance on multiple-choice exams.
2. Description of the Related Art
Multiple-choice examinations are very common today. These examinations typically test a set of predetermined subject areas and are usually time limited. One's performance on these exams is very important.
The Multistate Bar Examination (MBE) is a particular multiple-choice exam for which this invention was developed. The MBE is a rigorous multiple-choice examination which tests six substantive areas of law in a time limited manner. The MBE forms a significant portion of the bar examination for most of the states in the United States. The ability of the test-takers to achieve a passing score on this portion of the bar examination is critical. It is the difference between being able to practice law in a particular state, and not. Consequently, those who desire to pass the bar examination spend a great deal of time studying for the MBE.
Known study approaches make use of written materials and rely on a user's discipline and drive to keep them working. Several bar review courses provide potential examinees with workbooks which provide several hundred practice questions that the user can work through as he/she sees fit. At the back of these workbooks are contained answers and explanations for the questions.
A major problem with these known and traditional approaches is that they do not, and cannot, force the user to study in a consistent, systematic and effective way. As a result, users typically study in a haphazard way which varies with their mood, desire and drive. The danger with these conventional approaches is that user's tend not to develop a consistent problem-solving approach, but instead develop and utilize inefficient and undesirable study habits. Another serious problem is that users also tend not to fully understand a question, and why one answer choice is correct, while the other answer choices are incorrect.
Thus, there is a need for a system which offers greater efficiency and effectiveness by requiring the user to study in a consistent and systematic way.
SUMMARY OF THE INVENTION
Broadly speaking, the invention relates to a computerized learning approach that enables a user to improve performance on multiple-choice exams.
A first aspect of the invention concerns a computerized learning method which forces a user to continue attempting to answer a question until the user has selected the correct answer choice. This aspect can be implemented by a computerized learning method which displays a question and a plurality of answer choices on a display screen, awaits the user's selection of one of the answer choices, compares the selected answer choice with a predetermined correct answer choice for the question, and subsequently awaits selection of another one of the answer choices when the selected answer choice is not the correct answer choice. Alternatively, the method can force the user to indicate whether each of the answer choices are correct or incorrect.
Another aspect of the invention concerns a computerized learning method which displays an elapsed time for the user to select an answer choice for the question. This enables the user to monitor and evaluate his/her time performance on practice questions for the multiple choice exam. This aspect of the invention can be implemented by a computerized learning method which displays a question and a plurality of answer choices on a display screen, enables a timer to monitor a time duration for the user to answer the question, awaits selection of one of the answer choices by the user, displays a visual indication of the time duration, stops the time duration timer when one of the answer choices is selected, and determines whether the selected answer choice is the correct answer choice for the question. Further, a visual indication of a predetermined time may be displayed together with the visual indication of the time duration.
Yet another aspect of the invention provides the user with assistance so that the user can better understand the question to be answered or the knowledge needed to answer the question. This aspect can be implemented in one or a combination of the following ways. Typically, however, this aspect is invoked only when the answer choice selected by the user is not the correct answer choice. A first implementation provides the user with a hint towards the correct answer choice. A second implementation displays, for the user, substantive information relevant to answering the question. A third implementation displays an explanation of the correct answer choice once the user has selected the correct answer choice.
Still another aspect of the invention concerns a computerized learning method which provides detailed performance information to the user. For example, the invention can plot the time duration for each question or set of questions to produce a graph on a display screen. The graph may also include a visual indication of a predetermined time duration. Another example is that the invention can plot the percentage of correctness to produce a graph on the display screen. Here, the graph may also indicate a visual indication of a target percentage. The can also predict the user's future performance using the thus far obtained performance data on the user.
The invention can also be implemented as an apparatus to improve a user's performance on multiple-choice exams. The apparatus includes a computer having a display screen associated therewith, and a computer program executed by the computer. The computer program includes at least means for displaying a question and a plurality of answer choices on the display screen, means for awaiting selection of one of the answer choices by the user, means for determining whether the selected answer choice is the correct answer choice for the question, and means for awaiting selection of another one of the answer choices when the selected answer choice is not the correct answer choice.
Another apparatus implementing the invention concerns a computer diskette. The computer diskette includes practice questions for a multiple-choice exam, correct answers for the practice questions, and a stored computer program for improving performance on the multiple-choice exam.
When the computer program is executed by a computer, the program operates to carry out any aspects of the methods discussed above. The computer diskette can also include hints for each of the practice questions, specific topic identifiers for each of the questions; and a substantive outline containing detailed information on at least one area of knowledge being tested by the multiple-choice exam.
The invention forces test-takers to practice their examination skills and subject matter knowledge in a systematic way. The systematic way forces the users to follow a proven problem-solving approach designed to improve their performance. Additionally, the invention provides important performance feedback to user's, for example, elapsed time per question and percentage of correctly answered questions. The invention can also pinpoint for the user the substantive areas of the exam which the user is either weak or strong. Further, the invention is able to assist the user in predicting his/her eventual score.
The various aspects of the invention discussed above may also be combined in various ways to produce additional implementations of the invention. In addition, other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principals of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like elements, and in which:
FIG. 1 is a block diagram of an embodiment of an apparatus according to the invention;
FIGS. 2A and 2B are block diagrams of a first embodiment of a learning method according to the invention;
FIG. 3 is a block diagram of a substantive information routine according to the invention;
FIG. 4 is a block diagram of a performance evaluation routine according to the invention;
FIGS. 5A , 5 B and 5 C are graphs illustrating a user's performance;
FIG. 6 is a block diagram of a second embodiment of a learning method according to the invention; and
FIGS. 7A and 7B are block diagrams of a third embodiment of a learning method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention are discussed below with reference to FIGS. 1-7B . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments.
FIG. 1 is a block diagram of an embodiment of an apparatus according to the invention. The apparatus 2 includes a computer 4 , a display screen 6 , an input device 8 , and a memory 10 . The memory 10 provides storage for an operating system 12 , a learning program 14 , practice questions 16 , user's performance information 18 , and miscellaneous information 20 .
The computer 4 is preferably a microcomputer, such as a desktop or notebook computer. However, the computer 4 could also be a larger computer such as a workstation or mainframe computer. The computer 4 could also be remotely located from the user who would interact with the computer over a network.
The memory 10 is connected to the computer 4 . The memory 10 can consist of one or more of various types of data storage devices, including semiconductor, diskette and tape. In any case, the memory 10 stores information in one or more of the various types of data storage devices. The computer 4 of the apparatus 2 implements the invention by executing the learning program 14 . While executing the learning program 14 , the computer 4 retrieves the practice questions 16 from the memory 10 and displays them to the user on the display screen 6 . The user then uses the input device 8 to select an answer choice for the question being displayed. When the learning program 14 is executed by the computer 4 , a learning method according to the invention is carried out. The details of various learning methods associated with the learning program 14 are described in detail below in FIGS. 2A , 2 B, 3 , 4 , 6 , 7 A and 7 B.
The learning method according to the invention will cause performance information 18 and miscellaneous information 20 to be produced. The performance information 18 may, for example, include a correct/incorrect indicator and an elapsed time for each question or set of questions. The performance information 18 may also include a subject and a topic for each question. The miscellaneous information 20 can include any additional data storage as needed by the computer 4 , e.g., various flags and other values which indicate options selected by the user or indicate user's state of progress. The user's performance information 18 and miscellaneous information 20 are stored to, or retrieved, from the memory 10 as needed by the computer 4 . The operating system 12 is used by the computer 4 to control basic computer operations. Examples of operating systems include Windows, DOS, OS/2 and UNIX.
FIGS. 2A and 2B are block diagrams of a first embodiment of a learning method according to the invention. The learning method 22 begins by displaying 24 a question and a plurality of answer choices to a user. For example, the question and its answer choices can be retrieved from the various practice questions 16 stored in the memory 10 and then displayed on the display screen 6 . Preferably, the question and its answer choices are very similar to the questions and answers which actually appear on the MBE. It is also preferable that the questions and answers be displayed in a format and font which are very close to those used in the MBE. The closer the appearance and the format of the question and its answer to that of the MBE, the more comfortable the user will be on the actual MBE exam.
Once the question and its answer choices are displayed 24 , a question timer is started 26 . The question timer operates to keep track of the amount of time elapsed from the time the question was displayed until the user selects an answer choice. Due to the fact that the MBE is a severely time limited exam, keeping track of the users time performance for each question is very important. As the question timer monitors the elapsed time, a visual indication of the elapsed time is displayed 28 . For example, a digital stopwatch, a bar graph, or some other graphical technique could be displayed 28 on the display screen 6 to provide a visual indication of the elapsed time to the user. By displaying 28 a visual indication of the elapsed time, the user becomes sensitized to the amount of time he/she spends to answer questions and how he/she is doing time-wise with respect to a predetermined duration of time. Alternatively, an audio signal could be used with reduced effectiveness. The visual indication of the elapsed time is far superior to an audio signal because the user is able to see the elapsed time as he/she attempts to determine the correct answer choice for the question.
Next, a decision 30 is made based on whether the user has selected an answer choice for the question. If the user has not yet selected an answer choice, the learning method 22 awaits the user's selection while periodically updating the visual indication of the elapsed time being displayed 28 . Once the user has selected an answer choice for the question, the question timer is stopped 32 . The question timer is stopped at this time so that only the time for the user to select his/her first answer choice is measured.
A decision 34 is then made based on a comparison of the selected answer choice and a predetermined answer choice for the question. If the selected answer choice is not the correct answer choice (that is, the selected answer choice does not equal the predetermined answer choice), then the learning method 22 forces the user to keep working on the question. Initially, the learning method 22 displays 36 a hint towards the correct answer choice. For example, a hint for the particular question could be retrieved from the memory 10 and displayed on the display screen 6 for the user. The hint might identify the issue or state the appropriate rule of law for the question. Next, the learning program 22 again awaits the user's selection 38 of another answer choice. Preferably, the learning method 22 prevents the user from selecting an answer choice he/she already incorrectly selected.
Once the user selects 38 another answer choice, a decision 40 is made based on a comparison of the selected answer choice and the predetermined answer choice for the question. If the selected answer choice is still not the correct answer choice, then the learning method 22 again forces the user to keep working on the question. However, for the next go around, the learning method 22 may provide additional assistance to the user by displaying 42 (or provide the option of displaying) substantive information relevant to the question. For example, the substantive information could be a portion of a substantive outline of a subject of the MBE. The portion would be the portion of the outline which discussed the rules of law the user needs to understand and correctly answer the question.
In any case, once the user selects the correct answer choice (after block 34 or 40 ), an explanation of the correct answer choice is displayed 44 . By displaying such information to the user, the user is encouraged to verify that his/her reasoning for choosing the correct answer choice was correct, or if his/her reasoning was incorrect, to help the user understand the proper approach to the question.
Next, a decision 46 is made based on whether a question set is complete. Although not previously mentioned, the questions are preferably presented to the user in sets of questions. Preferably, a set could include about fifteen questions. The user is required to work through at least one entire question set in a single sitting. This forces the user to concentrate on the questions and the problem-solving approach for a reasonable period of time (typically 30-60 minutes), even if the user works through a single set. Using sets of questions also helps to balance users' performance parameters over the set. Users' performance parameters tend to be fairly consistent over a reasonable sized set, whereas question by question the parameters tend to have large variations. In this regard, if the question set is not yet complete, the learning method 22 will reset the question timer 48 and return to the beginning of the method 22 to display a next question of the question set. On the other hand, once the question set is complete, the learning method 22 is completed, at least for the given question set.
FIG. 3 is a block diagram of a substantive information routine according to the invention. The substantive routine 49 is performed by the computer 4 to display 42 substantive information relevant to the question as shown in FIG. 2 B. The substantive routine 49 begins by identifying a subject and topic for the question. The topic is preferably a heading section within a substantive legal outline for a particular subject of the MBE. For example, the substantive information for a question concerning contract law might have topics such as assignment, statue of fraud, acceptance, etc.
After the subject and topic are identified 50 for the question, the computer 4 searches 52 the substantive information for the topic. For example, the contracts legal outline could be searched for the heading “assignment” using known word searching techniques. Alternatively, the searching 52 could be performed by a table look-up into a table containing information on the location of topics within the outline. A portion of the substantive information pertaining to the topic is then displayed 54 . For example, the portion could be the information in the contracts legal outline in the section identified by the heading “assignment”. Preferably, in a Windows environment, a separate viewing window would be opened to contain the portion of the outline, and the question and answer choices would be displayed concurrently with the outline viewing window. It is also preferable that the displayed substantive information (e.g., portion of legal outline) have the same format and font as the printed outline which the user has available for studying.
A decision 56 is then made based on whether the question has been is answered correctly or the user has requested removal of the portion of the outline being displayed. Once the substantive routine 49 determines 56 that the question has been answered correctly or the user has requested removal of the window displaying the portion of the outline, the substantive routine 49 removes 58 the display 54 of the substantive information. Otherwise, the displayed 54 substantive information remains so that the user can read the pertinent portion of the outline and scroll to other sections if so desired.
FIG. 4 is a block diagram of a performance evaluation routine according to the invention. As the user works through the learning method 22 , performance information 18 is routinely saved by the computer 4 to the memory 10 . At the end of a question set, the performance evaluation routine 60 would enable a user to display performance information to the user in a useful way to enable the user to understand his/her performance. Specifically, the performance evaluation routine 60 begins by displaying 62 the question number, elapsed time, a correct/incorrect indicator, and subject and topic categories for each question in the question set. For example, the displayed information might be displayed in a table such as Table I below.
TABLE 1
Question No.
Subject
Topic
Result
Time
1
Evidence
Hearsay
Correct
3:21
2
Contracts
Assignment
Incorrect
1:38
3
Contracts
Acceptance
Correct
2:20
.
.
.
.
.
.
.
.
.
.
.
.
15
CrimLaw
Battery
Correct
1:58
Next, a percentage of questions in the question set which were answered correctly is computed and displayed 64 . For example, if the user answers eight of the fifteen questions correctly, the percentage displayed would be 53.33%. This percentage is useful to the user because the user can directly compare his/her set percentage with the percentage the user eventually desires to achieve on the MBE, which is usually at least 65% and typically between 70 and 75%. An average elapsed time for the user to answer the questions in the question set is also be computed and displayed 64 .
A decision 66 is then made based on whether the user desires to eliminate the correctly answered questions from the master questions set. Although this decision may be made mandatory to prevent the user from repeating questions and thereby polluting his/her performance data, the decision 66 is shown here as being the user's choice. If the user desires to eliminate the correctly answered questions from the set, then the questions answered correctly are disabled 68 . This disabling 68 can be achieved by setting an enable/disable flag associated with each of the questions. Such flags are located in the memory 10 , e.g., with the practice questions 16 or the miscellaneous storage 20 . Nevertheless, the questions which have not been answered correctly can be repeated in a review mode, but are preferably not repeated in the practice or study mode, as such would corrupt the user's performance data.
Thereafter, a decision 70 is made based on whether the user desires to view his/her performance history. Here, the computer 4 makes use of the performance data 18 for each question or set of questions to produce elaborate performance feedback to the user. If the user desires to view his/her performance history, the user's performance history is displayed 72 . Although the performance data could be displayed in tables, preferably, graphical presentations are made. For example, (i) graphs of users time verses question set or (ii) correctness verses question set can be displayed as shown in FIGS. 5A and 5B , respectfully. FIG. 5A is a graph 74 illustrating average elapsed time per question for a set. A target elapsed time value 76 is also depicted to provide the user with a reference for their desired performance. FIG. 5B is a graph 78 illustrating average correctness (as a percentage) for a set. A target correctness percentage 80 is also depicted to provide a reference for their desired performance. The graphs 74 , 78 are produced by plotting the average elapsed time and a percentage of correctness for the question sets the user has completed. The plotted points can be connected together with line segments. Alternatively, bar graphs could be used.
In any case, these graphs 74 , 78 allow the user to see just how his/her performance is improving. Namely, the user can see the target values for each performance measure (time, correctness) and how they are fairing and whether their performance is improving, worsening or stable. Although graphs 74 , 78 primarily pertain to overall values, similar graphs can also be produced by subject or topic so as to inform the user if certain of the subject areas or topics of the exam are hurting his/her overall performance. In fact, the graphs of several subjects or topics can be simultaneously shown to the user. For example, the average time and average correctness for each of the subjects of the exam could be simultaneously placed on graphs 74 , 78 using different colors or other visually distinguishing marks. Such graphs 74 , 78 would also inform the user of the user's relative performance by subject or topic.
The invention can also be used to predict the user's performance. In particular, the invention can determine and display a user's rate of performance improvement, overall or set to set. This rate would provide the user with some indication as to how his/her performance will improve with future sets. Alternatively, the invention can use the acquired performance data 18 on the user to extrapolate out a general trend of his/her performance to determine if he/she is on track to meet the goals. In this regard, a line or curve of best fit for the user could be computed using known methods and displayed for the user. FIG. 5C is a graph 81 of a curve which uses the user's performance data for sets 1 - 5 to extrapolate out an estimated future performance of the user. Note that in computing the extrapolated curve it is preferable to use a maximum value for the performance measure. Using a maximum value prevents the extrapolated curve from being overly biased by inconsistent performance data, particularly when only a few set of questions have been answered. The maximum values are statistical approximations of users' maximum performance values, preferably about 75% for correctness and about 1.5 minutes for elapsed time. From the graph 81 in FIG. 5C , the user will understand that based on his/her performance so far that to meet the target correctness percentage 80 at least 11 sets will need to be completed.
FIG. 6 is a block diagram of a second embodiment of a learning method according to the invention. The learning method 82 in this embodiment forces the user to indicate whether each of the answer choices is correct or incorrect. By forcing the user to consider all the answer choices, the learning method makes the user practice the problem-solving approach employed by most exam takers, namely to make an educated guess at the correct answer after eliminating answer choices known to be incorrect.
In any case, the learning method 82 begins by displaying a question and a plurality of answer choices. Next, the user chooses 86 one of the answer choices. The learning method 82 then asks the user to indicate 88 whether the chosen answer choice is the correct answer choice. Note, here the user can select any of the answer choices, not just the correct answer choice, and thereafter, indicate whether it is correct or incorrect.
If the user indicates that the selected answer choice is a correct answer, a decision 90 is made based on whether the selected answer choice is the correct answer choice. On the other hand, if the user indicates that the selected answer choice is an incorrect answer, a decision 92 is made based on whether the selected answer choice is not the correct answer choice.
When either decision 90 , 92 is answered in the affirmative, then a correct message is displayed 94 to the user. Alternatively, when either decision 90 , 92 is answered in the negative, then an incorrect message is displayed 96 to the user. Following either block 94 or block 96 , the learning method 82 displays 98 an explanation indicating why the selected answer choice is the correct/incorrect answer choice, thereby allowing the user to confirm the reasoning or analysis behind his/her answer choice.
Thereafter, a decision 100 is made based on whether all the answer choices have been selected by the user. If not, blocks 86 - 98 of the learning method 82 are repeated until all the answer choices have been selected, thereby forcing the user to indicate whether each of the multiple answer choices is either correct or incorrect. Once all the answer choices have been selected, a decision 102 is made based on whether the question set is complete. If the question set is not yet completed, then the learning method 82 returns to block 84 where the next question and answer choices are displayed for a user according to the learning method 82 . On the other hand, if the question set is complete, then the learning method 82 is completed.
FIGS. 7A and 7B are block diagrams of a third embodiment of a learning method according to the invention. In this embodiment, the learning method 104 sequences through the answer choices prompting the user to indicate whether he/she believes the answer choice to be correct or incorrect. The user can also answer “unsure” if the user cannot make an educated guess at the present time.
The learning method 104 begins by displaying 106 a question and a plurality of answer choices to the user. Next, a selected answer (SA) is set 108 to “A”, indicating a first answer choice. The learning method 104 then prompts the user to decide 110 whether SA is the correct answer choice. If the user answers in the affirmative, then block 112 is performed. Block 112 represents blocks 90 and 94 - 98 shown in FIG. 6 . On the other hand, if the user answers negatively, then block 114 is performed. Block 114 represents blocks 92 - 98 shown in FIG. 6. A third option is also available to the user. If the user is unsure as to whether or not SA is the correct answer choice, the user can skip the answer choice.
Thereafter, the learning method 104 performs similar processing for the remaining answer choices. Namely, the selected answer (SA) is set 116 , 120 , 124 to the other answer choices and the user is prompted for a decision 118 , 122 , 126 just as was done for the first answer choice. Blocks 112 , 114 are also used in the same manner for each of the answer choices.
Once all the answer choices have been processed (answered or skipped), then the same process repeats 128 for the answer choices which the user may have skipped. The process repeats 128 until the user indicates whether each answer choice is correct or incorrect. Hence, skipping answer choices simply delays the decision because the learning method will prompt the user for an answer. After all the answer choices have been indicated as being correct or incorrect, a decision 130 is made based on whether the question set is complete. If the question set is not yet complete, the learning method 104 returns to block 106 to process the next question in the same manner. When the question set is eventually completed, the learning method 104 is completed.
Although not shown, the second and third embodiments of the learning method (like the first embodiment) can also provide the user with a hint or the option of accessing substantive information to help the user answer the question. Performance information can be displayed at the users option.
The above-described embodiments of the learning method can also be combined. A first stage could be designed to focus on the fundamentals of the proven problem-solving approach. Namely, it may be preferable to start the user in either the second or third embodiments of the learning method because these embodiments stress the basic problem approach. Hence, the second and third embodiments force the user to learn and follow the desired problem-solving approach. The basic problem-solving approach is to read the question, then while reading the answer choices, discarding those answer choices deemed clearly wrong. Thereafter, the remaining answer choices are re-read, and the best answer choice is selected. The question or portions thereof can be re-read as needed.
A second stage could be designed as a practice mode. Here, since the user would have already become comfortable with the basic problem-solving approach, the first embodiment of the learning method would be used. The first embodiment is particularly useful because it operates similar to actual exam conditions and offers important performance feedback.
Moreover, within the second stage, various levels of study could be possible. In a first level, all the questions in a set can be for the same subject. This allows the user to concentrate on questions of the same subject. This is beneficial because it frees the user from having to decide which subject category the question pertains to and because the user can concentrate on learning the detailed rules pertaining to the subject. Thereafter, in a second level, the questions in a set can be from various subjects. Although the second level would be more difficult than the first level, it would more closely represent the actual exam.
A third level may also be provided. In the third level, the question in a set would again be from mixed subjects but would be more difficult questions than those in the second level. This level would serve as advanced level studying for the user.
A fourth level may be provided to permit a user to focus on a specific topic which he/she wishes to study in depth. For example, if the performance information indicates that the user is struggling with assignments (topic) in contracts (subject), then the fourth level can be used to practice on question pertaining to assignments. A fifth level may be provided to allow the user to repeat questions he/she previously answered incorrectly.
A third stage could be designed as an exam practice mode. In this stage the user would actually take practice exams under exam-like conditions. The computer system would provide the user with questions, record the user answers, and time the exam.
The many features and advantages of the invention are apparent from the written description, and thus, it is intended by the appended claims to cover all such features and advantages of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention. | A computerized learning approach that enables a user to improve their performance on multiple-choice exams is disclosed. Although the learning approach includes various aspects and implementations, in general, the invention forces test-takers to practice their examination skills and subject matter knowledge in a systematic way. The systematic way forces the users to follow a proven problem-solving approach designed to improve their performance. The learning approach provides important performance feedback to user's, for example, elapsed time per question and percentage of correctly answered questions. The invention can also pinpoint for the user the substantive areas of the exam which the user is either weak or strong. Further, the learning approach is able to assist the user in predicting his/her eventual score. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an interferometric system for the detection and location of reflecting faults in light-guiding structures.
The term "light-guiding structures" is understood to mean optical waveguides, such as e.g. optical fibers, optical couplers and even lasers.
The present invention more particularly applies to the field of optical telecommunications and permits the location of weakly reflecting diopters in such optical guides with a high resolution.
The invention also makes it possible to measure the transmission characteristics of such optical guides, as well as the reflection coefficients of passive or active guiding structures.
An interferometric system for the detection and location of reflecting faults is already known from the document "High-spatial-resolution and high-sensitivity interferometric optical-time-domain reflectometer", Masaru Kobayashi, Juichi Noda, Kazumasa Takada and Henry F. Taylor, SPIE Conference, Orlando, Fla., Apr. 1-5, 1991, 1474-40.
SUMMARY OF THE INVENTION
The present invention solves the problem of obtaining an interferometric system able to accurately define the position of propagation "incidents" distributed along optical guides. For this purpose, the present invention makes use of a Michelson interferometer in incoherent light, as well as interferometric means with counting of interference fringes by laser.
More specifically, the present invention relates to an interferometric system for the detection and location of reflecting faults of light guidance structures, the system being characterized in that it includes:
an incoherent light source,
a monomode laser source, whose wavelength is substantially equal to the central wavelength of the incoherent source,
first and second optical couplers, whose first respective branches are optically coupled to the incoherent source and to the laser source,
a first support displaceable in translation in a given direction and to which are fixed the ends of the second branches of the first and second couplers,
a second support able to oscillate in a given direction,
first and second light reflectors fixed to the second support and respectively placed facing the ends of the second branches of the first and second couplers in order to reflect there the light passing out of the same,
a third support displaceable in translation in the given direction and to which is fixed the end of a third branch of the second coupler,
a third light reflector fixed and positioned facing said end of the third branch of the second coupler in order to reflect there the light passing out of the same, a third branch of the first coupler being optically coupled to the guiding structure,
first and second photodetectors respectively optically coupled to fourth branches of the first and second couplers,
an interference fringe counter, whose input receives the signals supplied by the second photodetector and
means for analyzing signals supplied by the first and second photodetectors, said analysis means serving to locate the reflecting faults of the guidance structure, with the aid of appropriate displacements of the first, second and third supports and the counter.
The present invention also makes it possible, by using the signal processing by correlation, to lower the detection threshold or "minimum detectable power" by at least one decade compared with the aforementioned known system and without having a prejudicial influence on the spatial resolution.
The system according to the invention can also comprise a third optical coupler, whose first and second branches are respectively optically coupled to the incoherent source and to the laser source and whose third and fourth branches are respectively optically coupled to the first branches of the first and second couplers.
According to a special embodiment of the system according to the invention, the analysis means incorporate a two-channel oscilloscope respectively receiving the signal supplied by the first and second photodetectors, said oscilloscope displaying interferograms corresponding to said signals.
The system according to the invention can also comprise piezoelectric means which are able to oscillate the second support in the given direction.
According to a preferred embodiment of the system according to the invention, the system includes means for regulating the speed of the displacement of the second support, the regulating means serving to impose a constant displacement speed on the second support.
These regulating means can comprise a Michelson interferometer having a light source, whose coherence length is above the amplitude of the displacement of the second support, two arms respectively terminated by two light reflectors, whereof one is rendered rigidly integral with the second support and a third photodetector, as well as means for controlling the piezoelectric means as a function of the signal supplied by said third photodetector, the control means imposing a constant displacement speed on the second support via the piezoelectric means.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and with reference to the attached drawings, wherein:
FIG. 1 A diagrammatic view of a special embodiment of the system according to the invention.
FIG. 2 An interferogram obtained by means of the system according to FIG. 1 and which corresponds to a weakly reflecting diopter.
FIG. 3 Another interferogram obtained with a laser source used in said system.
FIG. 4 A partial, diagrammatic view of means for regulating the displacement speed of the system plate shown in FIG. 1.
FIG. 5 Diagrammatically electronic means forming part of the regulating means.
FIGS. 6A to 6C Diagrammatically the possibility of displacing an interferogram on the screen of an oscilloscope of the system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An interferometric system according to the present invention, which is diagrammatically shown in FIG. 1, is used for detecting and locating one or more reflecting faults which an optical waveguide 2 my have. This system also comprises an incoherent light source 4 constituted by an electroluminescent diode emitter having a wide optical spectrum, as well as a monomode laser emitter 6, whose wavelength is substantially equal to the central wave-length of the incoherent source 4.
The system of FIG. 1 also comprises first, second and third optical couplers 10, 20 and 30 of the 2×2 type and having monomode optical fibers. Each optical fiber has four optical fiber branches which, for the first coupler 10, carry the references 11, 12, 13 and 14, for the second coupler 20 the references 21, 22, 23 and 24 and for the third coupler 30 the references 31, 32, 33 and 34.
The system according to FIG. 1 also comprises three supports respectively constituted by a first plate 36, which is displaceable in translation parallel to a given direction D, a second plate 38 able to oscillate in the same direction D and a third plate 40 displaceable in translation in the same direction D.
The first and third plates 36 and 40 are respectively associated with motors 37 and 41 permitting their translation in the direction D and the second plate 38 is associated with piezoelectric means 39 able to oscillate the second plate 38 in said direction D.
The ends of the optical fibers 12 and 22 respectively belonging to the first and second couplers 10 and 20 are fixed to the plate 36 parallel to the direction D.
In the same way, one end of the optical fiber 23 belonging to the second coupler 20 is fixed to the third plate 40 parallel to the direction D.
On the second plate 38, which follows the first plate 36 and which faces the first plate 36, are mounted light reflectors 42, 43, respectively facing ends of the fibers 12 and 22. These light reflectors 42, 43 reflect light beams passing out of the fibers 12, 22, so as to return the beams into the fibers 12, 22.
Optics 44, 45 are respectively fixed to the first and second plates 36, 38, the optics 44 being on the first plate 36 positioned facing the end of the fiber 12 and the optics 45 being positioned on the second plate 38 facing reflector 42, so that a light beam from the fiber 12 is transformed into a beam having parallel rays by the optics 44 and said latter beam is focussed on the reflector 42 by the optics 45, said beam then returning into the optical fiber 12 by means of the optics 45, 44.
In the same way, optics 46, 47 are respectively fixed to the plates 36, 38, the optics 46 being placed on the first plate 36 facing the end of the optical fiber 22 and the optics 47 being placed on the second plate 38 facing the light reflector 43, the optics 46 transforming a light beam from the fiber 22 into a beam having parallel rays, which is focussed onto the light reflector 43 by the optics 47, said beam being reflected by the reflector 43 and returning into the optical fiber 22 by means of the optics 47 and then the optics 46.
There is a fixed light reflector 48 in front of the third plate 40. The reflector 48 is more precisely positioned facing the end of the fiber 23, which is fixed to the third plate 40. The reflector 48 reflects a light beam from the end of the fiber 23, so that said beam returns into the said fiber.
An optics 49 is fixed to the third plate 40 facing the said end of the fiber 23 in order to transform a light beam emitted from the fiber 23 into a beam having parallel rays.
An optics 50 is positioned facing the reflector 48 and is fixed with respect to the reflector 48, so as to focus the beam with parallel rays onto the reflector 48, so that it returns into the end of the fiber 23 via the optics 50 and then the optics 49.
The system shown in FIG. 1 also comprises two photodetectors 52, 54, which are respectively optically first and second coupled to the ends of the fibers 14, 24 belonging to the couplers 10, 20. Thus, the photodetector 52 supplies an electric signal when it receives a light beam from the optical fiber 14 and the photodetector 54 supplies an electric signal when it receives a light beam from the optical fiber 24.
Moreover, as can be seen in FIG. 1, the fibers 31, 32 are respectively optically coupled to the incoherent source 4 and the laser source 6, the end of the optical fiber 13 of the first coupler 10 being optically coupled to on end of the optical guide 2 and the ends of the fibers 11 and 21 of the first and second couplers 10 and 20 are respectively optically coupled to the ends of the optical fibers 33, 34 of the third coupler 30, so that the light beams are propagated in said ends of the fibers 33 and 34 and then respectively are able to pass into the fibers 11 and 21 of the first and second couplers 10 and 20.
The system of FIG. 1 also comprises an interference fringe counter 56, whose input is connected to the output of the photodetector 54, as well as a two-channel, digital oscilloscope 58, whereof one channel receives the output signal from the detector 52 via an amplifier 60 and whose second channel receives the output signal of the photodetector 54 via an amplifier 62.
The third coupler 30 supplies half the light intensity reaching it from the incoherent source 4 and/or the laser emitter 6 to the fiber 11 and the other half of said intensity to the fiber 21.
The first optical coupler 10, which is an essential component of the interferometric system diagrammatically shown in FIG. 1, serves as the beam splitter of a Michelson interferometer. When the first coupler 10 receives radiation by its fiber 11, it delivers half of this radiation to the fiber 12 and the other half to the fiber 13 and then mixes the radiation from the reflector 42 reaching it by the fiber 12 and the radiation reflected by one or more reflecting faults of the guide 2 and reaching it by the fiber 13, in order to supply the mixed radiation to the photodetector 52.
The second optical coupler 20 also serves as a beam splitter for a second Michelson interferometer. The second coupler 20 receives radiation by its fiber 21 and delivers this radiation to the fiber 22 and the other half to the fiber 23. The second coupler 20 mixes the radiation respectively reflected by the reflectors 43 and 48 and reaching it by the fibers 22 and 23 in order to deliver the thus mixed radiation to the photodetector 54.
Initially, the question as to whether a reflecting diopter is in the optical waveguide 2 is ignored. If such a diopter exists, the photodetector 52 will indicate its presence by supplying electric signals leading to an interferogram of the type shown in FIG. 2 on the oscilloscope 58 (channel 1).
Such an interferogram is obtained by varying the distance between the end of the fiber 12, which is fixed to the first plate 36, and the reflector 42.
The interferogram of FIG. 2, which corresponds to a diopter having a low reflection coefficient, is plotted in a marking system, whose ordinate axis corresponds to the reflection amplitudes A and whose abscissa axis corresponds to a distance covered by the second plate 38 and expressed in micrometers.
The maximum amplitude of the interferogram corresponds to the equality between the optical length of the arm of the first Michelson interferometer, which is terminated by the light reflector 42, and the optical length of the branch of the interferometer, which is terminated by the reflecting diopter of the optical waveguide 2.
If the optical waveguide 2 has several reflecting diopters, obviously several successive interferograms will be obtained.
The form and amplitude of each interferogram is dependent on the optical spectrum of the incoherent light source 4 used for producing these interferograms and is also dependent on the optical characteristics of the reflecting diopter, as well as the displacement speed of the light reflector 42 with respect to the end of the optical fiber 12.
If a harmonic analysis in Fourier transform is made of the interferogram of FIG. 2, a component at frequency Fo (carrier frequency of the interferograms) indicates the presence of a reflecting diopter, or reflecting center, with a signal quality which is better than in the case of FIG. 2.
Thus, it is pointed out that all the interferograms "contain" a carrier frequency close to Fo and it is sufficient to seek all the signals spectrally centered on Fo in the photocurrent supplied by the photodetector 52 in order to find all the reflecting diopters.
This frequency Fo is also the carrier frequency of the interferograms supplied by the photodetector 54, because the latter interferograms are produced during identical translations of the reflector 42 and the reflector 43.
Thus, the reflectors 42 and 43 are fixed to the second plate 38, which is put into movement with the aid of the piezoelectric means 39 and travel at the same speed and over the same distance.
The displacement of the first plate 36 is controlled by counting fringes with the aid of the photodetector 54 in the second Michelson interferometer, when the laser emitter 6 is used as the light source.
FIG. 3 shows an interferogram obtained on the oscilloscope 58 (channel 2) with the aid of the photodetector 54, when the laser emitter 6 is used as the light source and on the basis of this interferogram it is possible to obtain information on the frequency Fo of the interference fringes and which is the carrier frequency of the interferograms.
The collimating system formed by the end of the fiber 23 and the optics 49 is kept fixed during the displacements of the first plate 36.
When the first plate 36 occupies the position in which the arms of the first interferometer, respectively terminated by the reflector 42 and the reflecting diopter of the guide 2, have the same optical length (cf. hereinbefore), the third plate 40 is put into movement and the photodetector 54 resumes its fringe counting in order to control this movement until the third plate 40 reaches a position in which the respective optical lengths of the arms of the second interferometer, which are terminated by the light reflectors 43, 48, are equal. When this position is reached, the laser emitter 6 is cut out and the electroluminescent diode 4 is used as the light source for supplying a light beam into the fiber 21 of the second coupler 20.
The displacement of the plate 38 finally gives rise to two interferograms, which are supplied by the photodetectors 52, 54 and whose carrier frequencies are extremely close.
The first of these two interferograms is detectable under optimum conditions by correlation with the second interferogram and the appearance of this first interferogram is perfectly located by fringe coating in the second interferometer (having the second optical coupler 20).
More precise details will be given hereinafter of the way of using the interferometric system shown in FIG. 1.
The first step is to define an origin with respect to which the position of the reflecting diopter of the optical waveguide 2 will be given. This origin corresponds to the end of the optical waveguide 2, which is optically coupled to the optical fiber 13 of the first coupler 10. In order to do this, the incoherent light source 4 is made to operate, the laser emitter 6 being extinguished.
The first plate 36 is moved until the quality is obtained between the optical lengths of the arms of the first interferometer, which are respectively terminated by the reflector 42 and the reflecting diopter taken as the origin (end of the guide 2). During these operations the second plate 38 is kept fixed.
On the oscilloscope 58 (channel 1) is obtained an interferogram, whose maximum amplitude corresponds to equality between these optical lengths.
The first plate 36 is then immobilized in this position corresponding to equality of the optical lengths. The second plate 38 is oscillated. The motor 37 of the first plate 36 is actuated so as to bring the interferogram obtained to a chosen position on the screen of the oscilloscope 58. The first plate 36 is then stopped. The laser emitter 6 is then made to function.
The third plate 40 is moved until equality of the optical lengths of the arms of the second interferometer is obtained and this is terminated by the reflector 43 and the reflector 48.
This is detected by means of the photodetector 54 and an interferogram (channel 2) is obtained on the screen of the oscilloscope 58.
Coincidence is then brought about between the respective maxima of the two interferograms obtained on said screen, by displacing the third plate 40 over a length permitting this coincidence. The fringe counter 56 is set to zero. The laser emitter 6 is extinguished. It is then possible to find the distance between the reflecting defect of the optical waveguide 2 and the thus defined origin. To do this, the first plate 36 is moved until detection takes place of the reflecting defect or fault of the waveguide 2. This detection takes place when a new interferogram appears on the channel 1 of the oscilloscope 58. The first plate 36 is then stopped (with the second 38 still oscillating). The laser emitter 6 is put into operation.
The fringe counter 56 is actuated and the third plate 40 is displaced until coincidence is brought about between the maximum of the interferogram of channel 2 and the maximum of the new interferogram of channel 1. The third plate 40 is then stopped .
However, each interference fringe is spaced from an adjacent fringe by a length equal to half the wavelength of the laser emitter 6.
Thus, it is possible to determine the distance between the origin and the reflecting fault of the waveguide 2 by multiplying the number N of interference fringes counted by half said wavelength.
In order to make the oscillation speed of the third plate 38 as constant as possible, the third plate 38 is provided with means for regulating the speed. An optical method is advantageously used for measuring the displacement of the second plate 38.
Such a method makes it possible to measure displacements of approximately 0.1 micrometer in accordance with the wavelength of the light source used for performing the optical method. The principle of the method is diagrammatically illustrated in FIG. 4.
This measurement is performed by using another Michelson interferometer 82, which once again has a type 2×2 optical coupler 64 with optical fibers, hereafter referred to as the fourth optical coupler.
The fourth coupler 64 has four branches or optical fibers, the first branch being coupled to a light source 66, the second to a receiving photodiode 68 and the third to a total reflection mirror 70, which is fixed and which reflects into said branch the light passing out of the same.
A mirror 72 is rigidly integral with the second plate 38, so that it moves parallel to the direction D. The end of the fourth branch of the fourth coupler 64 is fixed and positioned facing the mirror 72.
Two fixed optics 74, 76 are placed between the mirror 72 and the end of the fourth branch of the fourth coupler 64.
The optics 76 transforms a beam from the end at the fourth branch into a beam having parallel rays. The optics 74 focusses the beam with parallel rays onto the mirror 72, which reflects it and returns it into the end of the fourth branch of the fourth coupler 64 via the optics 74 and 76.
The intensity I(t) of the light detected by the photodiode 68 and therefore the intensity of the electric signal supplied by said photodiode 64 vary, as indicated hereinafter, as a function of the time t:
I(t)=Io(1+((4πF(t)/1))
in which Io is a constant, π is 3.14 and l represents the wavelength of the light emitted from the light source 66.
The frequency F(t) is a function of the displacement speed of the second plate 38 and the wavelength of the light source 66. In order to regulate the speed, it is therefore sufficient to regulate the frequency of the signal supplied by the photodiode 68.
It is necessary to use a light source 66, whose coherence length exceeds the amplitude of the displacement of the second plate 38, the displacement being approximately 1 millimeter in the example described.
The light source 66 is, in exemplified manner, a laser diode DFB with a wavelength of 1550 nanometers.
The frequency control device of the signal supplied by the photodiode 68 is e.g. a phase locking control device, which is very simple to implement. This device is diagrammatically illustrated by FIG. 5.
It comprises a phase comparator 78 receiving at its input a reference frequency Fref, as well as the output signal of a Schnitt trigger, whose input is connected to the output of the photodiode 68.
In FIG. 5, block 82 represents the interferometer of FIG. 4.
The control device of FIG. 5 also comprises an integrator 84, whose input receives the output signal of the phase comparator 78, as well as an amplifier 86, which amplifies the output signal of the integrator 84. The output signal of the amplifier 86 controls the piezoelectric means 39 associated with the second plate 38.
Without servocontrol, the variation of the speed obtained with these piezoelectric means 39 is approximately 25% (the photodiode 68 then supplying a signal with a relatively wide spectrum).
However, the servocontrol described makes it possible to have a frequency variation smaller than 1 Hz around the reference frequency (e.g. 36 Hz, giving a speed of 28 micrometers per second), which corresponds to a speed variation below 2% (the spectrum of the signal supplied by the photodiode 68 then being very narrow).
On returning to the system of FIG. 1, it will be shown hereinafter that the displacement of a plate effectively makes it possible to displace an intererogram on the oscilloscope 58, with reference to FIGS. 6A to 6C. The fiber 13 and the optical waveguide 2 remain fixed.
The arms of the first Michelson interferometer, respectively comprising the fibers 12 and 13, have optical lengths which are very close to one another and which, for each position of the first plate 36, are perfectly equal for a given position of the second plate 38.
An oscillogram is plotted during the displacement of the second plate 38 (using the piezoelectric means 39) between two positions al and a2, for one position a of the first plate 36, while it is plotted during the displacement of the second plate 38 between two other positions b1 and b2, for another position b of the second plate 36.
FIG. 6A shows that the positions A and B corresponding to the interferograms obtained for the positions a and b of the first plate 36 are not positioned at the same locations on their respective segments ala2, blb2.
According to FIG. 6A, if the oscillograms are initiated at al and bl, the interferograms corresponding respectively to the positions a and b of the first plate 36 are observed in the manner shown in FIGS. 6B and 6C, where t represents the time and P the photocurrent obtained.
The following information is given in connection with the operation of the system of FIG. 1. The second plate 38 is driven, by piezoelectric means 39, in a continuous translation movement with a speed controllable by means of the reflector 43 (associated with the optics 47), whose movement is controlled, in the interferometer having the optical coupler 20, with the aid of the laser emitter 6, whose light reaches the second coupler 20 by the fiber 34, or with the aid of the laser emitter 4, whose light reaches the second coupler 20 by the optical coupler 30 and the fiber 34.
Thus, the position of the second plate 38 can be perfectly known by using the laser emitter 6 in the interferometer having the second coupler 20 and by counting the fringes passing during the displacement of the second plate 38, the third plate 40 being kept stationary.
As soon as the interferometer is balanced using the laser emitter 4 coupled by means of the fiber 34 (the arms of the interferometer comprising the fibers 22 and 23 then having the same optical length), there is no further displacement in translation of either the third plate 40 or the first plate 36. The second plate 38 is displaced in translation by the piezoelectric means 39. Thus, the photodetectors 52 and 54 supply interferogram signals. The photodetector 54 supplies a reference signal. The photodetector 52 supplies a signal characteristic of the optical reflection properties of the waveguide 2 and which is compared with the reference signal by correlation, in order to obtain in accurate manner the optical properties of the waveguide 2.
For example, if the waveguide 2 is a "perfect" mirror, as are the reflectors 42, 43 and 48 (respectively associated with the optics 45, 47 and 50), the two interferograms are perfectly identical and superimposable.
It is on the basis of the differences between the signals that it is possible to locate the diopter of the optical waveguide 2 and its reflection coefficient is measured as a function of the wavelength. | An interferometric system for sensing and locating reflective defects in light-conducting structures comprises a mono-mode laser source (6), an incoherent source (4) with substantially the same central wavelength as the laser source, first and second couplers (10, 20) connected to the sources and to light sensors (52, 54), a first support (36) movable in one direction (D) and connected to the ends of the first and second couplers, a second support (38) oscillating in the same direction (D), reflectors (42, 43) attached to the second support opposite the ends of the first and second couplers. A third support support (40) is movable in the same direction (D) and connected to one end of the second coupler (20), a further stationary reflector (48) opposite said end, of the second coupler. The first coupler is connected to an optical waveguide (2), and devices (56, 58) for locating reflective defects in the waveguide. | 6 |
SUMMARY OF THE INVENTION
The present invention relates to Coanda-effect air-distributing devices of the type comprising a duct set upstream that branches off into a number of ducts set downstream and means designed to deflect the flow of air that traverses said duct set upstream into one or the other of said ducts set downstream, exploiting the Coanda effect.
The Coanda effect is the phenomenon whereby a flow of air exiting from a duct tends to “stick” to a wall that is adjacent to it. In a device previously proposed by the present applicant, the aforesaid means of deviation by the Coanda effect comprise a first mobile element, which is provided on a wall of the duct set upstream in the proximity of the inlet of one of the ducts set downstream and can be displaced between a first position, in which it does not interfere with the flow of air through the duct set upstream, and a second position, in which it projects into said flow, so that, in the aforesaid first position of the mobile element, the flow enters a first duct set downstream, remaining adherent to a wall thereof by the Coanda effect, whilst, in the aforesaid second position of the mobile element, the flow that traverses the duct set upstream tends to adhere to a wall of a second duct set downstream that is opposite to said first wall, so that the flow enters the aforesaid second duct set downstream.
The purpose of the present invention is to provide an air-distribution device based upon the Coanda effect of the type indicated above that will be even more efficient than the devices proposed up to now.
In order to achieve said purpose, the subject of the invention is a Coanda-effect air-distributing device having the characteristics indicated above and characterized moreover in that the means of deviation of the air by the Coanda effect comprise a second mobile element, which is set on the aforesaid second wall and can be displaced between a first position, in which it does not interfere with the flow of air in the duct set upstream and a second position, in which it projects into said flow, and in that said first and second mobile elements are displaceable in synchronism with one another so that when said first mobile element is in its first position, the second mobile element is in its second position, whereas, conversely, when said first mobile element is in its second position, the aforesaid second element is in its first position.
Thanks to the characteristics indicated above, the means of deviation of the air by the Coanda effect according to the invention are more efficient and reliable than the systems so far proposed.
In a preferred embodiment, the aforesaid first and second mobile elements form an integral part of a single mobile member. Preferably, said mobile member is mounted oscillating on the structure that defines said main duct about an axis of articulation.
Once again according to the invention, there are provided actuator means for actuating each mobile element, said means being preferably selected between electromagnetic actuators, piezoelectric actuators, shape-memory actuators, fluid actuators, and electric motors.
A preferred application of the air-distributing device described above relates to the air-distribution systems associated to the dashboards of motor vehicles. It is, however, evident that the distributing device according to the invention is of general application.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to an example of application to the dashboard of a motor vehicle, as is illustrated in the annexed drawings, in which:
FIG. 1 is a diagram illustrating the principle underlying the air-distribution system according to the invention;
FIG. 2 is a partial schematic, perspective view of an air-distribution system for the dashboard of a motor vehicle according to the invention;
FIG. 3 is a view, at an enlarged scale, of a detail of FIG. 2 ;
FIGS. 4 , 5 and 6 are cross-sectional views, at an enlarged scale, of a detail of FIG. 3 , which show the system according to the invention in different conditions of operation;
FIG. 7 is a perspective schematic view of a detail of FIGS. 4–6 ;
FIG. 8 is a schematic view of the actuator of the item represented in FIG. 7 ; and
FIG. 9 illustrates a variant of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , the reference number 1 designates as a whole a dashboard (illustrated only schematically) of a motor vehicle, inside which there is provided an air-distribution system 2 . The system 2 comprises a main duct 3 , which receives air from an air-conditioning system, including a main fan 4 and a heater/evaporator 5 . The main duct 3 gives out into a manifold or rail 6 , from which there branch off four auxiliary ducts 7 , distributed in parallel along the dashboard, one pair on the driver side, and one pair on the passenger side, each pair comprising a duct adjacent to the central part of the dashboard and a duct closer to a side window of the motor vehicle. Each auxiliary duct 7 branches off into three terminal ducts 8 , 9 , 10 (see also FIG. 2 ), each of which terminates in air-outflow openings in the passenger compartment of the motor vehicle. In particular, the duct 8 supplies air to openings 11 , arranged at the base of the windscreen, for directing a flow of air onto the internal surface of the latter. The duct 9 terminates in one or more openings 12 , arranged at the front on the dashboard, for directing air towards the passenger compartment of the motor vehicle, and the duct 10 terminates in one or more openings 13 , which direct a flow of air towards the floor of the passenger compartment.
In the area in which each auxiliary duct 7 branches off into the three terminal ducts 8 , 9 , 10 , there are provided means for distributing the air flow between the terminal ducts, which will be illustrated in detail in what follows.
An important characteristic, which also forms a subject of a separate application, lies in the fact that each of the auxiliary ducts 7 is provided with an additional and independent unit for regulating at least one characteristic of the air flow. In particular, associated to each auxiliary duct 7 is, in the example of embodiment illustrated, a unit 14 for regulating the flow rate of the air, and a unit 15 for regulating the temperature of the air. In the example illustrated, the unit 14 comprises a fan with corresponding electric controlling motor, whilst the unit 15 comprises a section of duct in which an electrical resistor is inserted.
Therefore, the distribution system illustrated enables adjustment of the flow and/or the temperature of the flow of air exiting from the openings 11 , 12 , 13 , separately for each of the auxiliary ducts 7 , i.e., in the case of the example illustrated, separately for the driver area and for the passenger area and, for each of said areas, separately for the central area of the dashboard and for the area adjacent to the window.
FIGS. 4–6 illustrate the way in which the distribution of the air coming from each auxiliary duct 7 into the terminal ducts 8 , 9 , 10 that branch off therefrom is controlled.
With reference to said figures, the first terminal duct 8 has a first curved wall 8 a set on the prolongation of a corresponding wall 7 a of the auxiliary duct 7 . In a position corresponding to said wall, associated to the duct is a mobile element 16 that is mounted oscillating about an axis of articulation 17 on the wall 7 a and can be displaced between a first position, visible in FIG. 4 , and a second position, visible in FIG. 5 . In the first position illustrated in FIG. 4 , the mobile element 16 does not interfere with the air flow F coming from the auxiliary duct 7 , so that said flow remains “stuck” to the walls 7 a and 8 a and consequently enters the first terminal duct 8 . In the second position of the mobile element 16 , illustrated in FIG. 5 , said mobile element projects into the flow F so that it invites said flow to adhere, by the Coanda effect, to a curved wall 8 b opposite to the wall 8 a and situated at the inlet of the two terminal ducts 9 , 10 .
To obtain a more efficient distribution of the flow between the terminal duct 8 and the inlets 8 c of the two terminal ducts 9 , 10 , there is provided, according to the invention, a further mobile element 18 , which can be displaced between a first position, in which it does not interfere with the flow F (illustrated in FIG. 5 ), and a second position, in which it projects into the flow F (illustrated in FIG. 4 ). The two mobile elements 16 , 18 must be controlled in synchronism so that when the mobile element 16 is in its first position the mobile element 18 is in its second position ( FIG. 4 ), whereas when the first mobile element 16 is in its second position the second mobile element 18 is in its first position ( FIG. 5 ). In the case of the example illustrated, this is obtained very simply in so far as the mobile element 16 and the mobile element 18 form part of a single member 19 , mounted articulated on the structure of the duct 7 about the axis 17 . As may be seen in FIG. 7 , the member 19 comprises a vaned part, which defines the element 16 , and a U-shaped part, rigidly connected to the vane 16 and substantially orthogonal thereto, which includes a bent cross member that constitutes the mobile element 18 .
In the condition illustrated in FIG. 4 , the mobile element 18 encourages “sticking” of the flow F to the wall 8 in so far as it prevents the flow F from remaining adherent to the wall 8 b . In the condition illustrated in FIG. 5 , since the element 18 does not disturb the flow F it enables said flow top stick to the wall 8 b by the Coanda effect.
As may be seen in FIGS. 4–6 , a further mobile member 19 , which includes a first mobile element 16 and a second mobile element 18 altogether similar to the ones described above, is moreover provided in a position corresponding to the inlets 8 c of the two terminal ducts 9 , 10 . The mode of operation of said second mobile member is altogether similar to what is described above. In the condition illustrated in FIG. 5 , the second mobile member favours sticking, by the Coanda effect, of the flow to a first curved wall 9 a of the terminal duct 9 , so that the flow enters said duct, whereas, in the condition illustrated in FIG. 6 , it favours sticking of the flow to a wall 10 a , which is also curved, of the terminal duct 10 , so that the flow enters said duct. Furthermore, the mobile element 18 in this case also performs the function of interfering (in the condition illustrated in FIG. 4 ) with a possible part of the main flow F that were to enter the inlets 8 c , bestowing thereon a circulatory motion C ( FIG. 4 ) that “obstructs” the inlets 8 c , reducing to a minimum any undesired leakages of air into the ducts 9 , 10 .
For the same purpose, in a position corresponding to the inlets of the terminal duct 8 and of the terminal duct 9 there are provided air-recirculation passages 20 , which are shaped so that in the conditions illustrated in FIG. 5 and FIG. 6 , respectively, any possible undesired leakages of air give rise to an air circulation C that obstructs the duct into which the flow is to be directed.
The mobile members 19 are controlled by actuators of any type, for example electromagnetic actuators (such as the actuator 40 in FIG. 8 ), or piezoelectric actuators, or shape-memory actuators.
FIG. 8 illustrates a variant of the member 19 , in which the U-shaped portion defining the mobile element 18 also includes vanes 21 having the function of straightening the air flow.
Of course, without prejudice to the principle of the invention, the details of construction and the embodiments may vary widely with respect to what is described and illustrated herein, without thereby departing from the scope of the present invention. | An air-distribution device based upon the Coanda-effect comprises two mobile elements that move in synchronism and in phase opposition for distributing an air flow into two ducts. | 8 |
TECHNICAL FIELD
This invention relates to the water purification field. More specifically, this invention concerns a purification process effective for removing undesirable components from ground water or municipal water and for achieving low-sodium, low-particulate, sterile water suitable for the manufacture of food and beverage items. Specifically, the water obtained by this process is suitable for the bottling of beverages, for example drinking water and carbonated beverages.
BACKGROUND OF THE INVENTION
Past methods for obtaining water suitable for use in making soft drinks have employed a series of cumbersome procedures requiring large working areas and open systems highly susceptible to contamination and, hence, a need to add large amounts of chlorine to insure sterility of the water prior to the use of the treated water in bottling, for example, soft drinks. Distillation methods are a known alternative but are economically prohibitive for some large scale operations.
Most source water (including ground water or municipal water) contains amounts of salts such as sodium, calcium, magnesium and iron along with carbonates and particulate matter which make the source water unsuitable for use in bottling pure water or soft drinks. Of particular concern to the bottlers of soft drinks is the higher-than-desired content of carbonates in ground water obtained from municipal water supplies. The makers of soft drinks also require that the treated water be sterile to insure continued sterility of the soft drink product. Concentrated syrups used to make soft drinks contain a high concentration of sugar which would serve as an excellent growth substrate for the microbes should any be present in the water used in the bottling.
In order to rid the source water of the undesirable salts, particles and carbonates, one known method employs a first-step mixing procedure wherein source water is added to an open vat containing a mixture of calcium hydroxide, iron sulfate, lime and chlorine (sodium hypochlorite). The entire mixture is then stirred and allowed to settle. The calcium hydroxide, iron sulfate and lime serve to precipitate carbonate and bicarbonate ions as calcium salts, which settle to the bottom of the vat. The treated water is then siphoned off the top of the settled debris, which includes a mixture of calcium carbonate, calcium sulfate, iron oxide and lime. This debris must be disposed of. Typically, this sediment is disposed of down commercial drains for lack of alternate disposal systems. This disposal procedure is cumbersome and given the large quantities of water so treated, may create problems in subsequent municipal sewage treatment plants.
The foregoing procedure, also, fails to remove any of the sodium typically present in water supplies at about 200 parts per million. This first-stage mixing procedure may even result in an increased sodium content since sodium hypochlorite is typically added. Such a high sodium content makes this water unsuitable for individuals on sodium-restricted diets and may alter the taste of soft drinks prepared with this water.
Additionally, the use of an open vat which is highly susceptible to airborne microbial contamination necessitates the addition of large amounts, such as 15-20 parts per million of chlorine to insure sterility of the treated water. The added chlorine must then be moved as its presence would greatly interfere with the taste of the water so treated. It is undesirable to manufacture soft drinks from chlorine-containing water because the taste, color, and quality are adversely affected. The presence of even low concentrations of chlorine could make it impossible to achieve a soft drink product meeting quality standards. Present methods for removing the chlorine added in the first treatment step involve passing the first treated water through large closed tanks containing particles of sterile carbon.
This carbon treatment step currently employed is also undesirable as the activated carbon particles must be backflushed daily with treated water to remove residues, for example calcium carbonate, that coat and inactivate carbon. The backflushing process breaks down the carbon particles resulting in the necessity for carbon replacement at least once per year or more as needed. The entire tank, and its contents of carbon, sand and gravel must be sterilized regularly, at least once per week (or more depending on bacterial count) and the contents replaced periodically and additionally sterilized. Sterilization of the carbon particles is achieved by hot steam requiring an additional apparatus capable of flushing the carbon tanks with high pressure steam. Removal of the carbon from these tanks is a cumbersome, time-consuming, labor-intensive process and further necessitates the shut-down of the entire treatment process, sometimes for several days. As a result, water treatment rooms are often hot, unairconditionable, dusty, environments with occasional carbon black water-laden floors. It is difficult to keep such an environment sanitary. Additionally, since persons and objects are carriers of microbes, the introduction of large amounts of carbon, sand and gravel and high labor requirements of the burdensome process outlined above causes the introduction of numerous microorganisms to the tanks, equipment and the treatment room.
The requirement that large amounts of chlorine be employed also increases production costs in several ways. First a large capital investment in high-volume chlorine removal equipment is necessitated. Second, labor costs are greatly increased due to the extensive maintenance requirements of the necessary equipment and the labor-intensive sterilization procedure. Third, expenditures are increased for chlorine as the amount used is increased. Production costs are also increased due to chemicals used in the precipitation procedure, as they are both costly and expensive to store.
It was, therefore, desirable to develop a water treatment process which could remove the salts, iron, carbonates, sodium, particles, and any other undesirable materials from source water supplies, which treatment would not require the use of large quantities of sterile carbon to remove the high concentrations of chlorine which had to be added to water in prior methods. A need existed to develop a method for economically sterilizing large quantities of water, and delivering it sterile and chlorine-free to its end use. Finally, it was desirable to devise a method which would allow sanitary water treatment facilities to exist, to minimize the microbial contamination that would be brought into the plant, to reduce labor requirements, to eliminate shut-down time and undesirable treatment room conditions, and to develop a more economical process.
SUMMARY OF THE INVENTION
In accordance with the present invention, a process for obtaining essentially sodium-free, sterile water, suitable for bottling or other purposes, from municipal or ground water ("source water") is provided. More specifically, this invention relates to a process for obtaining sterile water for use in bottling commercial beverages and drinking water.
It has now been found that an economical, large-scale purification process can be achieved which avoids the expense of distillation, which effectively removes carbonates, sodium, and other contaminants from source water, and which does not require adding large quantities of chlorine to insure sterility. The disclosed method yields low-sodium, low-particulate, virtually chlorine-free, sterile water from source water. The characteristics of source water obtainable at any given time or location may vary, however the components of this purification method are adaptable to achieve the desired purification.
A reverse osmosis system is utilized in this method to remove total dissolved solids (including sodium) and microorganisms from the water. Total dissolved solids are reduced to about 5 to 15 ppm. The reverse osmosis procedure makes it possible to produce water with low sodium and low alkalinity. Additionally, reverse osmosis removes microorganisms.
Depending on the characteristics of source water available, it is often desirable to pre-treat the source water before the reverse osmosis step. Components of commercially available reverse osmosis systems will last longer if pre-treatment is employed. It has been found that a series of ion-exchange, particulate filtration, and ultrafiltration steps provide effective pre-treatment before the reverse osmosis step. If source water is chlorinated, it is most effective to employ a carbon filtration means capable of removing chlorine that may have been added in municipal treatment, for example. Chlorination of water would reduce the life of reverse osmosis permeators. A chilling procedure is necessary if source water exceeds 95° F. Heat-destruction of presently available commercial filters may otherwise occur.
Because it is undesirable to assess the characteristics of source water and re-adapt procedures to meet the changing purification requirements, a system has now been designed to provide a continuous process for the purification of typical source water. Therefore, a chilling means, an ion-exchange apparatus, particulate filtration means, ultrafiltration means and chlorine-removal means have been linked to provide a continous pre-treatment of source water that will undergo reverse osmosis. A commercially available reverse osmosis system is linked with the pre-treatment apparatuses. A continuous flow of pre-treated source water is provided to the reverse osmosis apparatus. After passing through the reverse osmosis step, the purified water may be used immediately or stored.
Another aspect of the present invention relates to the storage of purified water. In large scale operations, it is often necessary to store purified water for several days before it is used in production. Adding chlorine is an inexpensive way to check microbial growth during storage. However, no chlorine is desired in water used in many food and beverage applications. If water is stored in an open vat, large quantities of chlorine of about 20 parts per million ("ppm") or more would be required to effectively suppress microbial contamination. It has now been found that a closed holding tank, which has little exposure to the atmosphere can be used for the storage of purified water and that the amount of chlorine added can then be reduced to as little as 1-3 ppm of chlorine. The necessity of cumbersome chlorine removal procedures for which it is difficult to insure sterility can now be obviated by employing newly-designed, autoclavable activated carbon-containing tank(s). Purified water can now be economically sterilized with chlorine, stored as desired, and can be separated from that chlorine under sterile conditions to result in a purified, sterile water suitable for a variety of uses. A major problem in the beverage industry of storing large volumes of water without microbial contamination is thus solved by the present invention.
The storage step just described can be used as part of a continuous purification process suitable for the food and beverage industry. For example, it can be employed after the reverse osmosis step described in the first aspect of this invention. Additionally, it might be employed in conjunction with any water purification process where it is desired to economically sterilize substantially purified water with chlorine, yet where chlorine-free, sterile water is needed for end use.
Another aspect of this invention relates to autoclavable, carbon particle-containing tanks comprising a receptacle for carbon particles, the receptacle being manufactured from material capable of withstanding at least 250° F. which is also impervious to airborne microorganisms, and activated carbon particles effective for removing chlorine from water. A parallel bank of such autoclavable tanks may be employed to achieve high-volume chlorine removal under sterile conditions.
DETAILED DESCRIPTION OF THE INVENTION
Water, obtained directly from a municipal source or well, ("source water") is not suitable for the manufacture of beverages such as soft drinks.
A non-distillation method for suitably purifying source water, which can be economically employed, involves a series of steps which partially purify water from such contaminants as hard water cations (such as magnesium and calcium), particles exceeding about 20 microns in diameter, organic chemicals, municipally added chlorine, and others.
Most commercial filters cannot tolerate water temperatures exceeding 95° F. A pre-chilling step is therefore employed to reduce the temperature to about 75-95° F., and preferably to about 80° F. Any suitable system capable of cooling the amount of water to be processed would be satisfactory for this part of the method. A variety of commercial water chillers is available. In one aspect of this invention, a water chiller capable of cooling about 16-40 gallons of water per minute from about 95° F.-115° F. to about 75°-95° F. is employed.
After chilling, the hard water cations are removed via an ion-exchange means. In this step, sodium ions are exchanged for hard water ions such as, for example, calcium and magnesium. Any suitable, high-volume ion-exchange apparatus such as are well known to those skilled in the art is suitable for this step. One suitable apparatus is available from Continental Water Systems, Model FR 150 manufactured by Sta Rite.
It is desirable to remove any chlorine that may have been present in source water. A suitable filtration means to achieve this objective is a carbon filter. One type of carbon filter suitable is the Continental Ion Exchanger Tank (Model FR 150) filled with activated carbon.
Particulate material may be present in the original source water. Carbon fines may be introduced via the previous chlorine-removal step. It is desirable to remove these materials to prevent clogging and/or lengthen the life of components in the subsequent processes. A filtration means excluding particles larger than about 25 microns is suitable. It is preferable to use a 20 micron filter as it eliminates most undesired particles while allowing a flow rate that will not substantially slow the process. An example of an appropriate filter is Item #22, made by Water Equipment Technologies, West Palm Beach, Fla. 33407.
An ultrafiltration means is next employed. Commercially available ultrafiltration systems that remove most particles, colloids, microorganisms, and pyrogens are suitable. The approximate pore size of a suitable ultrafiltration means is about 1 to 5 micrometer. An example of suitable ultrafiltration system is that available from Continental Water Conditioning Corporation, Model 8031, 1220 Lumpkin Rd., Houston, Tex. 77043.
The preceding steps are employed to provide semi-purified water stock for the ensuing reverse osmosis process. It is evident that not all steps may be necessary if the original source water does not contain undesirable contaminants which the steps are designed to eliminate. Reverse osmosis of the water pre-treated as detailed above is capable of removing 90%-95% of dissolved solids, microorganisms, minerals, organic colloids and silica that may remain even after the above treatment steps. About 99% of bacterial particles, organics, and pyrogens over 300 in molecular weight are removable. A commercially available reverse osmosis device which has a capacity equal to or above the plant demand, and is capable of removing total dissolved solids that exceed about 5-15 ppm, would be suitable for this step of the procedure.
An example of a suitable reverse osmosis device is available from the Continental Water Conditioning Corporation, Model No. 3035. A reverse osmosis device with more permeators could handle more gallons per day, and it would be obvious to one skilled in the art to increase capacity by so modifying the reverse osmosis step.
The invention includes steps subsequent to reverse osmosis which insure the sterility of water used in bottling or other procedures. Although reverse osmosis removes most, if not all, of microorganisms contained in the water, it may be necessary to hold this substantially purified water for an indefinite period of time, but usually not exceeding 72 hours, before it is used in other procedures. The invention employs a new holding system, in which purified water is caused to flow into tanks. It is then chlorinated with at least 1 ppm (parts per million) chlorine, in the form of sodium hypochlorite, but not more than about 10 ppm chlorine. Preferably, the chlorine is added at a level of 2-3 ppm. A preferred means of insuring uniform chlorination is an automatic injection pump and recirculation means. The holding tanks must be substantially closed to prevent airborne microbial contamination. All airvents should be covered with a filter capable of excluding most or all microorganisms. A suitable holding tank is made from fiberglass.
When the water is ready for use, it is desirable for the manufacture of certain human consumables to eliminate the chlorine previously added. In particular, soft drinks require nearly chlorine-free water so that the flavor is appropriate. It has now been found that the sterility of the water can be maintained by passing the water through at least one sterile, autoclavable, tank having a receptacle which holds activated carbon particles capable of absorbing chlorine from the water. Such tanks must be impervious to microbial contamination when properly attached to the system, and the receptacles fabricated from a material capable of withstanding 250° F. They must be of a size which can fit into an autoclave. Stainless steel is a preferred material for the receptacles.
The autoclavable tanks also contain activated carbon which is sterilized while within the receptacle during the autoclaving process. A quantity of carbon effective to remove chlorine added in the treatment process is required. In a preferred embodiment, 2-3 ppm of chlorine are removed from about 9000 gallons of substantially purified water by passing the water through a parallel bank of four autoclavable tanks simultaneously, such that each tank processes about one-fourth the total water, each tank having an inlet means delivering water from previous treatment steps, and an outlet means, the outlet means comprising a dip tube, a mesh strainer and a connector connecting to further treatment steps or an end use. The inlet connector and the outlet connector diameters are selected to be large enough to produce the flow rate desired for the particular system. The dip tube is usually a hollow cylindrical pipe connectable to the outlet connection means. The dip tube must be made of autoclavable material which will not introduce undesirable contaminants into the water. One appropriate material is, for example, stainless steel. The diameter of the dip tube is preferably about equal to the diameter of the connector. It is preferred that a sterile filter capable of excluding particles larger than about 5 microns be employed following the chlorine-removal in the autoclavable tank(s) to remove carbon fines that may have been introduced. This filtration may be necessary for some end uses.
BRIEF DESCRIPTION OF THE DRAWINGS
The description that follows should be read in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic diagram of one embodiment of the water purification process herein described.
FIG. 2 is a partially cut-away top and side view of an autoclavable activated carbon-containing filtration device.
In FIG. 1, throttling valve 20 regulates the flow of a pre-chilled water supply into pipe 22 which connects to ion-exchange means 24. Water then flows through pipe 26 to carbon filtration means 28 wherein chlorine is removed. Throttling valve 32 regulates the flow from filtration means 28 through pipe 30. Pressure regulator means 34 and pressure gauge 36 insure proper pressure to twenty micron filter 38. Water then flows through pipe 40 to which low pressure switch 42, motor-operated ball valve 44, pressure gauge 46 are sequentially attached, through pipe 48 and high pressure switch 50 to either pipe 54 or through motor-operated ball valve 52 to backwash waste to drain 55. Water flowing through pipe 54 enters ultrafiltration device 56 where it undergoes further removal of contaminants. Water then flows through pipe 57, which is monitored by pressure gauge 58, passing through Y-check valve 60. Sampling port 62 allows for testing of water quality at this point, if desired. 64 denotes a flow indicator and flow element. Low pressure switch 68 regulates water pressure to feed pump 70. A pump discharge pressure gauge is interspersed between throttling valve 74 and permeator feed pressure gauge 76. 78 indicates a back pressure valve. Water then is made to flow through reverse osmosis permeators 80. Throttling valve 82 is placed to regulate flow. Reject pressure gauge 84, reject flow control valve 86 and reject flow meter 88 monitor the water rejected to drain waste. Purified water flow is monitored by permeator flow meter 90 and water quality meter 92. Water then flows through pipe 94 to which sampling port 86, is connected. Ball check valve 98 is placed between sampling port 96 and throttling valve 100. Water then flows into 4500 gallon storage tanks 102 or 104. Chlorine drum 106 is used to store chlorine to be introduced via chemical injection pump 108 into the tanks 102 or 104. Recirculating pump 110 keeps the chlorine uniform throughout the stored water in tanks 102 and 104. Throttling valves 112 and 114 regulate the flow of water into line 116. Water flows through line 116 and is equalized through 118 or 128 throttling valves, pumped by 120 or 126 repressurization pumps, then through 122 or 124 throttling valves. The water then flows through pressure equalizer 130. The water may then be directed through autoclavable chlorine-removal tanks, 148, 150, 152 or 154, or a bypass. Flow through the bypass is controlled by throttling valves 132 and 137. With valves 132 and 137 opened, and throttling valves 140, 142, 144, and 146 closed, water passes through impulse meter 134 which sends an impulse to injection pump 136 after about one liter of water has passed through. Injection pump 136 then causes chlorine from chlorine drum 106 to flow through line 135 through line 158 and continuing to 172 (all points of use).
140, 142, 144, and 146 are throttling valves for regulating water flow into autoclavable tanks 148, 150, 152, and 154. 156 is a pressure gauge. With valves 132 and 137 closed, and valves 140, 142, 144 and 146 open, water flows through an inlet of one autoclavable tank 148, 150, 152 or 154, filters through sterile carbon particles contained within, and out of the bottom through dip tube 139, 141, 143 or 145, through a mesh strainer and out through an outlet connector into line 158 after passing through throttling valve 149, 151, 153, or 155. Line 158 connects to throttling valve 160, then connects to pressure gauge 162, then to 5 micron filter 164. Pressure gauge 166 is then placed on the line followed by sampling port 168 and throttling valve 170, after which the water passes to use 172. Chlorine-free, sterile water flowing from tanks 148, 150, 152 or 154 may be used to flush points subsequent to throttling valves 149, 151, 153 or 155 to remove any residual chlorine in those pipes or equipment, and this flush water discarded until and appropriate chlorine test reads negative. A preferred chlorine test employs orthotolidine in a colorimetric assay, but any analytical chlorine detection method may be used.
FIG. 2 is an enlargement of tank 148, 150, 152, or 154 of FIG. 1. 300 is a receptacle made of autoclavable material which is also impervious to microorganisms. 302 is an inlet valve and 304 is an outlet valve. 306 are sterile, activated carbon particles contained within the receptacle. The water is filtered down through carbon particles 306 after entering the tank through inlet valve 302. Inside receptacle 300, the water is picked up by dip tube 303 which extends to about 1-3 inches from the bottom of receptacle 300 and passes through receptacle 300, then fine mesh strainer 305 which removes carbon particles greater than about 5 mesh, finally exiting through outlet valve 304. | A method for purifying source water to obtain sterile, low-sodium water is described. The improved method employs ion-exchange, adsorption, filtration by particulate size, ultrafiltration, and reverse osmosis in combination with a closed holding system requiring only 2-3 ppm chlorine for sterilization. A method for storing treated water sterilized with chlorine, keeping the chlorine uniformly distributed during storage, and for removing the chlorine just prior to using the water while maintaining sterility of the water is also disclosed. An additional aspect of the invention is novel sterile filtration means, disclosed for removing chlorine from treated water, comprising a receptacle for activated carbon particles, having a water inlet and a water outlet, yet which is sealed from contamination from airborne microbes, and an effective number of carbon particles. The novel filtration means is wholly autoclavable. | 1 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to color change devices, i.e. devices which undergo a change of color when physically disturbed in some way. More particularly, the invention relates to laminated color change devices capable of undergoing a change of color by means other than direct delamination of the constituent layers of the device.
2. DESCRIPTION OF THE PRIOR ART
In our prior U.S. Pat. No. 4,837,061 to Smits et. al. issued on Jun. 6, 1989 (the disclosure of which is incorporated herein by reference), a process for producing color change devices, particularly those used as tamper evident structures, is disclosed. The process involves anodizing a color generating metal, such as a valve metal (e.g. Ta, Nb, Zr, Hf and Ti), a refractory metal (e.g. W, V and Mo), a grey transition metal (e.g. Ni, Fe and Cr), a semi-metal (e.g. Bi) or a semiconductor metal (e.g. Si), in order to form an anodic film of oxide having a thickness in the order of the wavelength of light (referred to as an "optically thin" film) intimately contacting the color generating metal. The resulting laminates exhibit a strong interference color when illuminated with white light because of light interference effects between reflections from the closely spaced metal and oxide surfaces and because of light absorption which takes place at the metal/oxide interface when color generating metals are employed.
The resulting structures can be formed as color change devices if the anodization is carried out in an electrolyte containing an adhesion reducing agent, such as a fluoride, which lowers the normally tenacious adhesion of the oxide film to the metal substrate. This allows the oxide film to be detached from the substrate with consequent destruction or modification of the exhibited color. Re-attachment of the oxide layer does not result in regeneration of the original color, so the color change is essentially irreversible and forms an effective indication of tampering.
The detachment of the anodic film from the metal substrate can be assisted by adhering a transparent or translucent layer to the anodic film and using this layer to reinforce the delicate anodic film so that the film can be reliably detached from the metal substrate in large pieces without disintegrating.
While these prior color change devices have proven to be most effective, they are vulnerable to defeat to some extent when used in certain ways. In particular, when the devices are formed as thin flexible strips or sheets to be adhered to an article to be protected by a layer of adhesive or the like (referred to as tamper-evident labels), it may be possible to remove the entire device from the article without detaching the anodic film from the substrate metal and hence without producing a tell-tale color change. A device removed in this way could be reattached to the original article (e.g. a container that had been opened) or attached to a different (e.g. counterfeit) article. Tamper-evident labels of this kind are extremely useful in practice and it would be a considerable advantage to make them more secure.
OBJECTS OF THE INVENTION
An object of the present invention is to provide thin flexible color change devices which are capable of undergoing a color change when an attempt is made to remove such devices from articles to which they are attached.
Another object of the present invention is to provide self-voiding tamper-evident labels which undergo a color change when subjected to bending.
Yet another object of the invention is to provide a process for producing such devices and labels.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a process for producing a color change device capable of undergoing a change of color upon bending of the device, said process comprising providing a flexible substrate having a color-generating metal at a first surface of the substrate; and anodizing said color-generating metal at a voltage sufficient to form an anodic film on said substrate having a thickness suitable for generating a color; wherein said anodizing step is carried out in the presence of an adhesion-reducing agent for said anodic film having a concentration which results, at said anodizing voltage, in the formation of said anodic film in such a way that said generated color is changed when said substrate and attached anodic film undergo bending.
According to another aspect of the invention, there is provided a color change device, comprising a flexible substrate comprising a color generating metal at a first surface; and an optically thin anodic film on said color generating metal intimately contacting said first surface of said substrate and generating an interference color; said device having at least one area in which said interference color can be changed by bending said flexible substrate.
By the term "color-generating metal" as used herein, we mean a metal capable of generating a color different from its normal color when covered by an intimately contacting optically thin layer of transparent material, i.e. a layer having a thickness in the order of the wavelength of light suitable to generate optical interference effects.
The devices of the invention are considerably less vulnerable to defeat when used as tamper-evident labels because the bending which almost inevitably takes place when attempts are made to remove the devices from articles to which they are adhered causes the devices to change color and thus to indicate that tampering has taken place.
The devices of the present invention preferably have a layer of transparent or translucent material adhering to the anodic film in order to protect the delicate film from damage by scratching, etc. and to assist the color change effect which takes place upon bending of the device. The transparent or translucent material is preferably a plastic or polymer sheet attached to the anodic film by means of an adhesive or by other means such as heat sealing. In some cases the sheet may be made friable so that it disintegrates when bending takes place and provides further evidence of tampering.
The devices of the invention also normally have a layer of adhesive on the surface opposite to the color generating surface so that the devices may be attached to articles to be protected. This is not always essential, however, since the object to be protected may in some cases itself be adhesive or the user of the device may apply an adhesive at the time of application of the device to the article to be protected.
The ability of the devices of the invention to be activated by bending is unexpected because it would not normally be anticipated that anodic films thin enough to generate optical interference colors would detach from the substrate metal under the minimal forces exerted upon bending (the ratio of forces produced by bending is very low when the cross sectional area versus the adhesive strength is taken into account). For example, printing ink does not separate from paper upon bending, even though such ink is about five times thicker than the anodic films employed in the present invention. Moreover, other types of peelable layers adhering to bendable substrates, such as common adhesive tape on thin aluminum foil, do not become detached upon bending. The present invention therefore represents an unpredictable improvement of the type of devices disclosed in our prior patent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a thin, flexible label according to one form of the present invention attached to an article to be protected; and
FIG. 2 is a cross-section similar to FIG. 1 but showing the area of the bend, at which color activation takes place, on a slightly larger scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides flexible color change devices of the type described in our U.S. patent mentioned above which undergo changes of color when the devices are bent or flexed rather than requiring deliberate separation of the anodic film from the metal substrate, e.g. by peeling or puncturing. It has been found that such devices can be produced in essentially the same way using essentially the same color-generating metals as the devices of our prior patent, except for varying certain parameters, particularly the concentration of the adhesion-reducing agent present during the anodization step.
We have unexpectedly found that only the use of concentrations of adhesion-reducing agents from narrowly defined ranges during the anodization step leads to devices which can be activated by bending according to the present invention. The effective concentrations depend not only on the nature of the adhesion-reducing agent and the color-generating metal, but also to some extent on the thickness of the anodic film which is, in turn, governed by the anodization voltage (and possibly the anodization time). In general, the use of higher anodization voltages for the preparation of the device requires lower concentrations of the adhesion-reducing agent to produce devices of equal susceptability to activation by bending.
Additionally, the triggering of the change of color in the devices of the invention depends not only on the inherent sensitivity of the device to activation by bending, which is governed by the concentration of the adhesion-reducing agent and the voltage used for the formation of the device as indicated above, but also on the radius of curvature through which the device is bent or flexed. Bends involving small radii of curvature of this kind are more likely to cause activation of a device, so devices which tend to bend more easily through small radii of curvature when removed from an underlying object tend to be more sensitive to activation than devices that do not bend so readily, other things being equal. It has been found in practice that activation of the color change normally requires the device to be bent into a curve having a radius of about 0.085 inches or less.
The curvature through which a device bends during attempted detachment of the device from an article it is intended to protect depends on the overall stiffness of the device and its strength of attachment to the article. Devices having thicker or stiffer layers tend to bend less readily and may require the use of higher concentrations of adhesion-reducing agent during their preparation to compensate for this. Devices adhered more firmly to articles to be protected require the use of greater force for their removal and this can cause smaller bending radii (and possibly higher overall bending angles) for devices of any given stiffness. In practice, therefore, devices attached more firmly may be made less sensitive to activation by bending than identical devices attached more loosely.
Consequently, in order to produce effective devices according to the present invention it is often necessary to balance or optimize at least the concentration of the adhesion-reducing agent used for the preparation of the device with the effective range of the anodization voltage (and possibly time), the stiffness of the finished device and the strength of attachment of the device to the article to be protected, so that activation inevitably takes place when tampering is attempted, but not before.
As in our prior patent, the preferred adhesion-reducing agent is a fluorine-containing compounds may be used in the form of aqueous solutions of simple salts, e.g. NaF or KF, complex salts, or acids such as hydrofluoric acid, fluoroboric acid, etc. Our prior patent states in Column 6, line 54 that concentrations of fluoride can be as low as 0.1% by volume of the bath electrolyte (corresponding to 1,000 ppm) when the color-generating metal is Ta. Example 1 of the patent utilizes 0.1 vol % of 49% concentrated HF corresponding to 470 ppm F°, whereas Example 2 utilizes one drop of concentrated hydrofluoric acid in 500 ml which can be calculated as 20 ppm F°. Both these Examples relate to the anodization of Ta. In contrast to this, we have now unexpectedly found that by using concentrations of fluoride falling within the range of 40-350 ppm, devices according to the present invention can be produced from most color-generating metals at the anodization voltages required for color generation (usually 85-150 V). When the concentration falls outside this range, the desired color change is not produced on bending or, particularly in the case of higher concentrations, the anodic film may spall off prematurely leading to an unwanted color change.
In the case of tantalum, the effective concentration of F° is usually in the range of 40-90 ppm in the anodizing electrolyte. When the color generating metal is niobium, a concentration of fluoride in the range of 150-350 ppm produces good color loss activation upon bending.
Incidentally, the concentration of fluoride referred to in this specification is the concentration of the fluoride ion, preferably as measured directly by a fluoride ion electrode.
More exact maxima and minima of the effective fluoride concentrations for tantalum as the color generating metal at various anodization voltages are shown in Table 1 below.
TABLE 1______________________________________ ANODI- FLUORIDEANODI- ZATION CONCENTRATIONZATION TIME MAXIMUM MINIMUMVOLTAGE Color (s) (ppm) (ppm)______________________________________ 85 V yellow 10 90 80 20 90 70 30 80 70110 V red 10 80 50 20 70 50 30 70 50120 V blue 10 80 50 20 70 40 30 70 40140 V green 10 60 40 20 60 40 30 70 40______________________________________
In general, it can therefore be stated that for tantalum, a voltage of about 85 V requires fluoride concentrations of about 70-90 ppm, voltages of about 85 to 110 V require concentrations of about 50 to 80 ppm, voltages of about 110 to 120 V require concentrations of about 40-80 ppm, and voltages of about 120 to 140 V require concentrations of about 40-70 ppm.
As noted above, sensitivity to activation depends to some extent on the overall stiffness of the device, which is mainly governed by the thickness of the overlying transparent or translucent layers since the color-generating metal substrate is usually a very flexible thin foil of 10 μm in thickness or less. Tests have shown (see Example 8 below) that good results are achieved when the thickness of any overlying transparent or translucent polymer layer is about 125 μm.
The color generating substrate commonly comprises a very thin (usually sputtered) layer of the color-generating metal on a thin foil of inexpensive metal, such as aluminum. Such a structure makes it possible to minimize the quantity of the expensive color-generating metal required for the fabrication of the device. In some cases, the aluminum foil may itself be supported on a sheet of plastic, in which case the stiffness of this additional plastic sheet should of course be taken into account when estimating the overall stiffness of the device.
A typical device of the above kind having suitable flexibility consists of a metal foil of about 7 μm in thickness supported on an underlayer of polyester sheet of about 50 μm and covered by a second transparent polyester sheet of about 12.5 μm in thickness.
The adhesive used to attach the device to the article to be protected is usually an inexpensive contact adhesive of high adhesive strength to discourage attempts at removal of the device and to produce a small radius of curvature when removal is attempted. In some cases, however, a lower adhesive strength is required, for example if the device is intended to be removed from the article by hand during the legitimate use of the article (e.g. if the device is to form a removable seal for a container). In such cases, it will be appropriate to use devices of higher sensitivity to activation by bending. In general, it can be stated that the adhesive strength should be high enough to produce adequate bending but not higher than the tear strength of the material of the article to be protected.
The devices of the present invention are normally bent during activation into curves having the anodic oxide film on the inside of the curve because the anodic film must generally be outermost for the color to be generated. However, a color change is usually also produced if the device is bent through a curve having the anodic film on the outside, although it is observed that the sensitivity of the device may then be somewhat reduced.
In addition to the basic devices discussed so far, the present invention is capable of producing more complex devices similar to those described in our prior U.S. patent referred to above. In particular, our prior U.S. patent describes color change devices which incorporate "latent indicia", i.e. messages, patterns or designs which are not visible before the color change is produced, but which become visible when the color change is activated. These devices are produced by masking certain areas of the color-generating metal from the effects of the adhesion-reducing agent, at least during the initial stages of the anodization step. As a result, certain parts of the resulting anodic film become activatable while other parts remain substantially incapable of exhibiting a color change, but otherwise the anodic film is identical in all areas of the device. When attempts are made to remove the device from the underlying article, a color change takes place only in certain areas of the device. The resulting areas of contrasting colors form a visible message, pattern or design. When producing devices of this kind, care should be taken to ensure that the concentration of the adhesion-reducing agent is suitable for activation by bending but low enough to prevent premature development of the latent indicia. Suitable concentrations can be found by simple experimentation.
In addition to the procedure for incorporating latent indicia into the color change devices disclosed in our prior patent, which involves a two step anodization procedure, an alternative single step procedure as disclosed in our copending U.S. patent application Ser. No. 07/510,175 filed on Apr. 17, 1990, the disclosure of which is incorporated herein by reference, may also be employed.
When the devices of the present invention do not incorporate latent indicia, bending to activate the color change may in some cases result in complete separation of the anodic film, and the overlying transparent or translucent layer when present, from the underlying structure. When the devices incorporate latent indicia, the anodic film detaches only in those areas of the device which undergo a color change and remains attached in those areas which do not undergo a color change. The anodic film as a whole, particularly if reinforced by an overlying flexible layer of transparent or translucent material, therefore normally remains attached to the underlying structure in devices which incorporate latent indicia.
Incidentally, while it is usual to provide overlying flexible layers of transparent or translucent material in the devices of the present invention, whether or not they contain latent indicia, this is not essential because a color change is observed when devices having no such adhered overlying layers are bent through a suitable angle. However, such layers have the advantages of providing protection for the delicate anodic film prior to activation of the device and also of providing a further element of protection against tampering in that the tell-tale color change is produced if peeling apart of the device is attempted, as well as complete removal of the device from an article to which it adheres. This is because the devices of the present invention remain activatable by peeling or puncturing in exactly the same way as the devices of our prior U.S. patent mentioned above, but have the additional advantage of being activatable by bending.
Color change devices according to the present invention can present a variety of articles in a variety of ways. For example, the devices may be used as seals to prevent unauthorized opening of a container or to prevent an item such as a price tag from being removed from one article and attached to another article of higher value. If desired, devices of this type can also be used for the same type of security applications as the color change devices of our prior patent, i.e. as separable structures, but they have the additional advantage that the security feature cannot be circumvented by removing the entire device from an article it is intended to protect.
A particular embodiment of a device in accordance with the present invention is illustrated in FIGS. 1 and 2 of the accompanying drawings which show an article 10 to be protected against tampering having a thin flexible label 20 according to the invention attached to its surface by an adhesive layer 22. The label 20 consists of a flexible aluminum foil 24 having a thin layer 26 of a color generating metal coating one surface 28 of the foil. The layer 26 of color generating metal has an intimately associated anodic film 30 covering the outer surface 32 thereof formed by anodization in the presence of an adhesion-reducing agent at a concentration suitable for activation of the color change by bending. The entire label 20 is covered by a layer 34 of transparent or translucent material, such as a polymer sheet (preferably heat-sealed to the anodic film 30). As the entire label 20 is peeled from the article from one edge as shown by the arrow in FIG. 1, the inevitable bending causes the originally generated color to be destroyed. If desired, the device may contain latent indicia as indicated above.
FIG. 2 shows the device 20 on a larger scale in the region where it separates from the article 10. As the device separates from the article, its overall thickness and stiffness usually prevents it from forming a completely sharp angle, but instead it is bent around a short radius of curvature r at the apex of included angle α. The concentration of adhesion-reducing agent used in the formation of the device is sufficient to permit color change activation when r and α are in the range inevitably encountered when peeling of the entire device from the article 10 is attempted.
Labels of this kind are therefore useful as tamper evident devices because the destruction of the original color and the appearance of the latent indicia (if any) can be used to indicate that either an attempt has been made to remove the label from the original article or that the label has been removed from the original article and attached to another, e.g. a counterfeit.
Uses for the labels include such things as the protection of cigarette boxes, asset tags, bottle caps, automotive parts (numbers, bar codes, etc.).
The invention is illustrated further by the following non-limiting Examples.
EXAMPLE 1
Samples of niobium supported on aluminum foil were anodized (without masking) in electrolytes containing 150, 175 and 200 ppm of fluoride and at various voltages. The resulting samples were subjected to bending with the following results.
150 ppm--activates (i.e. generates color on bending) only at 150 V
175 ppm--activates starting at 120 V to 150 V
200 ppm--activates starting at 100 V to 150 V.
These results show that fluoride levels of at least 150 ppm are required to produce useful devices in the range of useful colors produced by normal voltages of 100 V to 150 V.
EXAMPLE 2
In this Example, a device containing a latent message was prepared by a single step anodizing process. Tantalum coated foil was printed with messages (VOID) using an uncured flexographic ink and was then anodized for 20 seconds at 110 V in a citric acid electrolyte containing a fluoride concentration of 65 ppm. After washing to remove the ink the sample was laminated with a 12.5μ transparent polyester film coated with a pressure-sensitive adhesive on top and an acrylic transfer adhesive on the bottom. The resulting product exhibited a wine color and showed no evidence of the latent message prior to activation but, upon bending, exhibited a color change in non-message areas (loss of the wine color in favour of a metallic grey) which made the messages (the areas still displaying a wine color) visible.
EXAMPLE 3
A circular label having a diameter of 30 mm used for sealing cardboard boxes was prepared in the following manner. Tantalum coated foil was printed with an "OPEN" message by means of silk screening and was then anodized for 20 seconds at 85 V in a citric acid electrolyte containing a fluoride concentration of 80 ppm. After washing, to remove the ink, a message stating "ALCAN SEAL" was screened in blue on the surface surrounding the hidden message. Then the label was laminated with the same overlayer and adhesive as in Example 2. The resulting label exhibited a visible blue message "ALCAN SEAL" on a yellow background prior to activation but, upon bending, exhibited a color change in the non-message areas (loss of the yellow color in favour of a metallic grey) which made the "OPEN" message (the areas still displaying a yellow color) also visible.
EXAMPLE 4
A rectangular label of size 35 mm by 50 mm was prepared in the following manner. Tantalum coated foil was printed with several small "VOID" messages by silk screening. Next it was anodized for 20 seconds at 110 V in a citric acid electrolyte containing 60 ppm fluoride. After removal of the ink by washing with water, a message illustrating an Alcan logo and stating "Genuine Part No. BX 2539 Void Upon Removal" was screened in blue on the surface. Next the label was laminated with the same overlayer and adhesive materials as used in Example 2. The resulting label exhibited a visible blue message of the Alcan logo and "Genuine Part No., etc.," on a wine background prior to activation, but, upon bending, exhibited a color change in the non-message areas (loss of wine color in favour of a metallic grey) which made the "VOID" messages (the areas still showing a wine color) also visible.
EXAMPLE 5
A label with a friable coating was prepared in the following manner. Tantalum coated foil was printed with "VOID" messages by silk screening. It was then anodized for 20 seconds at 120 V in a citric acid electrolyte containing a fluoride concentration of 55 ppm. After removal of the ink by washing with water a clear friable organic coating was applied as an overlayer. The coating was basically a melamine cross-linking resin containing an accelerator for curing purposes and some additional solvent. The formula was as follows:
20.0 g Resimene 731 resin
0.35 g Cycat 4045 catalyst
48.0 butyl cellosolve.
The layer was applied with a nylon drawdown bar and cured for 60 seconds at 230° C. Total thickness of the coating was 5 microns. An acrylic transfer adhesive was laminated on the bottom. The resulting product exhibited no evidence of the latent message prior to activation. Upon activation by bending the coating and oxide (on the non-masked areas) disintegrated leaving the blue message areas visible.
After activation, evidence of tampering was obvious due to the tiny iridescent flakes of coating found everywhere.
EXAMPLE 6
A rectangular label of size 5 mm by 25 mm was prepared in the following manner. Tantalum coated foil was printed with a flexographic ink with a "Genuine Product" message and then anodized on a pilot line for 20 seconds at 19 A to a wine color. The electrolyte was citric acid containing 65 ppm fluoride. After anodizing and washing, the material was printed with "Special Filter" using a gold colored flexographic ink. The same overlayer and adhesive as used in Example 2 were laminated on top and bottom. The resulting product showed a visible gold "Special Filter" message prior to activation but, upon bending, exhibited a color change in the non-message areas (loss of wine color in favour of a metallic gray) which made the "Genuine Product" message also visible. The label that could be placed on flap cover type cigarette packages to be used as a flap cover seal.
EXAMPLE 7
This Example relates to a bundle wrap label that could be used to seal a carton of cigarettes. It was prepared in the same way as Example 6 with the only difference being size, which was 35 mm by 150 mm.
EXAMPLE 8
1. Bending Tests
A standardized set of samples indicated below was prepared with two levels of sensitivity and various overlayers and then subjected to bending tests.
Substrate--8 micron foil/50 micron plastic laminate
Messages--Flexo printed generic Alcan logo/void
Anodizing--20 seconds at 125 V for a blue color
Fluoride--45 ppm and 70 ppm
Overlayers--12.5, 25, 50, 100 and 125 microns
Underlayer--Avery FasTape 1151 pressure sensitive adhesive
1.1 Test A--Regular Label with the Oxide on the Inside
After adhering the labels to a countertop they were peeled off to simulate an actual test condition. The following rating system was used for evaluating activation:
______________________________________ResultsOVER- LOWER SENSITIVITY HIGHER SENSITIVITYLAYER (45 ppm) (70 ppm)______________________________________12μ A A25μ A A50μ B A100μ B A125μ C B______________________________________ A = total B = partial C = no activation
1.2 Test B--Around a Radius with the Oxide on the Inside
This test consisted of bending a mounted label, i.e., adhered to a surface, over a radius with the oxide on the inside of the bend.
______________________________________ResultsOVER-LAYER 0.125" r 0.083" r 0.063" r 0.042" r 0.031" r______________________________________LOWER SENSITIVITY (45 ppm)12.5μ C C C B A25.0μ C C C B B50.0μ C C C B B100.0μ C C C B B125.0μ C C C C CHIGHER SENSITIVITY (70 ppm)12.5μ C C B A A25.0μ C C B A A50.0μ C C B B A100.0μ C C B B A125.0μ C C C B A______________________________________
1.3 Test C--Around a Radius with the Oxide on the Outside
One part of the label was adhered while the other side was bent over a radius.
______________________________________ResultsOVER-LAYER 0.125" r 0.083" r 0.063" r 0.042" r 0.031" r______________________________________LOWER SENSITIVITY (45 ppm)12.5μ C C C C C25.0μ C C C C C50.0μ C C C C C100.0μ C C C C C125.0μ C C C C CHIGHER SENSITIVITY (70 ppm)12.5μ C B B A A25.0μ C B B B A50.0μ C C C B A100.0μ C C C B A125.0μ C C C C C______________________________________
The bend test results show that:
Bending with the oxide on the outside is less sensitive than if it is on the inside especially with a fluoride level close to the bottom limit of the operating range.
Color change activation decreases with increasing overlayer thickness. | Color change devices which are capable of undergoing a color change on bending. The devices comprise a flexible substrate having a color generating metal (e.g. a valve metal such as Ta or Nb) at at least one surface and an intimately contacting optically thin anodic film covering the color generating metal and generating a visible color by light interference and absorption effects. The thin anodic film is produced by anodizing the color generating metal in the presence of an adhesion-reducing agent (e.g. a fluoride) for weakening the normally tenacious bond between the anodic film and the metal. Devices of this kind capable of being activated by bending, as well as by separation of the constituent layers, are produced by carrying out the anodization step in the presence of a particular concentration of the adhesion reducing agent from a narrow range (e.g. 40-350 ppm of fluoride). The devices can be used as tamper evident labels and the like which show evidence of removal of the labels from articles to which they are originally attached as an indication of tampering. | 8 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 10/083,631 filed on Feb. 26, 2002, issued as U.S. Pat. No. 6,737,543, which claims the benefit of provisional application U.S. Ser. No. 60/273,073 filed Mar. 02, 2001. The entire disclosures of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to fatty polypropoxylate esters of aliphatic and aromatic monocarboxylic fatty acids. These compounds have unique pigment dispersion and emolliency properties. The fatty polypropoxylate esters of the present invention are particularly useful in the formulation of sunscreen lotions, sunscreen sprays, self-tanning compositions, make-ups and other pigmented products, cold creams, lotions, skin moisturizers, antiperspirants, after shaves, pre-electric shaves, topical pharmaceutical products, lipsticks and cleansing creams. The present invention further relates to topical preparations incorporating the fatty polypropoxylate esters of the present invention.
[0004] 2. Prior Art
[0005] There has been an increased awareness among the public of the potential for skin damage from ultraviolet radiation, with frequent news reports of greater risk from sun-induced photo aging, melanoma, and other skin disorders. The contribution of UVA radiation as well as the widely recognized contribution of UVB radiation to skin damage has engendered the development of a broad range of sunscreen products from the cosmetic industry. Sophisticated sunscreen formulations have been developed which incorporate combinations of UVA and UVB absorbers in vehicles which provide wash-off resistance and enhanced esthetics. Because of the regulatory limitations on the levels at which organic sunscreens may be used in formulations and the desirability for high absorbency formulations (high SPF) with broad spectrum protection, the use of physical sunscreens in conjunction with organic sunscreens in formulations has increased greatly.
[0006] Physical sunscreens consist of very finely divided (micronized) inorganic metallic oxides, typically Titanium Dioxide or Zinc Oxide. These micronized physical sunscreens appear transparent on the skin by virtue of their small particle size. Similar to other finely divided particulate products used in cosmetic formulations such as pigments for foundations and makeups, micronized Zinc Oxide and micronized Titanium Dioxide are dispersed within the formulation by mixing, using either low-shear or high-shear methods. In order to make stable, cosmetically acceptable products, uniform dispersions must be produced, with all particles wetted out and which remain in suspension over a period of time without settling, gelling or agglomerating. Producing such stable suspensions has proved to be a challenge, although some successes have been achieved.
[0007] For example, U.S. Pat. No. 5,116,604 to Fogel describes the use of neopentanoate esters, in particular isoarachidyl neopentanoate, as cosmetic emollients for sunscreen products. U.S. Pat. No. 5,716,602 to Uick describes sunscreens formulated to include a water resistance agent and an insect repellent. One form has in an aqueous emulsion DEET, a sunscreen agent, an anionic surfactant, an alkylated PVP, and octyldodecyl neopentanoate. Both of these inventions use of Elefac I-205, i.e., Octyldodecyl Neopentanoate.
[0008] U.S. Pat. No. 5,476,643 to Fogel describes the use of two specific neopentyl glycol diesters, as wetting, dispersing, spreading and deterging agents for micronized TiO 2 , ZnO and other pigments. These esters, neopentyl glycol di-2-ethyl hexanoate and neopentyl glycol di-isostearate, are used in varying combinations and may also be used with an emulsifying agent for a water dispersible pigmented make-up cleaner composition.
[0009] Emollients such as Finsolv TN (C 12 -C 15 Alkyl Benzoate) and TRIVENT NP-13 (Tridecyl Neopentanoate) have also been employed with some success as dispersants for physical sunscreens, as have various glycols and propoxylates, such as PPG-3 Myristyl Ether. See for example, U.S. Pat. No. 5,928,631 to Lucas which describes a skin composition for controlling environmental malodors on the body. The composition comprises from about 0.1% to about 5%, by weight of a solubilized, water-soluble, uncomplexed cyclodextrin; from about 0.1% to about 36%, by weight of an oil phase selected from the group consisting of emollients, moisturizers, and skin protectants; one or more surfactants, and an aqueous carrier.
[0010] U.S. Pat. No. 4,559,226 to Fogel describes self-emulsifying alkoxylate esters useful in cosmetic compositions having a structural formula:
[0011] Wherein R 1 contains from 2 to 20 carbon atoms and is selected from the group consisting of aliphatic and aromatic substituents and R 3 is an alkyl or aryl substituent from 1 to 21 carbon atoms. One of R 1 and R 3 must contain greater than 8 carbon atoms.
[0012] R 2 is:
[0013] Wherein x is from 1 to 10 and y is from 1 to 20 and the ratio of y to x is from 2:1 to 10:1. Such esters are both ethoxylated and propoxylated.
[0014] Thus there remains a need for superior dispersants with desirable esthetic properties for use in pigmented cosmetic compositions, particularly sunscreen formulations that contain physical sunscreens.
[0015] Additionally, since formulators often find it useful to fully disperse pigments, e.g., micronized metallic oxides, in a portion of the oil phase by high shear techniques such as milling, there is a need for forming oil phase dispersions which have a high solids content of pigments, particularly micronized metallic oxides, that are fluid
OBJECTS AND SUMMARY OF THE INVENTION
[0016] It is a broad object of the present invention to provide a class of agents with superior dispersant properties suitable for use in the formulation of topical personal care products.
[0017] It is another object of this invention to provide compounds which are superior dispersants and have desirable esthetic properties for use in pigmented cosmetic compositions.
[0018] It is a further object of this invention to provide compounds which are superior dispersants, and have desirable esthetic properties for use in sunscreen formulations containing physical sunscreens.
[0019] It is yet another object of this invention to provide a dispersant that is useful for formulating by high shear techniques, such as milling, oil phase dispersions that have a high solids content of pigments and micronized metallic oxides.
[0020] It is a more specific object of this invention to provide dispersing agents having improved dispersant properties that are polypropoxylated fatty alcohol chains covalently bonded by ester linkages to aliphatic and aromatic monocarboxylic acids.
[0021] The aforedescribed objects and others are achieved through the present invention. Broadly, the invention is directed to certain aliphatic and aromatic monocarboxylic acid esters of polypropoxylated fatty alcohols. These compounds demonstrate unusual and unexpectedly superior properties as pigment dispersants, especially for micronized Zinc Oxide, e.g., Z-Cote HP-1 from BASF, micronized Titanium Dioxide, and uncoated pigments such as those used in foundations and makeup products. Additionally, these propoxylated alcohol esters can be used to produce uniform milled dispersions of pigments and micronized metallic oxide sunscreens that have exceptionally high solids content, exhibit unusual fluidity and when applied to the skin demonstrate a dry, elegant emolliency.
[0022] Generally, the fatty polypropoxylated esters of this invention are esters of an aliphatic or an aromatic monoacid formed by reacting an acid with a stoichiometric excess of a polypropoxylated fatty alcohol.
[0023] Broadly, the compounds of this invention have the following structural formula:
[0024] wherein R 1 is a polypropoxylated fatty alcohol and has the structural formula:
[0025] wherein R 5 is a saturated or unsaturated, substituted or unsubstituted aliphatic or aromatic moiety containing from 4 to 24 carbon atoms, and x is an integer from 3 to 30; and
[0026] wherein R, which is derived from an aliphatic or aromatic monocarboxylic acid, has the structural formula:
[0027] wherein R 2 , R 3 and R 4 are independently selected from the group consisting of methyl, ethyl, propyl or isopropyl; or
[0028] wherein R 6 is H or OH or NH 2 or methyl or ethyl.
[0029] A preferred group of compounds have the following structural formula:
[0030] wherein R 1 , which may be derived from a polypropoxylated fatty alcohol, has the structural formula:
[0031] wherein R 5 is a straight-chain or branched-chain saturated aliphatic moiety containing from 4 to 24 carbon atoms, an aromatic moiety containing 7 or 8 carbon atoms, or an unsaturated moiety containing 14 to 18 carbon atoms and containing 1, 2 or 3 double bonds, and x is an integer from 3 to 30; and
[0032] wherein R, which may be derived from an aliphatic or aromatic monocarboxylic acid, has the structural formula:
[0033] wherein R 2 , R 3 and R 4 are independently selected from the group consisting of methyl, ethyl, propyl or isopropyl.
[0034] These compounds, for example, may be derived from tert-butanol, n-octanol, n-hexadecanol (cetyl alcohol), octyldodecanol, benzyl alcohol, phenylethyl alcohol, oleyl alcohol or linoleyl alcohol.
[0035] The present invention provides fatty polypropoxylate esters possessing exceptional pigment dispersant and esthetic emollient properties long sought by formulators for use in personal care and topical pharmaceutical preparations.
[0036] In accordance with another aspect of the present invention, there are provided compositions for topical application that include such the fatty polypropoxylate esters.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] The emollient dispersants of the present invention are fatty polypropoxylate esters of aliphatic and aromatic monocarboxylic acids.
[0038] The aliphatic monocarboxylic acids suitable for preparing the compounds of the present invention contain from 2 to 24 carbon atoms. The aromatic monocarboxylic acids suitable for preparing the compounds of the present invention contain from 7 to 9 carbon atoms. Preferred aliphatic monocarboxylic acids contain from 4 to 18 carbon atoms. Examples of suitable aliphatic monocarboxylic acids include 2-Ethyl Hexanoic acid, Caproic acid, Neopentanoic acid, Isostearic acid, Neoheptanoic acid and Oleic acid. Examples of suitable aromatic moncarboxylic acids include Benzoic acid and p-Aminobenzoic acid.
[0039] The fatty polypropoxylate esters of the present invention are formed by reacting the above described aliphatic and aromatic monocarboxylic acids with polypropoxylated fatty alcohols. The polypropoxylated fatty alcohols preferably have between 3 and 30 moles of propoxylation, and most preferably between 3 and 10 moles of propoxylation. The fatty alcohols utilized to prepare these polypropoxylated fatty alcohols may be saturated or unsaturated, substituted or unsubstituted, aliphatic or aromatic, and may be straight chained or branched chained, having between 6 and 24 carbon atoms. Saturated aliphatic fatty alcohols, either straight chain or branched chain, with 12 to 14 carbon atoms are most preferred.
[0040] The fatty polypropoxylated esters of the present invention are particularly useful as agents that confer superior pigment dispersion and unusual, dry, elegant emollient properties to topical formulations, especially to those containing physical sunscreens and other pigments. The fatty polypropoxylated esters of the present invention are also singularly useful in the preparation of fluid, high solids content dispersion grinds of micronized physical sunscreens such as Zinc Oxide and Titanium Dioxide for use in sunscreen formulations. The esters are useful in the formulation of sunscreen lotions, sunscreen sprays, self-tanning compositions, make-ups and other pigmented products, cold creams, skin moisturizers, antiperspirants, after shaves, pre-electric shaves, topical pharmaceutical products, lipsticks and cleansing creams. The dry, elegant emolliency imparted by the fatty polypropoxylated esters of the present invention is manifested primarily when the esters are utilized as a full or partial replacement for the mineral oil and petrolatum emollient agents of the prior art. A distinct improvement in the esthetics and emollient properties of mineral oil and petrolatum-based products is discernible when as little as 25% of the mineral oil or petrolatum has been replaced by the fatty polypropoxylated esters of the present invention. Therefore, topical preparations in accordance with the present invention can include a second emollient agent of mineral oil, petrolatum and the like along with the fatty polypropoxylated esters of the present invention in a ratio of up to about 3:1 of the second emollient agent to the emollient agent of the present invention. These topical formulations include the essential compounds of the present invention, one or more active ingredients and water. As mentioned above, a second emollient agent of mineral oil, petrolatum and the like may be included as desired. Suitable active ingredients for use in topical preparations include organic sunscreens, physical sunscreens, self-tanning agents, pigments, opacifying agents, moisturizers, film-formers, thickening agents, emulsifiers, antiseptic agents, conditioning agents and deodorant actives.
[0041] The topical preparations of the present invention, in addition to including the primary components of the fatty polypropoxylated esters of the present invention, one or more active ingredients, water and the optional second emollient agent, may also include fragrances, humectants, protein derivatives, coloring agents, preservatives and the like.
[0042] Typical topical formulations in accordance with the present invention include the essential fatty polypropoxylated esters of the present invention either alone or in combination with the second emollient agent, in a range of from about 0.2% to about 40.0% by weight of the composition, preferably from about 2.0% to about 20.0% of the composition. As noted above, the second emollient agent, when present, may be blended with the fatty polypropoxylate ester emollients of the present invention in a ratio of about 3:1 of the former to the latter.
[0043] The topical preparations of the present invention are formulated using techniques that are well known to practitioners in the cosmetic formulating art. Typically, the ingredients are combined with mixing and the application of heat as necessary until a homogeneous product is obtained. The water soluble ingredients and water-insoluble ingredients are mixed together separately and combined with suitable emulsifying agents.
[0044] The topical compositions of the present invention are topically applied directly to the skin. The compositions can be delivered by placing the composition into a dispensing means and applying an effective amount via spraying or rubbing the composition onto the desired skin surface, either the entire body or selected portions thereof. Preferably the dispensing means is a wipe or a spray dispenser. Distribution of the composition of the present invention can also be achieved by using a pre-formed applicator such as a roller, pad, sponge, tissue, cotton ball, hand, etc. Alternatively, the user may combine the composition of the present invention with a wipe substance of his or her own choosing. To do this, the user simply chooses a wipe substance such as a commercial paper towel, tissue, sponge, cotton, pad, washcloth, or the like; and pours, from a bottle or other suitable container, a solution of the composition of the present invention over the chosen wipe substance and applies the composition to the desired area of the body. In this manner, the user may use as much or as little of the composition of the present invention as he/she desires, depending upon their intended use.
[0045] The following examples set forth below are intended to illustrate certain aspects of the present invention, and are not to be considered limiting as to the scope and nature of the present invention.
EXAMPLES
[0046] Preparation of Compounds
[0047] The fatty alcohol, e.g., Myristyl alcohol, was reacted with Propylene Oxide in the presence of alkaline catalysts in the conventional fashion, followed by neutralization with a suitable acid such as Phosphoric Acid. The resultant polypropoxylated fatty alcohol was reacted in the conventional fashion with a stoichiometric amount of the aliphatic or aromatic fatty acid, e.g., Ethylhexanoic acid, followed by neutralization with a suitable base such as Sodium Carbonate. The typical reaction is as follows:
[0048] Preparation of PPG-3 Myristyl Ether Neoheptanoate
[0049] 3 moles (642 grams) of Myristyl Alcohol were charged to an autoclave, and 0.1% of Potassium Hydroxide was added as a catalyst. The autoclave was purged with Nitrogen and 9 moles (522 grams) of Propylene oxide were added at a temperature of 150-160° C. and a pressure of 30-40 psi. At the completion of the addition reaction, the batch was cooled to 80° C. and neutralized with Phosphoric Acid. The resultant 1,164 grams of product, PPG-3 Myristyl Ether, a pale yellow liquid, was charged to a four-neck flask. 3 moles (390 grams) of Neoheptanoic Acid were charged to the flask, along with a catalytic amount of methanesulfonic acid. The reaction mixture was heated with agitation to 190° C. until an acid value of less than 8 mg KOH was obtained. The reaction mixture was cooled to 80° C., washed with a dilute Sodium Carbonate solution sufficient to neutralize the residual acid present, followed by washing with water. The ester layer was separated and heated under vacuum until a moisture content of less than 0.3% was obtained, followed by vacuum filtration. The resultant product, PPG-3 Myristyl Ether Neopentanoate, was a clear pale yellow liquid having an acid value of 0.12 mg KOH.
[0050] Preparation of PPG-4 Butyloctyl Ether Ethylhexanoate
[0051] 4 moles (744 grams) of Butyloctanol were charged to an autoclave, and 0.1% of Potassium Hydroxide was added as catalyst. The autoclave was purged with Nitrogen and 16 moles (928 grams) of Propylene Oxide were added at a temperature of 150-160° C. and a pressure of 30-40 psi. Upon completion, the batch was cooled to 80° C. and neutralized with Phosphoric Acid. The resultant product, PPG-4 Butyloctyl Ether, was a very pale yellow liquid. A four-neck flask was charged with 1,224 grams of the PPG-4 Butyloctyl Ether, along with 3 moles (432 grams) of 2-Ethyl Hexanoic Acid. A catalytic amount of p-Toluenesulfonic Acid was added and the reaction mixture was heated with agitation to 160° C. until an acid value of less than 5 mg KOH was obtained. The reaction mixture was cooled to 80° C., washed with a dilute Sodium Hydroxide solution sufficient to neutralize the residual acid present, followed by washing with water. The ester layer was separated and heated under vacuum until a moisture content of less than 0.2% was obtained, followed by vacuum filtration. The resultant product, PPG-4 Butyloctyl Ether Ethylhexanoate, was a clear very pale yellow liquid having an acid value of less than 0.1 mg KOH.
[0052] PPG-4 Butyloctyl Ether Ethylhexanoate
[0053] Dispersion Efficacy Testing
[0054] By use of a simple screening test for dispersant effectiveness, we have discovered that these aliphatic and aromatic esters of polypropoxylated fatty alcohols demonstrate greatly superior pigment wetting properties and greatly enhanced ability to keep physical sunscreen ingredients such as micronized Zinc Oxide in suspension. The tests show that these aliphatic and aromatic monocarboxylic acid esters of polypropoxylated fatty alcohols are superior to commonly used dispersants such as C 12 -C 15 Alkyl Benzoate, Octyldodecyl Neopentanoate, Neopentyl Glycol Dietylhexanoate, and Tridecyl Neopentanoate, Propylene Glycol, and PPG-3 Myristyl Ether.
[0055] A dispersion of 20 grams of micronized Zinc Oxide (Z-COTE HP-1) and 80 grams of the dispersant to be tested was prepared by adding the Zinc Oxide to the test dispersant under low shear propeller agitation and mixing for 15 minutes. A 10 ml aliquot of the dispersion was then centrifuged for 10 minutes at 3500 rpm in a graduated conical centrifuge tube, and the degree of separation was noted. Using this test, dispersions were made with two of the test compounds, PPG-3 Myristyl Ether Neoheptanoate and PPG-3 Butyloctyl Ether Ethylhexanoate. These tests showed essentially no evidence of separation after centrifugation. By comparison, dispersions made with C 12 -C 15 Alkyl Benzoate, Octyldodecyl Neopentanoate and Neopentyl Glycol Dietylhexanoate demonstrated approximately 30-35% separation after centrifugation, while a dispersion made with Tridecyl Neopentanoate showed an approximate 25% separation. Dispersions made with Propylene Glycol and PPG-3 Myristyl Ether demonstrated separations in excess of 50% upon centrifugation.
[0056] In other tests, 50 percent milled dispersions of micronized Titanium Dioxide (WC&D CTFA 328) were prepared in PPG-3 Myristyl Ether Neoheptanoate and in Elefac 1-205 by first mixing the pigment with the vehicle until the pigment was thoroughly wetted, and then passing the resultant mixture over a three roller mill. The quality of the grind was measured using a Hegman Gauge, confirming a particle size of less than one micron for each preparation. The grind prepared using Elefac 1-205 was an immobile paste, while the grind prepared using PPG-3 Myristyl Ether Neoheptanoate was a thin fluid. Using the same methodology, 50 percent milled dispersions of Ultrafine Zinc Oxide (Z-Cote, untreated) were prepared in PPG-3 Myristyl Ether Neoheptanoate and in Finsolv TN. The grind prepared using Finsolv TN was an immobile paste, while the grind prepared using PPG-3 Myristyl Ether Neoheptanoate was a thin fluid.
[0057] Cosmetic Preparations
[0058] The following examples, while not intended to be limiting, demonstrate topical preparations formulated into a lipstick, a sunscreen lotion containing micronized Titanium Dioxide, a waterproof sunscreen lotion containing micronized Zinc Oxide, and a pigmented cream foundation.
[0059] Preparation of Emollient Lipstick
Phase INCI Name Percent A PPG-3 Myristyl Ether Neoheptanoate 10.00 (TRIVASPERSE NH - Trivent) Castor Oil 41.35 B Red #6 (1:2 in Castor Oil) 1.90 Red #7 (1:1 in Castor Oil) 2.38 Yellow #5 (1:2 in Castor Oil) 0.32 Titanium Dioxide (1:1 in Castor Oil) 1.75 Blue #1 (0.75:2.25 in Castor Oil) 0.10 C Mango Butter (Trivent) 7.00 Octyl Methoxycinnamate (Trivent OMC - Trivent) 2.50 Hydrogenated Polyisobutene (Panalane H-300 E - Lipo) 5.00 Candelilla Wax 4.50 White Beeswax 4.50 Ozokerite Wax 5.00 Carnauba Wax 1.50 Emulsifying Wax 0.75 Polyglyceryl-3 Methylglucose Distearate 2.50 (Tego Care 450 - Goldschmidt) D Nylon 12 And Boron Nitride (Liponyl 10 BN 6069 - 8.00 Lipo) E Tocopheryl Acetate 0.10 Wheat Germ Oil 0.25 Isopropylparaben, Isobutylparaben, Butylparaben 0.60 (Liquipar Oil-Sutton Labs) Total 100.00
[0060] Disperse B into A. Heat C to 80°-85° C. and mix until melted and uniform. Heat AB to 80°-85° C. and add to C while mixing slowly. Maintain temperature and mix until uniform. Take care not to aerate batch. Mix and cool to 65° C. Add D and E. Maintain temperature, mix until uniform, then pour into molds.
[0061] Preparation of Cream Foundation
Phase INCI Name Percent A Deionized Water 35.95 Triethanolamine, 99% 1.85 Glycerine, USP 3.00 Trisodium EDTA 0.10 Simethicone (Anti-Foam AF-Dow Corning) 0.10 B Glyceryl Stearate 3.50 Stearic Acid 3.00 Laureth-2 31.00 Cetyl Alcohol 3.00 Hydrogenated Vegetable Oil 7.50 C PPG-3 Myristyl Ether Neoheptanoate 5.00 (TRIVASPERSE NH - Trivent) Dimethicone 2.00 Iron Oxide Red 0.20 Iron Oxide Yellow 0.63 Iron Oxide Black 0.08 Iron Oxide Brown 0.09 Titanium Dioxide 1.00 Talc 1.00 D Carbomer (Carbopol 940, 2% aqueous solution - 30.00 BFGoodrich) E Phenoxyethanol (and) Methylparaben (and) Butylparaben 1.00 (and) Ethylparaben (and) Propylparaben (Phenonip - Nipa) Total 100.00
[0062] In main vessel, mix and heat Phase A to 65-70° C. In a separate vessel, mix and heat Phase B to 65-70° C. In an appropriately-sized vessel, mix Phase C until completely dispersed. When Phase B is at temperature, add Phase C to Phase B and mix until uniform. Begin homogenizing Phase A. Slowly add combined Phase B to Phase A while homogenizing. Homogenize for 5-10 minutes, until uniform. Switch to propeller mixer and begin cooling batch. At 55-60° C., add Phase D to main batch. Maintain minimum temperature of 50° C. Cool batch with stirring to 35-40° C. and add Phase E. Mix until uniform. Continue mixing while cooling batch to room temperature (20-25° C).
[0063] Preparation of Waterproof Sunscreen (Zinc Oxide)
Phase INCI Name Percent A Polyglyceryl-4 Isostearate (and) Cetyl Dimethicone 5.00 Copolyol (and) Hexyl Laurate (Abil WE-09 - Goldschmidt) Cetyl Dimethicone (Abil Wax 9801 - Goldschmidt) 1.00 Beeswax 0.75 Octyl Methoxycinnamate (Trivent OMC) 7.50 Octyl Palmitate (Trivent OP) 3.00 Cetyl Acetate (and) Acetylated Lanolin Alcohols 2.00 (Trivent ALA) Cyclopentasiloxane 3.00 Cetyl Palmitate (Trivent CP) 1.00 Dimethicone 0.25 B PPG-3 Myristyl Ether Neoheptanoate 7.50 (TRIVASPERSE NH - Trivent) Zinc Oxide (Z-Cote - BASF) 7.50 C Deionized Water 59.60 Sodium Chloride 0.80 Trisodium EDTA 0.10 D Phenoxyethanol (and) Methylparaben (and) Butylparaben 1.00 (and) Ethylparaben (and) Propylparaben (Phenonip - Nipa) Total 100.00
[0064] In main vessel, mix and heat Phase A to 70° C. In an appropriately-sized vessel, mix Phase B until completely dispersed. When Phase B is dispersed, add to Phase A. In a separate vessel, mix and heat Phase C to 70° C. At temperature, add Phase C to Phase A slowly with stirring. Homogenize batch for 5-10 minutes. Switch to propeller mixer and cool batch to 45° C. At 45° C., add Phase D to batch and mix until uniform. Continue mixing and cool batch to room temperature (20-25° C.).
[0065] Preparation of Sunscreen Lotion (Titanium Dioxide)
Phase INCI Name Percent A Deionized Water 60.20 Trisodium EDTA 0.10 Butylene Glycol 2.00 Xanthan Gum 0.30 B Octyl Methoxycinnamate (Trivent OMC) 7.50 Glyceryl Stearate/PEG-100 Stearate 1.50 Cetyl Dimethicone (Abil Wax 9801 - Goldschmidt) 1.00 Pentaerythritol Tetra-2-Ethylhexanoate (Trivent PE-48) 3.00 Cetearyl Alcohol 2.50 Ceteareth-20 0.40 Tocopheryl Acetate 0.50 Beeswax 0.50 Cetyl Palmitate (Trivent CP) 1.25 C PPG-3 Myristyl Ether Neoheptanoate 8.75 (TRIVASPERSE NH - Trivent) Titanium Dioxide (Micro LA-20 - Grant) 6.50 Polysorbate-20 1.00 D Polyacrylamide (and) C 13-14 Isoparaffin (and) Laureth- 72.00 (Sepigel 305 - Seppic) E Phenoxyethanol (and) Methylparaben (and) Butylparaben 1.00 (and) Ethylparaben (and) Propylparaben (Phenonip - Nipa) Total 100.00
[0066] In main vessel, mix and heat Phase A to 65-70° C. In a separate vessel, mix and heat Phase B to 65-70° C. In an appropriately-sized vessel, mix Phase C until completely dispersed. At temperature, add Phase B to Phase A and begin homogenization. While homogenizing, add Phase C to batch. Continue homogenizing and add Phase D to batch. Homogenize for 5 minutes, until uniform. Switch to propeller mixer. Cool batch to 40-45° C. and add Phase E. Mix until uniform. Continue mixing and cool batch to room temperature (20-25° C.).
COMPARATIVE DISCUSSION AND COMPARATIVE EXAMPLES
[0067] Generally, there are substantive differences in properties between propoxylates and ethoxylates of any given reactive substrate. For example, propoxylates of fatty alcohols, fatty acids, fatty amines, and fatty amides, generally have similar properties and functionality with respect to aqueous solubility, aqueous dispersibility, physical form and surfactancy. Likewise, ethoxylates of fatty alcohols, fatty acids, fatty amines, and fatty amides, also have similar properties and functionality with respect to aqueous solubility, aqueous dispersibility, physical form and surfactancy. However, the properties and functionality of propoxylates compared to ethoxylates are generally completely different from each other. For example, whereas the propoxylates are insoluble in water, will not emulsify in water without the aid of surfactants, are oily liquids and do not function as surfactants, ethoxylates are soluble in water, are waxy solids and function as surfactants and emulsifiers.
[0068] While ethylene oxide and propylene oxide differ only by a methyl group, they nevertheless impart vastly different properties to substrates with which they are reacted. As a typical example, fatty alcohols may be derivatized by reaction with either propylene oxide or with ethylene oxide, yielding propoxylated fatty alcohols and ethoxylated fatty alcohols, respectively.
[0069] As a typical example, Cetyl Alcohol (1-hexadecanol), a fatty alcohol which is a waxy solid with a melting point of approximately 45° C., is essentially insoluble in water. For example, when Cetyl Alcohol, is reacted with 6 moles of ethylene oxide (Comparative Example 1), the resultant derivative, POE-6 Cetyl Ether, is a soft waxy solid which is completely soluble in water, and which functions both as an emulsifier and as a surfactant. In contrast thereto, when Cetyl Alcohol is reacted with 6 moles propylene oxide (Comparative Example 2), the resultant derivative, PPG-6 Cetyl Ether, is an oily liquid which is essentially insoluble in water and which does not function either as an emulsifier or a surfactant.
Comparative Example 1
[0070] [0070]
Comparative Example 2
[0071] [0071]
[0072] While the compound of Comparative Example 1 only differs from the compound of Comparative Example 2 by the absence of methyl groups along the polyoxypropylene chain, its properties and functions are very different.
[0073] If one were to further derivatize the compounds of Comparative Example 1 and Comparative Example 2 above by reaction with a carboxylic acid, the essential attributes of propoxylated fatty alcohols and of ethoxylated fatty alcohols are still retained. For example, the Acetic Acid ester of Comparative Example 1 above, POE-6 Cetyl Ether Acetate, is a soft waxy solid which is completely soluble in water, and which functions both as an emulsifier and as a surfactant. In contrast, the Acetic Acid ester of Comparative Example 2 above, PPG-6 Cetyl Ether Acetate, is an oily liquid which is essentially insoluble in water and which does not function either as a emulsifier or as a surfactant.
[0074] Compounds which incorporate both ethylene oxide and propylene oxide reacted with a fatty substrate, for example PPG-3 POE-3 Cetyl Ether, exhibit properties intermediate between those of Comparative Example 1 and Comparative Example 2. Typically, they tend to be dispersible in—rather than miscible with—water, and exhibit lessened emulsifier and surfactant properties versus compounds of Comparative Example 1. Carboxylic acid esters of these mixed alkoxylates also retain these intermediate properties.
[0075] With this background information, reference is made to the compounds disclosed in U.S. Pat. No. 4,559,226 to Fogel. The essence of the invention of '226 Fogel, lies in the discovery that certain carboxylic acid esters of fatty alcohols which have been both ethoxylated and propoxylated in certain defined ratios, form novel self-emulsifying emollients. These compounds were found to be particularly useful in preventing chalking in antiperspirant compositions containing volatile silicone oil. The novel functionalities and properties for the compounds disclosed in '226 Fogel (e.g., water dispersability) are directly attributable to the presence of both the ethoxylate and propoxylate substituents of the compounds.
[0076] For example, a typical compound disclosed in '226 Fogel is PPG-1 Ceteth-3 Acetate (PPG-1 POE-3 Cetyl Ether Acetate). Because this molecule incorporates both propoxylation and ethoxylation within its structure, it exhibits properties intermediate between ethoxylate esters and propoxylate esters, giving it its unique self-emulsifying characteristics. In contrast thereto, the compound of the present invention, for example, PPG-3 Myristyl Ether Neoheptanoate [which is only propoxylated, i.e., there is no ethoxylation in the structure] is essentially insoluble in water.
[0077] The compounds of the present invention do not exhibit the self-emulsifying properties of the alkoxylate esters disclosed in '226 Fogel, in that they will not disperse in water and do not function as self-emulsifiers. They do, however, exhibit their own unique properties not shared by the compounds disclosed in '226 Fogel, in that they function as exceptional pigment dispersants with unusually elegant emolliency. Their exceptional pigment dispersant properties were demonstrated in the Dispersion Efficiency tests described herein.
[0078] To demonstrate the differences between these two classes of compounds, Dispersion Efficiency tests were performed, utilizing the same protocols described herein, using PPG-1 Ceteth-3 Acetate as the test dispersant.
Comparative Example 3
[0079] A dispersion of 20 grams of micronized Zinc Oxide (Z-COTE HP-1) and 80 grams of PPG-1 Ceteth-3 Acetate was prepared by adding the Zinc Oxide to the PPG-1 Ceteth-3 Acetate under low shear propeller agitation and mixing for 15 minutes. A 10 ml aliquot of the dispersion was then centrifuged for 10 minutes at 3,500 rpm in a graduated conical centrifuge tube, and the degree of separation was noted. Under these test conditions, the PPG-1 Ceteth-3 Acetate dispersion demonstrated a 50% separation upon centrifugation. This result was in marked contrast to this same test using PPG-3 Myristyl Ether Neoheptanoate as the dispersant, where essentially no evidence of separation following centrifugation was noted.
Comparative Example 4
[0080] A 50 percent milled dispersion of micronized Titanium Dioxide (WC&D CTFA 328) was prepared in PPG-1 Ceteth-3 Acetate by first mixing the pigment with the vehicle until the pigment was thoroughly wetted, and then passing the resultant mixture over a three roller mill. The quality of the grind was measured using a Hegman Gauge, confirming a particle size of less than one micron for the preparation. The resultant grind was an immobile paste. This result was in marked contrast to the same test using PPG-3 Myristyl Ether Neoheptanoate, where the resultant grind was a thin fluid.
Comparative Example 5
[0081] A 50% milled dispersion of ultrafine Zine Oxide (Z-COTE, untreated) was prepared in PPG-1 Ceteth-3 Acetate by first mixing the pigment with the vehicle until the pigment was thoroughly wetted, and then passing the resultant mixture over a three roller mill. The quality of the grind was measured using a Hegman Gauge, confirming a particle size of less than one micron for the preparation. The resultant grind was an immobile paste. This result was in marked contrast to the same test using PPG-3 Myristyl Ether Neoheptanoate, where the resultant grind was a thin fluid.
[0082] The differences in physical properties, aqueous solubilities, and functionalities between ethoxylates, propoxylates and alkoxylates containing both ethylene oxide and propylene oxide are substantial, although they differ only in the presence or absence of methyl groups on the ether portions of the molecules. In our testing, these differences extend beyond physical appearance, surfactancy and water-dispersibility to include large differences in pigment dispersing power between the two classes of compounds.
[0083] It is understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention. All such variations and modifications are intended to be included within the scope of the invention. | A novel fatty polypropoxylate ester which is an ester of an aliphatic or an aromatic monoacid formed by reacting the acid with a stoichiometric excess of a polypropoxylated fatty alcohol. The compounds have the following structural formula:
wherein R 1 has the structural formula:
wherein R 5 is a saturated or unsaturated, substituted or unsubstituted aliphatic or aromatic moiety containing from 4 to 24 carbon atoms, and x is an integer from 3 to 30; and
wherein R has the structural formula:
wherein R 2 , R 3 and R 4 are independently selected from the group consisting of methyl, ethyl, propyl or isopropyl; or
wherein R 6 is H or OH or NH 2 or methyl or ethyl.
The compounds possess exceptional pigment dispersant and esthetic emollient properties for use in personal care and topical pharmaceutical preparations, e.g., lipsticks, cream foundations, waterproof sunscreens, sunscreen lotions. | 0 |
FIELD OF THE INVENTION
[0001] The present invention is related to the human medicine and especially with the generation of pharmaceutical compositions comprising a humanized monoclonal antibody recognizing the leukocyte differentiation antigen CD6, and particularly with therapeutic formulations which contain a humanized monoclonal antibody that recognizes the leukocyte differentiation antigen CD6 able to induce a long-lasting therapeutic effect in Rheumatoid Arthritis patients.
DESCRIPTION OF THE PRIOR ART
[0002] Autoimmune Diseases and particularly, Rheumatoid Arthritis (RA) have available different strategies with therapeutic purposes, associated to their known immunopathologic mechanisms (Smolen, J. S. et al. (2003) Nature Reviews Drug Discovery 2:473; Feldmann, M. et al. (2005) Nature 435:612). However, there is not a treatment for Rheumatoid Arthritis that administered for a short period of time may induce a long-lasting clinical response (Garber, K. (2005) Nature Biotechnology 23(11):1323).
[0003] Several biotherapies are currently available for the treatment of patients with Autoimmune Diseases and particularly for therapy of Rheumatoid Arthritis patients, although their clinical effect as monotherapies is very limited (Olsen, N. J. et al. (2004) N Engl J Med 350:2167). Moreover, combinatorial therapies of biological agents with Methotrexate may induce clinical remission in 30-40% of Rheumatoid Arthritis patients, but the disease remains significantly active in most of the patients despite the treatment and complete remissions rarely occur (Pincus, T. et al. (1999) Ann Intern Med 131:768; Olsen, N. J. et al. (2004) N Engl J Med 350:2167). Additionally, multiple and severe adverse events have been described for such therapeutic approximations (O'Dell, J. R. (2004) N Engl J Med 350:2591).
[0004] Monoclonal antibodies (mAbs) are biological agents used in the treatment of Autoimmune Diseases (Feldmann, M. et al. (2005) Nature 435:612). Particularly, monoclonal antibodies depleting with the capacity to deplete autoreactive cells are of medical interest due to the consideration that a prolong depletion of lymphocytes is required to induce a therapeutic effect in Autoimmune Disease patients, such as Rheumatoid Arthritis (Edwards, J. C. et al. (2004) N Engl J Med 350:2572; Stohl, W. et al. (2006) Clinical Immunology 121:1; Browning, J. L. (2006) Nature Reviews Drug Discovery 5:564). This immunosuppression induced by lymphocyte depletion is a common mechanism of therapeutic effect for several therapeutic options in Autoimmune Diseases (Kahan, B. D. (2003) Nature Reviews Immunology 3:831). Nevertheless, therapeutic effects are limited and associated to significant adverse events (Edwards, J. C. et al. (2004) N Engl J Med 350:2572; Hale, D. A. (2004) Current Opinion Immunology 16:565; Goldblatt, F. et al. (2005) Clinical and Experimental Immunology 140:195).
[0005] Consequently, a better understanding of molecules and mechanisms involved in the physiopathology of Autoimmune Diseases, and particularly in Rheumatoid Arthritis, should lead to the discovery of new therapeutic targets where the intended therapy switch from the elimination of autoreactive cells to the induction or the restoration of the mechanism of tolerance and immunoregulation in the patient (Taylor, P. C. et al. (2004) Current Opinion Pharmacology 4:368; Feldmann, M. et al. (2005) Nature 435:612).
[0006] The leukocyte differentiation antigen CD6 is a molecule no well studied and characterized yet. The CD6 is a surface glycoprotein expressed primarily in T lymphocytes and in a minor subpopulation of B lymphocytes in peripheral blood of normal individuals. However the origin and the functional characterization in these cells are very limited. Basically, it is considered that CD6 in these cells is a receptor with co-stimulatory function, but the mechanism in unknown (Aruffo, A. et al. (1997) Immunol Today 18(10):498; Patel, D. D. (2000) J Biol Regul Homeost Agents 2000 14(3):234). Its expression in mature thymocytes has been associated to the lymphocyte maturation process in this lymphoid organ (Singer, N. G. et al. (2002) Int Immunol. 14(6):585).
[0007] The CD6 model has been of therapeutic interest and it has been claimed that the mechanism of action for anti-CD6 monoclonal antibodies is based in their capability to inhibit and modulate the CD6 binding to its ligand named ALCAM (Activated Leukocyte Adhesion Molecule) (U.S. Pat. No. 6,372,215). Consequently, those monoclonal antibodies are considered useful for the treatment of Autoimmune Diseases, but therapeutic evidences in patients based on such claim are not substantially documented.
[0008] CD6 molecule is recognized by the mouse monoclonal antibody ior-t1. Therapeutic formulations of this murine monoclonal antibody have therapeutic effect in Psoriasis (Montero, E. et al. (1999) Autoimmunity 29(2):155). Subsequently, based on methods of genetic engineering (U.S. Pat. No. 0,699,755 E.P. Bul.) it was obtained a humanized version of this mouse anti-human CD6 monoclonal antibody designated T1h (EP 0 807 125 A2).
[0009] The novelty of this invention relies on the generation of therapeutic formulations containing anti-CD6 monoclonal antibodies for their use in Autoimmune Disease patients and particularly, in Rheumatoid Arthritis patients. Surprisingly, the administration of the humanized T1h monoclonal antibody during 6 weeks as a monotherapy, in Autoimmune Disease patients and particularly in Rheumatoid Arthritis patients with a prolonged evolution and in active phase of the disease, induce a long-lasting therapeutic effect lasting for months after finished the administration of the treatment, without significant adverse events. This effect is not associated to the depletion of the CD6+ cells because the recovery to the normal value of that cellular subpopulation does not impede a persistent clinical improvement of the disease. The humanized T1h monoclonal antibody does not inhibit the binding of CD6 to the ALCAM, effect that was previously claimed for therapies in this therapeutic model, indicating its potential association to an alternative mechanism. Additionally, T1h treatment may sensitize autoimmune cells to the effect of anti-inflammatory agents, steroids or chemotherapies as Methotrexate, which may lead to the combinatorial use of humanized monoclonal antibody T1h with other drugs or other biotherapies.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The present invention relates with therapeutic formulations of monoclonal antibodies that recognize the human antigen CD6, effective in the treatment of patients with Autoimmune Diseases. More particularly, the present invention comprises the use of pharmaceutical compositions containing the humanized monoclonal antibody T1h, which recognizes the human leukocyte differentiation antigen CD6 and their use for the diagnosis and treatment of the Rheumatoid Arthritis.
[0011] It is a subject of the present invention a therapeutic formulation containing the humanized monoclonal antibody T1h, which induces a long-lasting therapeutic effect in Rheumatoid Arthritis patients by the recognition of the CD6 molecule. The term “humanized Monoclonal Antibody” refers to a monoclonal antibody obtained by genetic engineering methods as described in the U.S. Pat. No. 0,699,755 (E.P. Bul).
[0012] 1.—Generation of Pharmaceutical Compositions Contains the Humanized Anti-Human CD6 Monoclonal Antibody T1h.
[0013] The pharmaceutical composition of the present invention contains a humanized monoclonal antibody T1h that recognizes the human leukocyte differentiation antigen CD6. The humanized anti-human CD6 monoclonal antibody T1h is obtained from the secreting hybridoma IO-T1A with deposit No. ECACC 96112640, as described in (EP 0 807 125 A2). Additionally, this composition contains as an appropriate excipient a physiological buffered solution, similar to others used for the formulation of monoclonal antibodies for intravenous use, as described in EP 0807125. The composition of the present invention is administered in the way of injections in a range of doses from 0.05 to 1 mg/Kg of body weight
[0014] 2.—Characterization of the Therapeutic Effect of the Pharmaceutical Compositions Containing the Humanized Anti-human CD6 Monoclonal Antibody T1h.
[0015] Rheumatoid Arthritis patients diagnosed according to the standard criteria and in an active phase of the disease, resistant to conventional therapies, such as anti-inflammatory drugs, steroids or chemotherapeutic agents (e.g.: Methotrexate) are susceptible to the administration of the humanized monoclonal antibody T1h as monotherapy or in combination with anti-inflammatory drugs, steroids, chemotherapeutic agents (e.g.: Methotrexate) or monoclonal antibodies specific to surface molecules of T and B lymphocytes (e.g.: CD20) or cytokines (e.g.: Tumor Necrosis Factor alpha). The humanized monoclonal antibody T1h may be administered as a parenteral solution in a range of doses according to the body weight of the patient, with a variable frequency of administration which may comprise a daily, weekly or for a longer period administration. The therapeutic effect is evaluated by the reduction of the clinical activity of the disease, according to the standard criteria before, during and after finishing the treatment.
[0016] 3.—Characterization of the Effect on Peripheral Blood Mononuclear Cells of Pharmaceutical Compositions Containing the Humanized Monoclonal Antibody T1h. Peripheral blood mononuclear cells from Rheumatoid Arthritis patients are incubated with an anti-CD3 or an anti-CD6 monoclonal antibody conjugated to biotin or fluorescent substances (e.g.: FITC, PE or PE-Cy5). The binding of biotinylated antibodies is detected with a Streptavidin, PE-Cy5.5 conjugate. At least 10 000 living cells are acquired in a Flow Cytometer FACScan. Dead cells are excluded with the Propidium Iodine staining.
[0017] 4.—Characterization of the Ability of the Pharmaceutical Compositions Containing the Humanized Monoclonal Antibody T1h to Inhibit the CD6 Binding to its Ligand ALCAM.
[0018] The human epithelial cell line HEK-293 transfected with the human molecule CD6 is incubated with saturated concentration of the anti-human CD 6 monoclonal antibody T1h or an isotype control, an anti-human CD3 antibody during 30 minutes at 4° C. Cells are washed and incubated with 0.5 μg/mL of the fusion protein rhALCAM-Fc (ALCAM is a CD6 ligand) for 30 min at 4° C. Then, samples are stained with an anti-human IgG FITC-antibody conjugated for 30 min at 4° C. Ten thousand living cells are acquired in a Flow Cytometer FACScan. Dead cells are excluded with the Propidium Iodine staining.
EXAMPLES
[0019] The humanized anti-human CD6 Monoclonal Antibody T1h was obtained from the hybridoma IOR-T1A with deposit No. ECACC 96112640, as described in EP 0 807 125 A2.
Example 1
The Humanized Monoclonal Antibody T1h Induce a Long-Lasting therapeutic effect in Rheumatoid Arthritis patients
[0020] The therapeutic effect of the humanized Monoclonal Antibody T1h was evaluated or assessed in 13 Rheumatoid Arthritis patients. Patients received a weekly dose of the humanized monoclonal antibody T1h during 6 weeks in a range of doses of 0.2, 0.4, 0.6 and 0.8 mg/Kg of body weight. The therapeutic effect was evaluated by the reduction of the clinical activity of the disease, considering the number of affected joints according to the standard criteria before, during and after finishing the treatment. Each curve represents the mean values of the percentage of improvement of the clinical sign or symptom per group of patient according to the administered dose.
Example 2
The Treatment with the Humanized Monoclonal Antibody T1h Transiently Reduces the Number of Peripheral Blood Mononuclear Cells from Rheumatoid Arthritis Patients
[0021] Peripheral blood mononuclear cells from Rheumatoid Arthritis patients treated with the humanized monoclonal antibody T1h were analyzed. The expression of the CD3 molecule, as a distinctive T lymphocyte marker, as well as the CD6 molecule was determined. The humanized monoclonal antibody T1h treatment induces a transient reduction of CD3+ and CD6+ lymphocytes. However, a recovery to the normal values does not influence the persistent clinical improvement of the disease. The study was performed by flow cytometry using a FACScan to analyze the samples. Each curve represents the values of individual patients in different time points.
Example 3
The Humanized Monoclonal Antibody T1h does not Inhibit the CD6 Binding to its Ligand ALCAM
[0022] The capacity of the humanized monoclonal antibody T1h to inhibit the binding of ALCAM to the human epithelial cell line HEK-293, transfected with the human CD6 molecule was evaluated. (A) Red histogram: recognition of the human recombinant protein ALCAM bound to a human Fc fragment (rhALCAM-Fc) pre-incubated with the anti-CD6 (T1h) or anti-CD3 (control) antibodies; Black histogram: binding of the rhALCAM-Fc to non-treated cells; and Grey Histogram: labeled cells with the FITC-conjugated anti-human IgG antibody. The mean fluorescence intensity values are depicted in the figure. (B) Dot plots show the double staining for rhALCAM-Fc and anti-CD6 or anti-CD3 antibodies.
BRIEF DESCRIPTION OF THE FIGURES
[0023] FIG. 1 .—Therapeutic effect of the humanized monoclonal antibody T1h in Rheumatoid Arthritis patients evaluated by the reduction of the percent of swollen and tender joints.
[0024] FIG. 2 .—Quantification of the number of lymphocytes CD3+ and CD6+ in peripheral blood mononuclear cells from Rheumatoid Arthritis patients
[0025] FIG. 3 .—Demonstration of the non inhibition of the CD6 binding to the ALCAM ligand by the humanized monoclonal antibody T1h. | The present invention is related to the branch of immunology and particularly with the generation of pharmaceutical compositions containing a humanized monoclonal antibody recognizing the leukocyte differentiation antigen CD6. Accordingly with that statement, the purpose of this invention is to provide pharmaceutical compositions which contain a humanized anti-CD6 monoclonal antibody for the diagnosis and treatment of Autoimmune Diseases, particularly the Rheumatoid Arthritis. | 2 |
TECHNICAL FIELD
This disclosure generally relates to a device that can convertibly be used as a hang tag for an item and a container for the item.
BACKGROUND
Many items for sale, in particularly clothing items, utilize hang tags as a way to convey information about the item the tag is hanging from. Hang tags on garments today are usually used to convey information about a product including, but not limited to, a brand name, description of the garment, garment benefits, size information, price, fabric content, care instructions, marketing information, where the garment was manufactured, and distribution information. These hang tags are disposable and are not kept by the consumer. Hangs tags known in the art generally do not have any other purpose than to convey information such as listed above.
The items that the hang tags are attached to are typically stored somewhere after purchase. Most typically, this requires use of a dresser or similar furniture piece. Drawers can be messy with many small items. Drawer organizers are helpful but expensive. Moreover, the purchaser may be at an atypical location where they do not have access to their home storage areas or any storage areas at all. In these situations, a storage area can be separately purchased for the item, but the portability and disposability of such storage areas are lacking. Additionally, in today's world of being more ecologically friendly, re-purposing of any printed matter is important. Disposing of an item when it can serve a valuable purpose for the end user such as drawer organization is hot environmentally efficient.
Therefore, a need exists in the art for hang tags that are utilized for reasons other than the display of information. There is a further need for such a device that provides an immediate and portable storage area for the purchased item and that can serve as a drawer organizer.
SUMMARY
I solve these needs and provides a novel hang tag with two foldable embodiments and method for using the same. The two foldable embodiments include a hang tag for providing information about an item and a storage area that can be used for the same said item.
This disclosure further contemplates a convertible hang tag formed from a foldable blank, the foldable blank including a front panel having a multiplicity of sides, at least three end panels hingedly attached to the sides of the front panel wherein each end panel includes at least one interlocking mechanism to interlock with an adjacent end panel; at least one front panel aperture in the front panel; and at least one end panel aperture in at least one of the end panels, wherein the at least one end panel aperture overlaps the at least one front panel aperture when the end panel containing the at least one aperture is hingedly folded toward the front panel.
This disclosure further contemplates a convertible hang tag for identification of clothes, including a front panel haying a multiplicity of sides, at least three end panels hingedly attached to the sides of the front panel such that each side is hingedly attached to at least one end panel, and wherein each end panel includes at least one opening and at least one tab extending outwardly from an edge thereof, such that the at least one tab of one panel can interlock with at least one opening of an adjacent panel to form a storage area.
This disclosure further contemplates a method for converting a tag for identifying an item into a container, including the steps of unfolding a tag to provide a front panel having a multiplicity of sides and at least three end panels hingedly attached to the sides of the front panel, and interlocking the end panels together to form a storage area.
BRIEF DESCRIPTION OF THE DRAWINGS
Without restricting the full scope of my disclosure, various preferred forms of the disclosure and its related articles are illustrated in the following drawings.
FIG. 1 is a plain view of a hang tag blank having four end panels.
FIG. 2 is a plain view of a second embodiment of the hang tag with adhesive closures.
FIG. 3 is a back view of the second folded embodiment of the hangtag.
FIG. 4 is a closed view of a first embodiment with a sticker closure.
FIG. 5 is a front view of the first folded closed embodiment of the hang tag.
FIG. 6 is a front view of the first folded embodiment on an item.
FIG. 7 is a front view of a square first folded embodiment.
FIG. 8 is a side perspective view of the hang tag blank being folded into a second folded embodiment.
FIG. 9 is a side perspective view of the second folded embodiment.
FIG. 10 is a top perspective view of the second folded embodiment.
FIG. 11 is a top perspective of a second folded embodiment with adhesive closures.
FIG. 12 is a top perspective view of the second folded embodiment containing an item.
FIG. 13 is a plan view of a hang tag blank having eight end panels.
FIG. 14 is a front view of a first folded embodiment of the hang tag having eight end panels.
DETAILED DESCRIPTION
FIG. 1 shows a foldable blank combination device generally designated by reference number 10 . As discussed below, blank 10 can be folded into either a tag that can hang off an item, typically a piece of saleable merchandise, or placed into a container for holding the same item. Blank 10 includes front panel 12 and at least three end panels 14 that are hingedly attached to front panel 12 . In preferred embodiments, end panels 14 are hingedly attached to front panel 12 along fold lines 16 with outer edges 11 that are at least the same length as fold line 16 . In alternate embodiments, end panels can be attached to front panel 14 with other devices, such as binding or laced string, that allow for relative, hinged movement between the front and end panels.
FIG. 1 shows a preferred embodiment of a symmetrical blank 10 having four end panels of substantially the same size. The number of end panels can vary widely while maintaining the advantages can include substantially any number of sides greater than two. For example, FIG. 10 shows a blank having eight side panels. It will be understood by one skilled in the art that changing the number of end panels will change the shape of the ultimately formed tag or container without substantially changing the functionality. In preferred embodiments, the number of sides of front panel 12 is equal to the number of end panels, as this is the most efficient way to achieve dual foldability. Due to this variety, front panel 12 can be a variety of shapes depending on the number of end panels 14 used. In one preferred embodiment, shown in FIG. 1 , front panel 12 is substantially a square shape. At least one aperture 32 is formed in front panel 12 . Apertures 32 are used to hang the device from an item in one of the devices functional embodiments. As shown in FIG. 1 , blank 10 can include two apertures 32 of circular shape. One skilled in the art could understand, however, that the shape or even the number of apertures can vary within the spirit of my disclosure.
Blank 10 is preferably made of any foldable material known in the art. Most typically, blank 10 would be of a paper material having enough stiffness to enable portions of the blank to be folded in an upward direction. The size of the blank can be increased or decreased in scale as needed.
In preferred embodiments, each end panel includes at least one opening 18 and at least one tab 20 hingedly extending from side 22 . For simplicity's sake, the preferred embodiments have each panel including only one opening 18 and only one tab 20 as pictured in FIG. 1 . It is conceivable, however, to have multiple tabs and openings on each panel. For example, an end panel 14 could have two tabs substantially next to one another on side 22 and two corresponding openings also next to each other. In alternate embodiments, any interlocking mechanism known in the art can be utilized. For example, as shown in FIG. 2 , an alternate interlocking mechanism embodiment comprises a tab 25 that includes a peel away paper 23 on an adhesive strip 21 . In the embodiment shown in FIG. 2 , end panels 14 do not require openings 18 .
FIGS. 3-5 show a first folding embodiment of blank 10 into tag 38 . Each end panel 14 is hingedly moved along fold lines 16 toward front panel 12 . The end panels are folded as shown in FIG. 3 such that each end panel partially overlaps a first adjacent end panel and is in turn partially overlapped by a second adjacent panel. The end panels are held in place by the friction and pressure provided by the other end panels. In this foldable embodiments, the panels are not interlocked by openings 18 or tabs 20 . Tabs 20 are folded inwardly and are not visible or in use when tag 38 is formed. In another embodiment, shown in FIG. 4 , the end panels can also be folded to overlap opposite panels and held in place with a removable sticker 13 .
When the panels are folded into tag 38 , the apertures 32 are folded on top of one another such that a deeper aperture 40 is created, having the thickness of one front panel and at least one side panel. As shown in FIG. 3 , aperture 40 is visible from the front side of tag 38 . FIG. 6 shows tag 38 attached to an item 42 . In preferred embodiments, item 42 is a saleable merchandise wherein tag 38 provides identifying information for it. To best take advantage of the features of the box, item 42 is foldable such that it can later fit into the container folded embodiment depicted in FIGS. 8-12 . Most typically, this would be a clothing item, one example of which is FIG. 6 . In preferred embodiments, the tag is provided on items such as underwear, jock straps, sports bras, bras, athletic apparel, bike shorts, capri pants, shirts, t-shirts, camisoles, shapers, longline underwear, pantyhose, shaping pantyhose, leggings and boy shorts. One skilled in the art would understand, however, that the tag could be used on numerous other products as well.
Tag 38 is attached to item 42 using a fastening device or assembly 44 . In preferred embodiments, the tag is attached to the item via at least one aperture in the tag. In these embodiments, fastening assembly 44 includes a pliable material 46 such as a string that is entered through the apertures 40 of tag 38 and a fastener 46 such as a safety pin. As one skilled in the art would understand, however, other types of fastener assemblies could be used with aperture 40 to attach tag 38 to item 42 such as a tag gun.
In FIG. 7 the visible face of front panel 12 of tag 38 can be imprinted with any type of printing desired. Most typically, this will be identifying information such as a logo of the clothing manufacturer. Tag 38 can also be imprinted with any color or design.
In the embodiment in FIGS. 3-5 , apertures 40 are shown in a corner of tag 38 . This creates a diamond-shaped tag as it hangs off of item 42 , as shown in FIG. 5 . In alternate embodiments, apertures 40 can be located in other locations around the tag. One such embodiment is shown in FIG. 7 , wherein the apertures 40 are substantially centered along one side of front panel 12 . To create this embodiment, apertures 32 of FIG. 1 will have to be located elsewhere on blank 10 . This embodiment will create a square tag 38 as it hangs off item 40 . As would be readily understood, the apertures can be located elsewhere on the tag other than those locations depicted in FIGS. 1-7 .
As shown in FIG. 8-11 , blank 10 can be folded into a second folding embodiment. As shown in FIG. 8 , at least one tab 20 of end panel 14 is entered into an opening 18 of an adjacent end panel 14 , thereby interlocking the two adjacent panels together. Each tab extends from side 22 of end panel 14 and is designed to fit into an opening 18 in a substantially adjacent end panel. One skilled in the art will understand that the precise shapes and sizes of tabs 20 and openings 18 can vary widely while still maintaining the same functionality. In preferred embodiments, tabs 20 includes opposing converging sides 24 that converge as tab 20 extends from side 22 . Converging sides 24 extend to a crown 26 having a flat top side 28 and rounded sides 30 . Rounded sides 30 meet converging sides 24 at two opposing indents 36 .
Opening 18 is preferably a slit through which a portion of tab 20 can fit through, thereby interlocking two adjacent side panels. In this embodiment, a length “1” of opening 18 is smaller than a length “L” of crown 26 but greater than the length “L 1 ″” between the converging sides 24 . Opening 18 can accept crown 26 if crown 26 is entered on through opening 18 on a suitable angle. After entry, opening 18 can hold crown 26 on one side of the opening while the remainder of tab 20 is on the other side of the opening, thereby interlocking adjacent end panels 14 as shown in FIG. 9 .
Each tab 20 is entered into an opening in an adjacent end panel, interlocking the end panels together, until a container 48 is formed. As shown in FIG. 9 , completed container 48 provides a storage area 50 into which items can be placed. In preferred embodiments, shown in FIG. 12 , the item placed in storage area 50 is the same item 42 to which tag 38 was attached. To this end, a purchaser can buy an item 42 and simultaneously receive a storage container for the item that can be used as needed. This provides a purchaser with an inexpensive, portable and disposable alternative to purchases requiring separate boxes or containers to hold their purchases.
FIG. 11 shows an alternate embodiment wherein a container is formed when self adhesive tabs 25 are adhered onto adjacent end panels 14 .
I thereby provide a method for storing an item by converting a tag for identifying an item into a storage container for the item. The method includes the steps of unfolding a tag to provide a front panel having a multiplicity of sides and at least three end panels hingedly attached to the sides of the front panel and interlocking the end panels together to form a storage area. The item can thereafter be stored in the storage area. The resulting storage area is also preferably stackable with other like storage areas formed from like tags.
In further embodiments, the combination device can come in various shapes. FIGS. 13-14 show an octagonal combination device that can be folded into two separate folding embodiments. Blank 52 includes an octagonal front panel 54 having sides 56 . At least one aperture 64 is cut into the front panel at a location near sides 56 . Eight end panels 58 are attached to each side 56 , creating fold lines at each side 56 . Each end panel 58 includes at least one opening 60 and at least one tab 62 . At least one of the end panels includes at least one aperture to overlap at least one aperture 64 on the front panel. As shown in FIG. 13 , front panel 54 includes two aperture holes and two adjacent end panels 58 have one aperture each, such that when the end panels are folded toward each other, each aperture of the adjacent end panels cover one aperture of the front panel. In alternate embodiments, the apertures are in different locations on blank 52 .
Functionally, FIG. 13 octagonal blank 52 is the same as blank 10 of FIG. 1 . Each end panel 58 can be folded along fold lines 56 toward front panel 54 such that each end panel overlaps one adjacent end panel and is overlapped by an opposing adjacent end panel. This forms a first foldable embodiment that can be hung from a saleable item as a tag 66 as shown in FIG. 14 . Tag 66 can be imprinted with any design desired such as a clothing logo. Alternatively, each end panel 58 includes at least one opening 60 and at least one tab 62 such that they can be interlocked together to form a storage area for the saleable item. In this embodiment, the storage area has a generally octagonal shape. As could be readily understood by one skilled in the art, the combination device can include substantially any number of sides greater than two and any known interlocking, mechanism known in the art such as a peel away strip can be utilized.
I create a method and apparatus for identifying an item of sale and storage of the item after purchase. Various changes and modifications can be made without departing from its scope or spirit. For example, each end panel does not have to be identical in shape, and can have varying lengths and widths as relative to each other.
While the preferred embodiments of my disclosure have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of my disclosure, the scope of which is defined by the appended claims. | I provide a hang tag, preferably used for a saleable item such as clothing, that is convertible into a storage container. The storage container can then be used to store the purchased item. In a method of use, a user can remove the hang tag from a recently purchased saleable item of clothing, and, through a series of folds and interlocking of panels, create the storage containers in which the user could place the item. | 1 |
CROSS-REFERENCE
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/873,067 filed Aug. 30, 2013 entitled “METHOD AND APPARATUS FOR CREATING INTER DATACENTER COLLISION DOMAIN NETWORK STRETCH”, the contents of which are all herein incorporated by reference in its entirety.
FIELD
[0002] The disclosure generally relates to enterprise cloud computing and more specifically to a seamless cloud across multiple clouds providing enterprises with quickly scalable, secure, multi-tenant automation.
BACKGROUND
[0003] Cloud computing is a model for enabling on-demand network access to a shared pool of configurable computing resources/service groups (e.g., networks, servers, storage, applications, and services) that can ideally be provisioned and released with minimal management effort or service provider interaction.
[0004] Software as a Service (SaaS) provides the user with the capability to use a service provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through either a thin client interface, such as a web browser or a program interface. The user does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities.
[0005] Infrastructure as a Service (IaaS) provides the user with the capability to provision processing, storage, networks, and other fundamental computing resources where the user is able to deploy and run arbitrary software, which can include operating systems and applications. The user does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, and deployed applications; and possibly limited control of select networking components (e.g., host firewalls).
[0006] Platform as a Service (PaaS) provides the user with the capability to deploy onto the cloud infrastructure user-created or acquired applications created using programming languages, libraries, services, and tools supported by the provider. The user does not manage or control the underlying cloud infrastructure including network, servers, operating systems, or storage, but has control over the deployed applications and possibly configuration settings for the application-hosting environment.
[0007] Cloud deployment may be Public, Private or Hybrid. A Public Cloud infrastructure is provisioned for open use by the general public. It may be owned, managed, and operated by a business, academic, or government organization. It exists on the premises of the cloud provider. A Private Cloud infrastructure is provisioned for exclusive use by a single organization comprising multiple users (e.g., business units). It may be owned, managed, and operated by the organization, a third party, or some combination of them, and it may exist on or off premises. A Hybrid Cloud infrastructure is provisioned for exclusive use by a single organization comprising multiple users (e.g., business units). It may be owned, managed, and operated by the organization, a third party, or some combination of them, and it may exist on or off premises.
[0008] The promise of enterprise cloud computing was supposed to lower capital and operating costs and increase flexibility for the Information Technology (IT) department. However lengthy delays, cost overruns, security concerns, and loss of budget control have plagued the IT department. Enterprise users must juggle multiple cloud setups and configurations, along with aligning public and private clouds to work together seamlessly. Turning up of cloud capacity (cloud stacks) can take months and many engineering hours to construct and maintain. High-dollar professional services are driving up the total cost of ownership dramatically. The current marketplace includes different ways of private cloud build-outs. Some build internally hosted private clouds while others emphasize Software-Defined Networking (SDN) controllers that relegate switches and routers to mere plumbing.
[0009] The cloud automation market breaks down into several types of vendors, ranging from IT operations management (ITOM) providers, limited by their complexity, to so-called fabric-based infrastructure vendors that lack breadth and depth in IT operations and service. To date, true value in enterprise cloud has remained elusive, just out of reach for most organizations. No vendor provides a complete Cloud Management Platform (CMP) solution.
[0010] Therefore there is a need for systems and methods that create a unified fabric on top of multiple clouds reducing costs and providing limitless agility.
SUMMARY OF THE INVENTION
[0011] Additional features and advantages of the disclosure will be set forth in the description which follows, and will become apparent from the description, or can be learned by practice of the herein disclosed principles by those skilled in the art. The features and advantages of the disclosure can be realized and obtained by means of the disclosed instrumentalities and combinations as set forth in detail herein. These and other features of the disclosure will become more fully apparent from the following description, or can be learned by the practice of the principles set forth herein.
[0012] A Cloud Management Platform is described for fully unified compute and virtualized software-based networking components empowering enterprises with quickly scalable, secure, multi-tenant automation across clouds of any type, for clients from any segment, across geographically dispersed data centers.
[0013] In one embodiment, systems and methods are described for sampling of data center devices alerts; selecting an appropriate response for the event; monitoring the end node for repeat activity; and monitoring remotely.
[0014] In another embodiment, systems and methods are described for discovery of compute nodes; assessment of type, capability, VLAN, security, virtualization configuration of the discovered compute nodes; configuration of nodes covering add, delete, modify, scale; and rapid roll out of nodes across data centers.
[0015] In another embodiment, systems and methods are described for discovery of network components including routers, switches, server load balancers, firewalls; assessment of type, capability, VLAN, security, access lists, policies, virtualization configuration of the discovered network components; configuration of components covering add, delete, modify, scale; and rapid roll out of network atomic units and components across data centers.
[0016] In another embodiment, systems and methods are described for discovery of storage components including storage arrays, disks, SAN switches, NAS devices; assessment of type, capability, VLAN, VSAN, security, access lists, policies, virtualization configuration of the discovered storage components; configuration of components covering add, delete, modify, scale; and rapid roll out of storage atomic units and components across data centers.
[0017] In another embodiment, systems and methods are described for discovery of workload and application components within data centers; assessment of type, capability, IP, TCP, bandwidth usage, threads, security, access lists, policies, virtualization configuration of the discovered application components; real time monitoring of the application components across data centers public or private; and capacity analysis and intelligence to adjust underlying infrastructure thus enabling liquid applications.
[0018] In another embodiment, systems and methods are described for analysis of capacity of workload and application components across public and private data centers and clouds; assessment of available infrastructure components across the data centers and clouds; real time roll out and orchestration of application components across data centers public or private; and rapid configurations of all needed infrastructure components.
[0019] In another embodiment, systems and methods are described for analysis of capacity of workload and application components across public and private data centers and clouds; assessment of available infrastructure components across the data centers and clouds; comparison of capacity with availability; real time roll out and orchestration of application components across data centers public or private within allowed threshold bringing about true elastic behavior; and rapid configurations of all needed infrastructure components.
[0020] In another embodiment, systems and methods are described for analysis of all remote monitored data from diverse public and private data centers associated with a particular user; assessment of the analysis and linking it to the user applications; alerting user with one line message for high priority events; and additional business metrics and return on investment addition in the user configured parameters of the analytics.
[0021] In another embodiment, systems and methods are described for discovery of compute nodes, network components across data centers, both public and private for a user; assessment of type, capability, VLAN, security, virtualization configuration of the discovered unified infrastructure nodes and components; configuration of nodes and components covering add, delete, modify, scale; and rapid roll out of nodes and components across data centers both public and private.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0023] FIG. 1 is a block diagram of an exemplary hardware configuration in accordance with the principles of the present invention;
[0024] FIG. 2 is a block diagram describing a tenancy configuration wherein the Enterprise hosts systems and methods within its own data center in accordance with the principles of the present invention;
[0025] FIG. 3 is a block diagram describing a super tenancy configuration wherein the Enterprise uses systems and methods hosted in a cloud computing service in accordance with the principles of the present invention;
[0026] FIG. 4 is a logical diagram of the Enterprise depicted in FIG. 1 in accordance with the principles of the present invention;
[0027] FIG. 5 illustrates a logical view that an Enterprise administrator and Enterprise user have of the uCloud Platform depicted in FIG. 1 in accordance with the principles of the present invention;
[0028] FIG. 6 illustrates a flow diagram of a service catalog classifying data center resources into service groups; selecting a service group and assigning it to end users;
[0029] FIG. 7 illustrates a flow diagram of mapping service group categories to user groups that have been given access to a given service group, in accordance with the principles of the present invention;
[0030] FIG. 8 illustrates the Cloud administration process utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration, as well as monitoring;
[0031] FIG. 9 illustrates a hierarchy diagram of the Cloud administration process utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration in accordance with the principles of the present invention;
[0032] FIG. 10 illustrates the logical flow of information from the uCloud Platform depicted in FIG. 1 to a Controller Node in a given Enterprise for compute nodes;
[0033] FIG. 11 illustrates the logical flow of information from the uCloud Platform depicted in FIG. 1 to the Controller Node in a given Enterprise for network components;
[0034] FIG. 12 illustrates the logical flow of information from the uCloud Platform to the Controller Node in a given Enterprise for storage devices;
[0035] FIG. 13 illustrates the application-monitoring component of the uCloud Platform in accordance with the principles of the present invention;
[0036] FIG. 14 illustrates the application-orchestration component of the uCloud Platform in accordance with the principles of the present invention;
[0037] FIG. 15 illustrates the integration of the application-orchestration and application-monitoring components of the uCloud Platform in accordance with the principles of the present invention;
[0038] FIG. 16 illustrates the big data component of the uCloud Platform depicted in FIG. 1 and the relationship to the monitoring component of the platform
[0039] FIG. 17 illustrates the process of deploying uCloud within an Enterprise environment;
[0040] FIG. 18 illustrates a flow diagram in accordance with the principles of the present invention;
[0041] FIG. 19 illustrates a flow diagram in accordance with the principles of the present invention;
[0042] FIG. 20 illustrates a flow diagram in accordance with the principles of the present invention;
[0043] FIG. 21 illustrates a flow diagram in accordance with the principles of the present invention;
[0044] FIG. 22 illustrates a block diagram in accordance with the principles of the present invention; and
[0045] FIG. 23 illustrates a combined block and flow diagram in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0046] The FIGURES and text below, and the various embodiments used to describe the principles of the present invention are by way of illustration only and are not to be construed in any way to limit the scope of the invention. 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. A Person Having Ordinary Skill in the Art (PHOSITA) will readily recognize that the principles of the present invention maybe implemented in any type of suitably arranged device or system. Specifically, while the present invention is described with respect to use in cloud computing services and Enterprise hosting, a PHOSITA will readily recognize other types of networks and other applications without departing from the scope of the present invention.
[0047] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by a PHOSITA to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.
[0048] 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. 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.
[0049] Reference is now made to FIG. 1 that depicts a block diagram of an exemplary hardware configuration in accordance with the principles of the present invention. A uCloud Platform 100 combining self-service cloud orchestration with a Layer 2- and Layer 3-capable encrypted virtual network may be hosted by a cloud computing service such as but not limited to, Amazon Web Services or directly by an enterprise such as but not limited to, a service provider (e.g. Verizon or AT&T), provides a web interface 104 with a Virtual IP (VIP) address, a Rest API interface 106 with a Virtual IP (VIP), a RPM Repository Download Server and, a message bus 110 , and a vAppliance Download Manager 112 . Connections to and from web interface 104 , Rest API interface 106 , RPM Repository Download Server, message bus 110 , and vAppliance Download Manager 112 are preferably SSL secured. Interfaces 104 , 106 , 107 and 109 are preferably VeriSign certificate based with Extra Validation (EV), allowing for 128-bit encryption and third party validation for all communication on the interfaces. In addition to SSL encryption on Message BUS 110 , each message sent across on interface 107 to a Tenant environment is preferably encrypted with a Public/Private key pair thus allowing for extra security per Enterprise/Service Provider communication. The Public/Private key pair security per Tenant prevents accidental information leakage to be shared across other Tenants. Interfaces 108 and 110 are preferably SSL based (with self-signed) certificates with 128-bit encryption. In addition to communication interfaces, all Tenant passwords and Credit Card information stored are preferably encrypted.
[0050] Controller node 121 performs dispatched control, monitoring control and Xen Control. Dispatched control entails executing, or terminating, instructions received from the uCLoud Platform 100 . Xen control is the process of translating instructions received from uCLoud Platform 100 into a Xen Hypervisor API. Monitoring is performed by the monitor controller by periodically gathering management plane information data in an extended platform for memory, CPU, network, and storage utilizations. This information is gathered and then sent to the management plane. The extended platform comprises vAppliance instances that allow instantiation of Software Defined clouds. The management, control, and data planes in the tenant environment are contained within the extended platform. RPM Repository Download Server 108 downloads RPMs (packages of files that contain a programmatic installation guide for the resources contained) when initiated by Control node 121 . The message bus VIP 110 couples between the Enterprise 101 and the uCloud Platform 100 . A Software Defined Cloud (SDC) may comprise a plurality of Virtual Machines (vAppliances) such as, but not limited to a Bridge Router (BR-RTR, Router, Firewall, and DHCP-DNS (DDNS) across multiple virtual local area networks (VLANs) and potentially across data centers for scale, coupled through Compute node (C-N) nodes (aka servers) 120 - 120 n. The SDC represents a logical linking of select compute nodes (aka servers) within the enterprise cloud. Virtual Networks running on Software Defined Routers 122 and Demilitarized Zone (DMZ) Firewalls are referred to as vAppliances. All Software defined networking components are dynamic and automated, provisioned as needed by the business policies defined in the Service Catalogue by the Tenant Administrator.
[0051] The uCloud Platform 100 supports policy-based placement of vAppliances and compute nodes ( 120 a - 120 n ). The policies permit the Tenant Administrator to do auto or static placement thus facilitating creation of dedicated hardware environment Nodes for Tenant's Virtual Machine networking deployment base.
[0052] The uCloud Platform 100 created SDC environment enables the Tenant Administrator to create lines of businesses or in other words, department groups with segregated networked space and service offerings. This facilitates Tenant departments like IT, Finance and development to all share the same SDC space but at the same time be isolated by networking and service offerings.
[0053] The uCloud Platform 100 supports deploying SDC vAppliances in redundant pair topologies. This allows for key virtual networking building block host nodes to be swapped out and new functional host nodes be inserted managed through uCloud Platform 100 . SDCs can be dedicated to data centers, thus two unique SDCs in different data centers can provide the Enterprise a disaster recovery scenario.
[0054] SDC vAppliances are used for the logical configuration of SDC's within a tenants private cloud. A Router Node is a physical server, or node, in an tenant's private cloud that may be used to host certain vAppliances relating SDC networking Such vAppliances may include the Router, DDNS, and BR-RTR (Bridge Router) vApplications that may be used to route internet traffic to and from an SDC, as well as establish logical boundaries for SDC accessibility. Two Router Nodes exist, an active Node (-A) and a standby Node (-S), used in the event that the active node experiences failure. The Firewall Nodes, also present in an active and standby pair, are used to filter internet traffic coming into an SDC. There is a singular vAppliance that uses the Firewall Node, that being the Firewall vAppliance. The vAppliances are configured through use of vAppliance templates, which are downloaded and stored by the tenant in the appliance store/Template store.
[0055] Reference is now made to FIG. 2 depicting a block diagram describing a tenancy configuration wherein the Enterprise hosts systems and methods within its own data center in accordance with the principles of the present invention. The uCloud platform 100 is hosted directly on an enterprise 200 which may be a Service Provider such as, but not limited to, Verizon FIOS or AT&T uVerse, which serves tenants A-n 202 , 204 and 206 , respectively. Alternatively, enterprise 200 may be an enterprise having subsidiaries or departments 202 , 204 and 206 that it chooses to keep segregated.
[0056] Reference is now made to FIG. 3 depicting a block diagram of a super tenancy configuration wherein the Enterprise uses systems and methods hosted in a cloud computing service 300 in accordance with the principles of the present invention. In this configuration, the uCloud platform is hosted by a cloud computing service 300 that services Enterprises 302 , 304 and 306 . It should be understood that more or less Enterprises could be serviced without departing from the scope of the invention. In the present example, Enterprise C 306 has sub tenants. Enterprise C 306 may be a service provider (e.g. Verizon FIOS or AT&T u-Verse) or an Enterprise having subsidiaries or departments that it chooses to keep segregated.
[0057] Reference is now made to FIG. 4 depicting a block diagram describing permutations of a Software Defined Cloud (SDC) in accordance with the principles of the present invention. The SDC can be of three types namely Routed 400 , Public Routed 402 and Public 404 . Routed and Routed Public SDC types 400 and 402 respectively are designed to be reachable through the Enterprise IP address space, with the caveat that the Enterprise IP address space cannot be in the same collision domain as these types of SDC IP network space. Furthermore, Routed and Public Routed SDC 400 and 402 respectively can re-use same IP network space without colliding with each other. The Public SDC 404 is Internet 406 facing only, it can have overlapping collision IP space with the Enterprise network. Public SDC 404 further provides Internet facing access only. SDC IP schema is automatically managed by the uCloud platform 100 and does not require Tenant Administrator intervention.
[0058] SDC Software Defined Firewalls 408 are of two/one type, Internet gateway (for DMZ use). The SDC vAppliances (e.g. Firewall 408 , Router 410 ) and compute nodes ( 120 a - 120 n ) provide a scalable Cloud deployment environment for the Enterprise. The scalability is achieved through round robin and dedicated hypervisor host nodes. The host pool provisioning management is performed through uCloud Platform 100 . The uCloud Platform 100 manages dedicated nodes for the compute nodes ( 120 a - 120 n ), it allows for fault isolation across the Tenant's Virtual Machine workload deployment base.
[0059] Referring back to FIG. 1 , an uCloud Platform administrator 102 A, an Enterprise administrator 102 B, and an Enterprise User 102 C without administrator privileges are depicted. To deploy uCloud platform 100 , Enterprise administrator 102 B grants uCloud Platform administrator 102 A information regarding the enterprise environment 101 and the hardware residing within it (e.g. compute nodes 120 a - n ). After this information is supplied, platform 100 creates a customized package that contains a Controller Node 121 designed for the Enterprise 101 . Enterprise administrator 102 B downloads and install Controller Node 121 into the Enterprise environment 101 . The uCloud Platform 100 then generates a series of tasks, and communicates these tasks indirectly with Controller Node 121 , via the internet 111 . The communication is preferably done indirectly so as to eliminate any potential for unauthorized access to the Enterprise's information. The process preferably requires uCloud platform 100 to leave the tasks in an online location, and the tasks are only accessible to the unique Controller Node 121 present in an Enterprise Environment 101 . Controller Node 121 then fulfills the tasks generated by uCloud platform 100 , and thus configures the compute 122 , network 123 , and storage 120 a - n capability of the Enterprise environment 101 .
[0060] Upon completion of the hardware configuration, uCloud platform 100 is deployed in the Enterprise environment 101 . The uCloud platform 100 monitors the Enterprise environment 101 and preferably communicates with Controller Node 121 indirectly. Enterprise administrator 102 B and Enterprise User 102 C use the online portal to access uCloud platform 100 and to operate their private cloud.
[0061] Software defined clouds (SDCs) are created within the uCloud platform 100 configured Enterprise 101 . Each SDC contains compute nodes that are logically linked to each other, as well as certain network and storage components (logical and physical) that create logical isolation for those compute nodes within the SDC. As discussed above, an enterprise 101 may create three types of SDC's: Routed 400 , Public Routed 402 , and Public 404 as depicted in FIG. 4 . The difference, as illustrated by FIG. 4 , is how each SDC is accessible to an Enterprise user 102 C.
[0062] Reference is now made to FIG. 5 that depicts a logical view of the uCloud Platform 100 that the Enterprise administrator 102 B and Enterprise user 102 C have in accordance with the principles of the present invention. Resources compute 502 , network 504 and storage 506 residing in a data center 507 are coupled to the service catalog 508 that classifies the resources into service groups 510 a - 510 n. A monitor 512 is coupled to the service catalog 508 and to a user 514 . User 514 is also coupled to service catalog 508 . Service catalog 508 is configured to designate various data center items (compute 502 , network 504 , and storage 506 ) as belonging to certain service groups 510 a - 510 n. The Service catalog 508 also maps the service groups to the appropriate User. Additionally, monitor 512 monitors and controls the service groups belonging to a specific User.
[0063] The service catalog 508 allows for a) the creation of User defined services: a service is a virtual application, or a category/group of virtual applications to be consumed by the Users or their environment, b) the creation of categories, c) the association of virtual appliances to categories, d) the entitlement of services to tenant administrator-defined User groups, and e) the Launch of services by Users through an app orchestrator. The service catalog 508 may then create service groups 510 a - 510 n. A service group is a classification of certain data center components e.g. compute Nodes, network Nodes, and storage Nodes.
[0064] Monitoring in FIG. 5 is done by periodically gathering management plane information data in the extended platform for memory, CPU, network, storage utilizations. This information is gathered and then sent to the management plane.
[0065] FIG. 6 illustrates a flow diagram of a service catalog classifying data center resources into service groups; selecting a service group and assigning it to end users. FIG. 7 illustrates a flow diagram of mapping service group categories to user groups that have been given access to a given service group, in accordance with the principles of the present invention.
[0066] Reference is now made to FIGS. 8 and 9 that illustrate the Cloud administration process its hierarchy respectively, utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration as well as monitoring;
[0067] It should be noted that reference throughout the specification to “tenants” includes both enterprises and service providers as “super-tenants”. Each Software Defined Cloud (SDC) has a management plane, as well as a Data Plane and Control Plane. The Management plane provisions, configures, and operates the cloud instances. The Control plane creates and manages the static topology configuration across network and security domains. The Data plane is part of the network that carries user networking traffic. Together, these three planes govern the SDC's abilities and define the logical boundaries of a given SDC. The Manager of Manager 604 in uCLoud Platform 100 which is accessible only to the uCloud Platform administrator 102 A, manages the tenant cloud instance manager 706 ( FIG. 10 ) in every tenant private cloud. The hierarchy of this management is shown in FIG. 9 .
[0068] Referring now to FIGS. 10 , 11 and 12 , the tenant cloud instance manager 706 is responsible for overseeing the management planes of various SDC's as well as any other virtual Applications that the tenant is running in its compute Nodes, network components and storage devices, respectively. The uCloud Platform 100 generates commands related to the management of Compute Nodes 120 a - n based on tenant cloud instance manager 706 and extended platform orchestrator. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of a tenant's uCloud platform 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node 121 of a specific Enterprise environment. The controller node 121 then accesses the compute Nodes 120 a - n and executes the commands. The launched cloud instance (SDC) management planes are depicted as 708 a -n in FIG. 10 . The ability of the tenant cloud instance manager 706 to modify and delete SDC management plane characteristics (compute, network, storage, Users, and business processes is provided over the internet 111 . Tenants (depicted in FIG. 3 as 302 , 304 and 306 ) each have a Tenant cloud instance manager 706 viewable to through the web interface 104 depicted in FIG. 1 .
[0069] Again with reference to FIG. 8 , the monitoring platform 602 is not limited to one controller but rather, its scope is all controllers within the platform. The monitoring done by the controller 512 ( FIG. 5 ) is performed in a limited capacity, periodically gathering management plane information data in the extended platform for memory, CPU, network, storage utilizations. This information is gathered and then sent to the tenant cloud instance manager 706 .
[0070] Centralized management view of all management planes across the tenants is provided to uCloud Platform administrator 102 A through the uCloud web interface 104 depicted in FIG. 1 .
[0071] Reference is now made to FIG. 11 illustrating the logical flow of information from the uCloud Platform 100 to the Controller Node in a given Enterprise. The uCloud Platform 100 generates commands related to the management of Network components 122 and 123 based on tenant cloud instance manager and extended platform orchestrator element. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node ( 121 in FIG. 1 ) of a specific Enterprise environment 101 . The controller node then accesses the pertinent router nodes, and within them, the pertinent vAppliances, and executes the commands.
[0072] Reference is now made to FIG. 12 illustrating the logical flow of information from the uCloud Platform to the Controller Node in a given Enterprise. The uCloud Platform 100 generates commands related to the management of Storage components tenant cloud instance manager and extended platform orchestrator. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node 121 of a specific Enterprise environment. The controller node then accesses the pertinent storage devices and executes the commands.
[0073] Reference is now made to FIG. 13 illustrating the application-monitoring component of the uCloud Platform 100 in accordance with the principles of the present invention. The platform indirectly communicates with the Controller Node which monitors the application health. This entails passively monitoring a) the state of Enterprise SDC's ( 400 , 402 , 404 in FIG. 4 ), and b) the capacity of the Enterprise infrastructure. The Controller Node also actively monitors the state of the processes initiated by the uCloud Platform and executed by the Controller Node. The Controller Node relays the status of the above components to the uCloud Platform monitoring component 1000 .
[0074] Reference is now made to FIG. 14 illustrating the application-orchestration component of the uCloud Platform in accordance with the principles of the present invention. The app orchestrator performs the process of tracking service offerings that are logically connected to SDC's. It takes the requests from the service catalog and deterministically retrieves information on what compute Nodes and vAppliances are part of a given SDC. It launches service catalog applications within the compute nodes that are connected to a targeted SDC.
[0075] The process is as follows:
[0076] 1. receive request for launch of a virtual application from service catalog 508 .
[0077] 2. retrieve information on destination of the request (which SDC in which tenant environment)
[0078] 3. Retrieve information of what devices compute Nodes and vAppliances are involved in the SDC
[0079] 4. once it determines the above, the app orchestrator sends a configuration to launch these virtual applications to the controller Node.
[0080] Additionally, the app orchestrator will be used in conjunction with the app monitor in the uCloud platform 100 as well as the monitoring controller present in the controller node in the extended platform to a) receive requests from controller node and b) access the relevant tenant extended platform, determines the impacted SDC, and c) perform appropriate corrective action.
[0081] Reference is now made to FIG. 15 illustrating the integration of the application-orchestration and application-monitoring components of the uCloud Platform in accordance with the principles of the present invention. FIG. 15 illustrates part of the Monitoring functionality of the uCLoud platform 100 . Through use of the monitoring controller, the app monitor collects health information of the extended platform (as detailed herein above). In addition, a tenant can define a “disruptive event”. In the event of a disruptive event the monitoring controller will alert the app orchestrator to perform corrective action. The monitoring controller performs corrective action by rebuilding relevant portions of extended platform control plane.
[0082] Reference is now made to FIG. 16 illustrating the big data component of the uCloud Platform 100 and the relationship to the monitoring component of the platform. Based on the data collected by the Controller Node 121 that is relayed to the Platform and stored in a Database, an analysis can be made of, a) SDC and compute nodes usage, and b) disruptive events reported. Heuristics of cloud usage is tracked by the Controller Node. Heuristic algorithmic analysis is used in 100 to understand aspects of tenant cloud usage.
[0083] SDC instance information is collected from the SDC management plane by the tenant cloud instance manager. (achieved by a) tenant cloud instance manager sending a command to the controller node via the message bus, b) controller node uses the command to retrieve collected information from the correct SDC management plane, c) information is relayed to tenant cloud instance manager, d) information is stored in a database)
[0084] SDC instance Information refers to Data about services usage, services types, SDC networking, compute, storage consumption data. This Data is collected continuously (via process outlined above) and archived to an external Big Data database ( 1303 , contained in 100 ). Big data analytics engine processes the gathered information and performs heuristic big data analysis to determine cloud tenant services usage, services types, SDC networking, compute, storage consumption data, and then suggests optimal cloud deployment for tenant (through web interface in 100 ).
[0085] This analysis can contain a determination of high priority events, and report it to the relevant administrators 102 A, and 102 B. Additional analysis can be made using business metrics and return on investment computations.
[0086] Reference is now made to FIG. 17 illustrates the process of deploying uCloud within an Enterprise environment. Using gathered information on compute nodes 120 a - n, uCloud Platform 100 creates a customized package that contains a Controller Node 121 , designed for the Enterprise 101 . Administrator 102 B then downloads and installs Controller Node 121 into the Enterprise environment 101 . The uCloud Platform then orchestrates the infrastructure within the Enterprise environment, via the Controller Node. This includes configuration of router nodes 122 , firewall node 123 , compute Nodes 120 a - n, as well as any storage infrastructure.
[0087] FIG. 17 represents a holistic view of the cloud management platform capabilities of uCloud Platform. The platform is separated into the hosted platform 100 and the management platform.
[0088] The uCloud Platform 100 can support many tenants recalling that a tenant is defined as an enterprise or a service provider. The multi tenant concept can be seen in FIG. 2 , as well as in FIG. 3 . The tenant environment prior to deployment of uCloud is a collection of Compute Nodes. Post uCloud deployment, the environment, now called a private cloud, comprises an extended platform and compute nodes. The extended platform comprises of a limited number of Nodes dedicated for the logical creation of clouds (SDC's). The compute Nodes are used as Enterprise resources, and can be part of a single or multiple SDC's, or software defined clouds. The SDC concept is seen in FIG. 4 . This is referred to as the “logical view” of the private cloud. The division of the extended platform and the compute nodes is seen in FIG. 1 . This will be referred to as the “hardware view” of the private cloud. The combination of the logical and hardware views is seen in ( FIG. 18 ). As mentioned, the extended platform consists of several Nodes (servers). Each Node will run specific types of virtual Appliances, or vAppliances, that regulate and create logical boundaries for an SDC. Every SDC will contain a specific set of vAppliances. The shaded regions of (FLOW 1 ) represent exclusive use of a set of vAppliances by a specific SDC. The Compute Nodes of a private cloud, seen in FIG. 1 and in FLOW as C-N, are a resource that can be shared between multiple SDC's. This sharing concept is seen in FIG. 18 .
[0089] The uCloud Platform manages SDC's by providing several features that will assist a tenant in operating the private cloud. These features include, but are not restricted to, a) service catalog of virtual applications to be run on a given SDC, b) monitoring of SDC's, c) Big Data analytics of SDC usage and functionality, and d) hierarchical logic dictating access to SDC's/virtual applications/health information/or other sensitive information. The process of performing each feature has been shown in FIGS. 5-14 .
[0090] The uCloud Platform configuration process is summarized as follows: Using gathered information on compute nodes 120 a - n, uCloud Platform 100 creates a customized package that contains a Controller Node 121 , designed for the Enterprise 101 . 102 B then downloads and installs 121 into the Enterprise environment 101 . The uCloud Platform then orchestrates the infrastructure within the Enterprise environment, via the Controller Node. This includes configuration of router nodes 122 , firewall node 123 , compute Nodes 120 a - n, as well as any storage infrastructure. The combination of all uCLoud Platform components in the hosted and extended platforms allows for the operation of a multi-tenant, multi-User, scalable Private cloud.
[0091] FIGS. 22 and 23 illustrate embodiments of systems and methods for creating inter datacenter collision domain network stretch. The tenant administrator accesses the uCloud platform 100 . The tenant administrator accesses the service catalog manager 2305 . The tenant administrator launches a software defined cloud (SDC) 2310 . In exemplary configuration, the launched SDC is of public or public routed types. The SDC is created successfully and the instance information is stored 2315 in the uCloud database 2320 .
[0092] At a second major step, the tenant administrator accesses the uCloud platform 100 . The tenant administrator accesses an interface presented by the uCloud platform, an SDC wizard via a web portal in exemplary configuration 2325 . The tenant administrator accesses virtual private network (VPN) setup settings 2340 . The tenant administrator accesses a VPN configuration interface presented by the system 2345 . The tenant administrator configures the VPN by launching a VPN virtual machine (VM) in the public or public-routed SDC 2350 . Via the VPN configuration interface, the tenant administrator configures the VPN application 2355 . It should be noted that manual steps may be needed for the remote-end to connect back into the SDC VPN application 2360 . It should also be noted that a VPN VM may be launched in the remote-end public cloud and the VPN application is configured to have connectivity to the SDC VM instance 2365 . Upon successful configuration, the VPN is completed and the layer 2, site-to-site VPN is established.
[0093] At the third major step, the tenant administrator accesses the SDC interface via web platform 2325 . The tenant administrator accesses the VPN tab 2330 . The VPN tab displays all existing site to site VPN connections with remote-end and near-end connectivity information between the public cloud and the public routed SDC 2335 .
[0094] While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. | Method and Apparatus for rapid scalable unified infrastructure system management platform are disclosed by discovery of compute nodes, network components across data centers, both public and private for a user; assessment of type, capability, VLAN, security, virtualization configuration of the discovered unified infrastructure nodes and components; configuration of nodes and components covering add, delete, modify, scale; and rapid roll out of nodes and components across data centers both public and private. | 7 |
[0001] This application is a continuation of U.S. patent application Ser. No. 10/475,783 filed on Oct. 23, 2003, which is a 371 application of PCT/GB02/00671 filed on Feb. 18, 2002, which claims priority to United Kingdom patent application number 0109814.4 filed on Apr. 23, 2001.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] This invention relates to a surface suitable for promoting the formation of droplets of a liquid on said surface in such a manner as to control the droplet dimensions. The invention is in particular suitable for enabling collection of that liquid from a wind-blown fog or mist.
[0004] (2) Description of the Art
[0005] It is well-known that certain materials exhibit surfaces that attract water whilst others actively repel it, such materials being described as hydrophilic and hydrophobic respectively. It is also still known that water is attracted or repelled due to the fact that it is a polar liquid, and that any similar polar liquid will be influenced in the same manner by such surfaces. It should also be noted that non-polar liquids such as oils will be attracted to a hydrophobic surface and repelled by a hydrophilic surface.
[0006] There are a number of situations where the collection and storage of liquids is of importance. One such situation is where the environment is arid and there is no easily accessible source of water. Another situation could be when chemicals are in vapour form during distillation.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a surface suitable for promoting the formation of liquid droplets of a tailored size. It is a further object to collect said droplets.
[0008] According to a first aspect of the present invention a surface suitable for promoting the formation of droplets of a liquid comprises regions of liquid repelling and liquid attracting material alternating in at least one direction across the surface whereby the diameter of the droplets is controlled by the size of the smallest dimension of the liquid attracting material.
[0009] If the liquid is polar, hydrophilic regions of the surface attract the polar liquid and the hydrophobic regions repel the polar liquid. If the liquid is an oil, the hydrophobic regions attract the liquid and the hydrophilic regions repel the liquid.
[0010] The smallest dimension (the width) of the liquid attracting regions determines the size of the droplet to be formed. There is a maximum diameter that a stable droplet can attain which is related to the width of the liquid attracting regions. The liquid repelling regions separating the liquid attracting regions are preferably of at least the same width, so as to prevent overlap of droplets on neighbouring liquid attracting regions.
[0011] Preferably, the liquid attracting regions take the form of discrete regions on a liquid repelling substrate i.e. each liquid attracting region is isolated from other liquid attracting regions. This enables the droplets to form in isolation, constraining them in two dimensions and limiting their surface contact area with the liquid attracting substrate (and hence their adhesion to the surface).
[0012] In a preferred embodiment, the surface is textured such that the regions of liquid attracting material protrude in relation to the regions of liquid repelling material. This allows for the droplets, when formed, to sit proud in relation to the liquid repelling regions, and encourages detachment of the droplets from the liquid attracting material when a specified droplet size is attained i.e. when the diameter of the droplet has reached its maximum stable size.
[0013] Preferably the said smallest dimension of the liquid attracting material regions is more than 150 μm, more preferably more than 200 μm, and for certain applications is preferably more than 300 μm, 400 μm, 500 μm, or even at least 600 μm. Preferably the said smallest dimension is in the said one direction of the surface. If the said smallest direction is in another direction from the said one direction, then in the said one direction the smallest dimension of the liquid attracting material region in the said one direction preferably also has the stated preferred minimum sizes (more than 150, 200, 300, 400, 500, or at least 600 μm).
[0014] The said surface is preferably substantially planar. It is also envisaged that the surface may be curved, e.g. concave or convex, or be a combination of curved and substantially planar parts. Where we say that a surface is substantially planar, this specifically includes substantially planar surfaces with regions projecting or protruding from the surface, e.g. protruding above the surface.
[0015] The surface is preferably designed in use to be inclined to the horizontal plane. This is described in more detail below with reference to other categories of the invention. It is mentioned here because, especially where the surface is substantially planar, the said one direction of the said surface is preferably the direction of the surface that defines the incline. More specifically, when the surface is inclined the angle of inclination is preferably defined as the angle between the horizontal and any line drawn along the surface in the said one direction.
[0016] Preferably the said smallest dimension of the liquid attracting region is at most 5 mm, more preferably at most 4 mm, and for certain applications is preferably at most 3 mm, 2 mm, 1 mm, or 0.8 mm (800 μm).
[0017] Where we talk about the smallest dimension of the liquid attracting region this will typically be the width, depending on the shape of the region. Thus, for example if the liquid attracting regions are in the shape of stripes, it will be the width of the stripes. Similarly if the liquid attracting regions are in the shape of discrete dots, it will be the width or diameter of the dots. For other less regular shapes it will be whatever is the smallest dimension in any direction. Preferably where there are a plurality of liquid attracting regions these will all be of similar shape and size. However it is envisaged that combinations of shapes and sizes of liquid attracting regions could also be used.
[0018] The liquid repelling regions are preferably at least as wide as the liquid attracting regions, and possibly twice as wide. Preferably the width or distance of liquid repelling region separating adjacent liquid attracting regions is at least 400 μm, more preferably at least 600 μm, especially at least 800 μm, or even at least 1 or 2 mm.
[0019] As mentioned above the smallest dimension of the liquid attracting regions control the diameter of the droplets formed on the surface. This can best be explained by considering a preferred substantially planar surface in its preferred use position in which it is inclined to the horizontal. In this orientation, when small liquid droplets from a vapour adjacent the surface strike the inclined surface, if they strike a liquid attracting region then they may form a droplet attached to the liquid attracting region, but if they strike a liquid repelling region they will roll down the inclined surface to the nearest liquid attracting region. The droplets grow, by joining with other droplets that attach to the same liquid attracting region, until they reach a point at which their surface contact area covers the liquid attracting region. Beyond this size the droplets are gaining in mass without any increase in contact area, so that the droplet has to move into the liquid repelling regions. As this happens the force of gravity increases without any increase in surface adhesion, causing the droplet to move down the inclined slope. If the surface is in a calm environment the droplets will fall directly down the slope, but if the surface is facing into a headwind the droplets may be blown randomly across the surface by the wind. Preferably the surface spacing and the size of the liquid attracting regions is sufficiently large that the droplets will roll down the slope only once they are sufficiently heavy to roll directly downwards even against a headwind.
[0020] According to a second aspect of the present invention a method of collecting a liquid carried by or condensed out of a vapour comprises passing a vapour across a surface; and collecting droplets of liquid formed on the surface in collecting means; wherein the surface comprises alternating regions of liquid repelling and liquid attracting material in at least one direction across the surface and the collecting means is disposed so as to collect drops formed on the surface.
[0021] The surface will usually be a man-made surface, and the method may comprise an initial step of selecting the smallest dimension of the liquid attracting regions so as to determine the droplet size having regard to the prevailing environmental conditions.
[0022] Throughout this specification, the term vapour is used to embrace media both in an entirely gaseous state and also in which liquid droplets are suspended in the gas forming for example a fog or a mist.
[0023] Preferably the surface is inclined to the horizontal plane. This enables the droplets to flow under the influence of gravity towards the collecting means which is a container of some description.
[0024] According to a third aspect of the present invention a system for collecting a liquid comprises a surface having alternating regions of liquid repelling and liquid attracting material in at least one direction across the surface; and collection means, whereby on the movement of a vapour across the surface, droplets within the vapour collect into larger droplets on the surface and are collected by the collection means.
[0025] In a preferred method and system according to the invention for collecting a liquid, the surface is preferably inclined to the horizontal plane by an angle of at least 5°, more preferably at least 10°. For certain applications the surface is preferably inclined by at least 20°, 30°, or even 40°. Preferably the surface is inclined at most 90°, especially at most 80°, or sometimes at most 70°. The angle of incline, like the width of the liquid attracting regions, is one of the factors determining when a droplet forming on the surface will roll down the slope for collection.
[0026] The surface, and the method and system for collecting a liquid are particularly applicable for collecting liquid from a vapour that is moving across the surface. This will be the case, for example in a headwind.
[0027] The behaviour of droplets of liquid falling on various surfaces, particularly where inclined into the headwind may be described as follows. For a vapour carrying headwind striking an entirely liquid attracting surface or an entirely liquid repelling surface, the liquid droplets would form on the surface in various sizes but would not amalgamate. These would therefore be blown in random directions across the surface by the headwind. For the surface of the present invention alternate regions of liquid attracting and repelling regions are provided. Droplets will either strike the liquid attracting regions and stay there, or roll to the nearest liquid attracting region if they initially land on a liquid repelling region. These droplets amalgamate until they are so large that no further purchase on the liquid attracting region is possible. At this time they will roll away (if the surface is inclined).
[0028] Where the surface is inclined it is preferably inclined to face any headwind. Typical preferred headwinds according to the invention may be at most, or of the order of 5 ms −1 , 10 ms −1 , 15 ms −1 or 20 ms −1 . The headwind is another factor that affects when a droplet forming on the surface will roll down the slope for collection: too large a headwind (for the size of drop and angle of surface incline) will cause a drop to be randomly blown across the surface, rather than rolling directly down for collection.
[0029] Where reference is made to “headwind” this may be in a natural environment, or in a controlled environment such as a distillation or a dehumidifier unit.
[0030] Preferably the smallest dimension of the liquid attracting regions is selected so that it can be used in a variety of headwinds, by appropriate variation of slope, such that in this controlled manner the droplets always grow to a sufficiently large size before rolling down the slope to be heavy enough to roll directly down the slope even against the headwind.
[0031] Preferably the arrangement of liquid attracting and repelling regions on the surface is such that along any line drawn along the surface in the said one direction there will be alternating liquid attracting and liquid repelling regions. The said one direction is preferably the direction which together with the horizontal defines the angle of tilt, so that with this arrangement any drop rolling down the slope in the said one direction will always meet a liquid attracting region as it rolls. This arrangement can be for example provided by stripes of liquid attracting and repelling regions crossing, preferably perpendicular to the said one direction. As another example there may be mentioned discrete portions, e.g. dots, of liquid attracting regions in a surround of liquid repelling material, the liquid attracting discrete portions being off set laterally to each other relative to the said one direction. Thus, dots in adjacent rows may be staggered with respect to each other so as to prevent there being a clear “uphill” path of liquid repelling regions along which droplets could be blown away.
[0032] In the method of collecting a liquid according to the present invention, and in the system for collecting a liquid according to the present invention the path into the collecting means of substantially all the liquid is preferably across both liquid attracting and liquid repelling regions.
[0033] The aforementioned method and/or system for collecting a liquid may be a water collection method or system being used or intended for use in an arid/desert environment and adapted to collect at least 100 ml, preferably at least 0.5 l and ideally at least 1 l per week.
[0034] According to a fourth aspect of the present invention a method of spreading a liquid across a surface comprises providing a surface having alternating regions of liquid repelling and liquid attracting material in at least one direction across the surface; placing a liquid on the surface; and spreading the liquid across the surface using spreading means.
[0035] Preferably, the regions of liquid attracting material comprise a pattern whereby on placing a sheet of printing material over the surface, the pattern produced by the positioning of the liquid attracting material is transferred to the sheet of printing material.
[0036] By tailoring the surface as described previously it is possible to dictate the maximum size of the droplets held at the liquid attracting regions when the surface is tilted, or otherwise treated to remove excess liquid, and hence dictate the density and distribution of liquid, for example an ink.
[0037] The patterned region may be made by a continuous liquid attracting region, or more preferably by a plurality of discrete liquid attracting regions, e.g. a plurality of liquid attracting dots, surrounded by liquid repelling regions. The latter configuration better controlling the density and distribution of liquid, e.g. ink
[0038] A surface as hereinbefore described has the added advantage that it may be self cleaning. The surface promotes droplet formation and those droplets may be directed under the influence of gravity. As the droplets move over the surface, small particles will be picked up by the droplets and thus removed from the surface.
[0039] In a further aspect the invention provides a water collection kit that may be assembled to form a collection system as described above, the kit comprising the surface, support means for supporting the surface at a desired inclination, and collection means. The kit may form part of a portable survival kit.
DESCRIPTION OF THE FIGURES
[0040] A number of embodiments of the invention will now be described by way of example only, with reference to the drawings, of which:
[0041] FIG. 1 is a schematic oblique illustration of a surface according to the present invention.
[0042] FIG. 2 shows an alternative surface according to the present invention.
[0043] FIGS. 3 a to 3 d show a schematic sectional illustration of a textured surface according to the present invention.
[0044] FIG. 4 shows a schematic sectional illustration of a textured surface suitable for collecting a liquid according to the present invention.
[0045] FIGS. 5 a and 5 b illustrates a surface suitable for a method of printing according to the present invention.
[0046] FIG. 5 c shows an alternative surface suitable for a method of printing according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0047] FIG. 1 shows a surface 1 having hydrophobic 2 and hydrophilic 3 regions.
[0048] The hydrophobic 2 and hydrophilic 3 regions alternate across the surface 1 and form a striped pattern. An efficient surface for the collection of water from wind-blown fogs consists of 600 to 800 micron width hydrophilic regions spaced a minimum of 800 microns apart on a hydrophobic substrate. This allows for the formation of droplets of a size whereby, under the influence of gravity on a tilted surface, the droplets flow downwards into a moderate headwind.
[0049] FIG. 2 shows a surface 10 having hydrophobic 12 and hydrophilic 13 regions.
[0050] The hydrophobic regions 12 form a grid structure across the surface 10 . The hydrophilic regions 13 , are raised above the hydrophobic regions 12 forming a textured surface. When a vapour is passed over the surface 10 , droplets within the vapour are attracted to the hydrophilic regions 13 . After a period of time, larger droplets of liquid begin to form on the hydrophilic regions 13 as the small droplets in the vapour combine on the surface. When the droplets reach a certain size, they move from one hydrophilic region 13 a to another hydrophilic region 13 b under the influence of gravity.
[0051] FIGS. 3 a to 3 d show a textured surface 20 inclined to the horizontal plane having hydrophobic 22 and hydrophilic 23 regions.
[0052] The hydrophilic regions 23 protrude in relation to the hydrophobic regions 22 . When small droplets from a wind-blown vapour strike the tilted surface 20 then they may form a droplet 24 attached to a hydrophilic region 23 . As such droplets grow larger (by joining with other droplets that attach to the surface or by getting larger), the drops will reach a point at which their surface contact area covers the hydrophilic region 23 ; as is shown in FIG. 3 b , 25 . Beyond this size they are gaining in mass without a corresponding increase in surface contact area, as shown in FIG. 3 c , 26 , thereafter, the droplet must now expand into the water-repelling hydrophobic regions of the surface, shown in FIG. 3 d , 27 . As this happens the gravitational forces on the droplet increase without a corresponding increase in surface adhesion, and eventually the droplet will move down the slope. By tailoring the slope of the surface, the size and spacing of the hydrophilic regions, and the exact hydrophobicity and hydrophilicity of the surface regions, droplets of a tailored diameter can be formed that can roll into the headwind of the wind-blown fog or mist and be collected at the lowest point of the tilted surface. In certain controlled environments, such as during distillation, the windspeed may also be controlled and tailored.
[0053] It should be noted that small droplets striking a hydrophobic surface would immediately be free to roll across that surface, but are likely to be blown away by the prevailing wind due to their small size, and may simply bounce from the surface back into the vapour. If the surface were entirely hydrophilic then the droplets would form a film that would move in a more random fashion, if at all, and limit the speed and efficiency of the water-collection process. When droplets move on such a tailored surface, they may also be guided by the hydrophilic regions, the surface attraction being sufficient to influence their direction and speed of motion. This would particularly be the case if the liquid attracting regions formed channels or stripes on the hydrophobic surface.
[0054] A textured surface as described above can manufactured using a variety of techniques. Clean (grease-free) glass surfaces are hydrophilic, and hence glass can be combined with hydrophobic materials such as waxes in order to produce appropriate patterns. Glass beads of 800 micron diameter can be partially embedded into a wax film to produce an array of hydrophilic hemispheres on a hydrophobic substrate. A clean glass surface can be made hydrophobic by exposure to materials such as hexamethyldisilazane, and this may be used in combination with contact masks to produce an appropriate pattern of hydrophilic regions. Surface texturing can be achieved via techniques such as the moulding and hot-pressing of plastics, which can subsequently be treated with hydrophilic/hydrophobic surface coatings.
[0055] FIG. 4 shows a schematic sectional illustration of a textured surface 30 suitable for collecting liquid 35 having a surface 31 with hydrophobic 32 and hydrophilic 33 regions. A collector 34 is positioned below the surface.
[0056] When a vapour is passed over the surface 30 , droplets in the vapour are attracted to the hydrophilic regions 33 . After a period of time, larger droplets of liquid begin to form on the hydrophilic regions 33 as more and more small droplets from the vapour are attracted to the surface. When the droplets reach a certain size, they move under the influence of gravity. The hydrophilic regions 33 are tapered towards the collector 34 and the droplets tend to move from one hydrophilic region to another so the liquid from a number of hydrophilic regions 33 is collected in one collector 34 .
[0057] An application of such a surface would be in distillation processes, for example, to purify a liquid. If a vapour is to be cooled and collected it is often passed through a tube that is enclosed in a cooling system (e.g. a second tube through which cold water flows). Vapour condenses on the walls of the inner tube and runs down to a collector. Since any vapour that condenses into a film on this inner wall insulates the remaining vapour from the cold surface, the inner tube is sometimes coated with a hydrophobic material to encourage condensed droplets to quickly flow downwards. However, small vapour droplets are more likely to be repelled from the hydrophobic walls, being deflected back into the vapour and hence slowing the collection process. Also, if the vapour is travelling in a specific direction (e.g. rising up a vertical pipe via convection currents) then small droplets are less likely to fall downwards against the vapour flow. For such applications a textured hydrophobic/liquid attracting surface such as those described above would improve the efficiency of the distillation process.
[0058] FIG. 5 a illustrates a surface 50 having ink attracting 51 and ink repelling 52 regions. The ink repelling regions 52 form or define a recognisable shape. Ink 54 (not shown) is spread across the surface 50 .
[0059] Ink 54 is attracted to the ink attracting 51 regions and repelled from the ink repelling regions 52 shown in FIG. 5 b . This causes the ink 54 to only be present on the surface 50 in the ink attracting regions 51 . A sheet of paper (not shown) placed over the surface 50 results in a transfer of ink from the surface 50 to the paper and thus in production of a print of the recognisable shape or negative thereof.
[0060] Whichever region is ink attracting and ink repelling depends on whether the ink is oil or water based.
[0061] FIG. 5 c shows an alternative surface 50 ′ having a plurality of densely distributed discrete dot shaped ink attracting regions 51 ′ in a surround or matrix of ink repelling material 60 . These ink attracting regions 51 ′ in a surround or matrix of ink repelling material 60 form a pattern (which is the letter “A” in the Figure). The pattern region is in a background of ink repelling material 52 as in the previous embodiment. Ink 54 (not shown) is spread across the surface 50 ′. As in the previous embodiment, ink is attracted to the regions 51 ′. Ink is repelled from regions 60 and 52 . The discrete dot nature of the liquid attracting regions 51 ′ in the “A” pattern better controls the density of the ink held on the pattern compared with the continuous liquid attracting region 51 of the FIGS. 5 a and 5 b embodiment. The pattern can then be printed by transfer to a sheet of paper as in the FIG. 5 a / 5 b embodiment. | A surface ( 30 ) suitable for promoting the formation of droplets of liquid ( 35 ) is provided comprising alternating regions of liquid repelling ( 32 ) and liquid attracting ( 33 ) material in at least one direction across the surface wherein the diameter of the droplets is controlled by the size of the smallest dimension of the liquid attracting material. The surface ( 30 ) may be textured and/or form a pattern. Also disclosed are a method and a system of collecting a liquid ( 35 ) carried by or condensed out of a vapour comprising passing a vapour across such a surface ( 30 ) and a method of purifying a liquid by passing a vapour containing droplets of a liquid over such a surface. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a double-rotatable universal head for machine tools.
Double-rotatable universal heads for machine tools are known. They receive their motion from a generally horizontal drive shaft and transmit it to the spindle shaft irrespective of the orientation of this latter.
One of such known heads comprises substantially a head carrier rotatably connected to the machine tool slide, and an actual head rotatably connected to the head carrier and having that surfaace in contact therewith inclined at 45° to the drive shaft axis.
The head carrier is provided internally with a motion transmission shaft inclined at 445° to the drive shaft and to the spindle axis.
In order to position the spindle in the required direction, the operator slackens the connection bolts, rotates the head carrier about the slide and rotates the head carrier. Suitable tables define the angles through which the head and head carrier have to be rotated in order to position the spindle in the required direction.
These known heads suffer however form certain drawbacks, and in particular:
a lengthy time period necessary to position the spindle in the required direction because of the bolt and screw connection system between the mutually coupled parts,
a certain operator difficulty in setting the spindle in the required position because of the weight and size of the head and head carrier.
To obviate these drawbacks, automatically positionable universal heads have been proposed in which the head and head carrier are oriented by means of two direct current motors.
However, such heads have other drawbacks, in particular an additional cost and large overall size due to the presence of the two motors and their relative dependent systems. Moreover, the power developed by the spindle cannot exceed a certain value because the head, head carrier and slide are locked together by the action of the motors and rotation mechanisms themselves, with obvious limited efficiency.
A head is also known in which the engagement between the head carrier and slide and between the head and head carrier is obtained by an insertion-fit system, commonly known as "irt" toothing, comprising two annular flanges having their facing surfaces provided with teeth. The head and head carrier are oriented by means of a motor or a pneumatic or hydraulic system, and once they have reached their required position they are locked together by the engagement of the teeth.
The drawbacks of this head consist of high cost due to the rotation system and coupling device, and the noninfinitely variable adjustment which is obviously related to the toothing pitch.
SUMMARY OF THE INVENTION
An object of the invention is to obviate the drawbacks jointly and separately present in known heads by providing a double-rotatable universal head for machine tools which is of low cost and small overall size, and which requires no manual fixing system.
A further object of the invention is to provide a head which enables the spindle to be oriented in any direction without requiring any additional positioning motor.
A further object of the invention is to provide a universal head which can also be controlled by a numerical control system.
These and further objects which will be apparent from the description given hereinafter are attained according to the invention by a double-rotatable universal head for fitting to a machine tool slide and comprising an actual head supporting the spindle, and if necessary a head carrier interposed between the actual head and slide in order to transmit the drive shaft rotation of the machine tool to the spindle, said head and said slide, as well as said head carrier being rotatably coupled to each other in an adjustable way according to surfaces angulated with respect to the axis of the respective rotation means, in order to orientate the spindle axis in the required direction, and being provided with mutual locking means in the preferred angular position, characterised in that said relative rotation means consist of a member for blocking the rotation of the spindle relative to the actual head, while said locking means are disactivated and the spindle is rotated.
BRIEF DESCRIPTION OF THE DRAWING
A preferred embodiment of the present invention is described hereinafter with reference to the accompanying drawing which shows an enlarged longitudinal section through a universal head according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As can be seen from the drawing, the universal head according to the invention comprises substantially a head carrier 1 and an actual head 2 supporting a spindle 3.
The head carrier comprises a cylindrical support 4 inserted into a complementary flange 5 rigid with the slide 6 of the machine tool 7. Rolling-contact bearings 8 are provided between the facing surfaces of the flange 5 and support 4.
To the rear end of the support 4 there is fitted an annular flange 9 which together with a corresponding stepped portion of the flange 5 forms an annular chamber 10 fitted with oil originating from a duct 11 connected to a central hydraulic unit (not shown on the drawing).
The front end of the drive shaft 12 of the machine tool 7 is housed within the support 4: at the rear end the shaft 12 is provided with a gear wheel 37 engaged with a pinion 38 rotated by the electric motor of the machine tool, not shown on the drawing; furthermore it is provided at its front with a bevel gear 13 engaging with a corresponding bevel gear 14 rigid with a distributor shaft 15 which extends axially into the head 2.
The shaft 15 has its axis disposed at 45° both to the axis of the drive shaft 12 and to the axis of the spindle 3, and is also provided at its front end with a further bevel gear 16.
The shaft 15 is housed in a cylindrical support 17 which is itself housed in a corresponding cylindrical cavity provided axially in the head 2, suitable rolling-contact bearings 18 being interposed between the facing surfaces of said cylindrical cavity and support 17.
The head carrier 1 also comprises a perimetral rim with precision toothing 19, in which there engages a corresponding gear wheel 20 the shaft of which is rigid with an encoder 21 mounted on the slide 6.
To the rear of the head 2 there is fitted an annular flange 22 which together with a forward-lying step provided in the support 17 forms a chamber 23 filled with oil and communicating by way of a duct 24 with the central hydraulic unit.
The head 2 also comprises a perimetral rim with precision toothing 25, in which there engages a corresponding gear wheel 26 the shaft of which is rigid with an encoder 27 mounted on the head carrier 1.
A gear wheel 28 is connected to the spindle 3 and forms a bevel gear pair with the gear wheel 16 connected to the shaft 15. An externally toothed flange 34 is provided in correspondence with the lower end of the spindle 3.
In correspondence with said flange 34 there is provided a piston 29 which is housed in a cylindrical cavity 30 formed in the head 2 and has its axis orthogonal to the axis of the spindle 3. That part 31 of the cavity 30 which lies upstream of the piston 29 is filled with oil, the feed duct of which is connected to the central hydraulic unit, whereas that part 32 of the cavity 30 which lies downstream of the piston 29 houses a spiral spring 33 disposed coaxially to the piston.
Both the encoders 21 and 27 are connected to a central electronic unit which controls the correct operation of the various components and enables all operations to be automated.
The operation of the universal head according to the invention is as follows: when in the configuration shown on the drawing, the head carrier 1 is connected to the slide 6 and the head 2 is connected to the head carrier 1 such that the axes of the drive shaft 12, distributor shaft 15 and spindle 3 are coplanar. In this configuration the rotary motion of the drive shaft 12 is transmitted to the spindle 3, which is disposed vertically.
In order to orientate the spindle in a predetermined direction the procedure is as follows: the angles through which the head carrier 1 is to rotate about the slide 6 and through which the head 2 is to rotate about the head carrier 1 in order to orientate the axis of the spindle 3 in the said predetermined direction are set on the central electronic control unit. These angle values are obtained from tables drawn up for this purpose.
On switching on the machine tool, the central electronic unit causes the oil to enter at high pressure into the chambers 10 and 23, which increases in volume and press against the relative flanges 9 and 22. In this manner, the facing surfaces of the head carrier 1 and slide 6 are caused to adhere to each other, as are the facing surfaces of the head 2 and head carrier 1, which thus become rigidly locked together.
The drive shaft 12 is then caused to rotate at minimum rotation speed, and the pressure in the chamber 10 is then reduced. By virtue of this pressure reduction, the force under which the head carrier surface presses against the facing surface of the slide 1 is substantially reduced, so enabling the head carrier 1 to rotate about the slide 6, while remaining engaged with it.
Oil is simultaneously fed under pressure into the chamber 31 to cause the piston 29 to advance and engage the toothed portion of the flange of the spindle 3, to block it so that it is unable to rotate with respect to the head 2. As a result of this blocking of the spindle 3, axial rotation of the distributor shaft 15 engaged with it is also prevented. However as the shaft 15 is also engaged with the drive shaft 12, which is in the process of rotating, the former is compelled to rotate about the latter with centre of rotation at the point 35 at which the axis of the shaft 12 meets the axis of the shaft 15. Consequently the head carrier 1 is compelled to rotate about the slide 6, and this rotation continues until the encoder 21 has coded the previously set rotation value. At this point, the central electronic unit halts the rotation of the drive shaft 12 and stops the feed of pressurised oil into the chamber 10, while at the same time reducing the pressure in the chamber 23.
In this manner the rigid connection between the head carrier 1 and slide 6 is re-established, whereas the head and head carrier become mutually released.
The drive shaft 12 is again operated, and as the spindle 3 is still blocked with respect to the head 2, it is compelled to rotate about the distributor shaft 15 with centre of rotation at the point 36 at which its axis meets the axis of said shaft 15. Consequently the head is compelled to rotate about the head carrier, and this rotation continues until the encoder 27 has coded the set rotation value.
When this value has been attained, the central electronic unit causes oil to be fed under pressure into the chamber 22 so that the head and head carrier again become connected to each other, while simultaneously reducing the pressure in the chamber 31 so that the elastic reaction of the spiral spring 23 causes the piston 29 to disengage from the toothed portion of the flange 34 of the spindle 3, which is thus free to rotate.
From the aforegoing it is clear that the universal head according to the invention offers numerous advantages, and in particular:
it is of low cost as it uses the same drive shaft for rotating the head and head carrier,
it is of small overall dimensions, its size being substantially that of currently known heads, it makes it possible to orientate the spindle in any direction in an almost infinitely variable manner, it does not require the use of connection elements such ad bolts or screws, as engagement takes place by mutual adhesion between the individual parts,
it allows complete automation of the machine tool which is preferably controlled by a computer.
In a preferred embodiment it is foreseen to use together with the motor driving the spindle, a further direct current motor which is used only for adjustment operations. This low-power motor, which can be engaged with the drive shaft 12, e.g., through a second pinion 39, shown with the dotted line on the drawing, allows to very effectively adjust the angular position of the head 2 with respect to the head carrier 1 and of the head carrier 1 with respect to the slide 6.
Furthermore, in order to reach an almost absolute precision, at least in the more used configurations, it is preferable that the moving reciprocally elements, that is the head 2, the head carrier 1 and the slide 6, are provided with holes (not shown on the drawing) which in correspondence of these positions are faced and such as to allow the automatic insertion of the pins which rigorously determine these positions. Practically the four most used positions are those in correspondence of which the axis of the spindle is vertical (see the drawing), or it is parallel to the axis of the drive shaft 12, or it is placed horizontal and orthogonal with respect to this at the left or at the right.
Furthermore between the head 2, head carrier 1 and slide 6, a pair of electronic cards is foreseen connected to each other to transmit the data necessary for the correct operating of the head, independently from their mutual angular position. This connection between the cards can be carried out through an electronic joint (wiping contact) which allows the free rotation of the several elements without any restrictions. It is also possible to provide an electronic circuit which automatically zeros the rotation of 360° and only takes into account the fraction of circle angle, thus avoiding accumulating the possible mistakes that a high number of complete rotations could cause.
The described double-rotatable universal head allows one to orientate, as already said, the axis of the spindle 3 in any direction. Moreover it belongs to the scope of the protection, as it uses at least in its general principle the same inventive idea, also a universal head having an easier realization, in which the head 2 is directly engaged with the slide 6. It is clear that this embodiment requires that the axis of the spindle cannot be oriented in the desired direction, but only along the generatrices of a conic surface having an opening angle corresponding to the angle formed by the axis of the drive shaft and the axis of the spindle, but it is also clear that this restriction can be accepted for particular works, taking into account the more constructive simplicity that in such a case can be obtained. | A universal head for fitting to a machine tool slide comprises a spindle head supporting a spindle and a head carrier interposed between the spindle head and the slide in order to transmit torque from the machine tool drive shaft to the spindle. The carrier is rotatable with respect to the slide and the spindle head is rotatable with respect to the carrier along mutually oblique axes. Ordinarily, relative rotation between the spindle head, carrier and machine tool are prevented by hydraulically-actuated brakes and only the spindle is driven by the drive shaft; however, when it is desired to reorient the spindle axis, rotation of the spindle is prevented while the brakes are selectively released so that drive shaft rotation results in movement of the spindle head. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a conveyor. More particularly, it relates to a display apparatus for a conveyor.
[0003] 2. Background Art
[0004] In recent years, conveyors have been introduced progressively in public gathering places such as train stations and airports, shopping centers, department stores, and hotels in order to prepare for an coming aged society.
[0005] Such a conveyor provided with a display device for showing a sign to indicate a moving direction of the conveyor or a sign to inform that no passengers are allowed to board the conveyor. The conveyor also has safety devices disposed on various points which detect malfunctions of equipments and suspend an operation of the conveyor. The operation condition display device is generally disposed on an end of a handrail panel so as to be recognized by a passenger on a platform.
[0006] Japanese Patent Laid-Open Publication No. 201682/1993 shows an example of a conventional operation condition display device used in a conveyor.
[0007] In a conventional display device, each of indicating items shown on a display corresponds to signal transmitting lines of the safety devices respectively. Thus, when the number of detection point is increased, or the number of displayed messages indicating operation conditions is increased, for example, the number of signal transmitting lines is also inevitably increased. The growing number of signal transmitting lines causes an increase of input circuits of the display device, which complicates a structure of the display device and is thus inefficient.
[0008] In addition, when an operation control unit for controlling an operation of a conveyor has gone wrong, there may be a case where a backup function does not work so that a misinformation signal is sent to the display device and thus a wrong message is displayed.
SUMMARY OF THE INVENTION
[0009] Therefore, an object of the present invention is to provide a display apparatus for a conveyor that can eliminate the above disadvantages of the conventional art, and can increase the number of items to be displayed by means of the less number of signal wires so as to convey more messages to passengers and maintenance workers.
[0010] In order to achieve the above object, the invention according to claim 1 is a display apparatus for a conveyor comprises a plurality of safety devices disposed on a conveyor; a display configured to indicate information relating to operational conditions of the conveyor or positions of a malfunctioned safety device; a contactor for intermittently charging to a motor driving circuit of the conveyor, or changing running operation between normal and reverse running directions; a safety device detector means configured to be capable shutting down a power source of the contactor, when any of the safety devices is actuated; and a display controller configured to specify the operation condition of the conveyor or the actuated safety device, and providing the information to the display.
[0011] The invention according to claim 2 is a display device for a conveyor comprising; a plurality of safety devices disposed on a conveyor; a display configured to indicate information relating to operational conditions of the conveyor or positions of a malfunctioned safety device; a contactor for intermittently charging to a motor driving circuit of the conveyor, or changing running operation between normal and reverse running directions; a safety device detector configured to be capable shutting down a power source of the contactor, when any of the safety devices is actuated; a binary signal means configured to generate a binary signal which specifies the operation condition of the conveyor or the actuated safety device; and a display controller configured to determine a indication to be displayed in compliance with a combination of introduced binary signals, and providing the display signal to the display.
[0012] The invention according to claim 3 is the display device for a conveyor according to claim 2 , wherein the binarizing means includes a controller for outputting to the display controller the binary signals specifying the positions of the actuated safety device based on potentials of the respective safety devices, the controller also serving for controlling an operation of the conveyor; and a contact which is opened and closed in conjunction with ON/OFF of the contactor, and is connected to an input of the display controller.
[0013] The invention according to claim 4 is the display device for a conveyor according to claim 3 further comprising: a signal interrupting means for Interrupting all the signals to be delivered to the display controller, upon a detection of an malfunction of the controller.
[0014] The invention according to claim 5 is the display device for a conveyor according to claim 4 , wherein the signal interrupting means sends a signal informing of the malfunction to a monitoring panel, simultaneously with interrupting the signals.
[0015] The invention according to claim 6 is the display device for a conveyor according to claim 1 or 2 , wherein the display controller has a function for encrypting a indication to be displayed.
[0016] The invention according to claim 7 is the display device for a conveyor according to claim 3 , wherein the controller has a storing means for storing malfunction data.
[0017] The invention according to claim 8 is the display device for a conveyor according to claim 7 , wherein the controller has a battery as an emergency power.
[0018] In accordance with the present invention, a lot of messages can be displayed in compliance with a combination of binary signals, without increasing the number of signal wires. Since the number of items to be displayed can be increased, more messages can be conveyed to passengers and maintenance workers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a circuit diagram of a first embodiment of a display apparatus for a conveyor according to the present invention;
[0020] FIG. 2 is a circuit diagram of a contactor disposed on a driving part of a conveyor;
[0021] FIG. 3 is a reference chart showing a relation between a combination of binary signals and messages to be displayed;
[0022] FIGS. 4 (A) to 4 (C) are examples of displayed messages;
[0023] FIG. 5 is a perspective view of a platform and its vicinity of a conveyor to which the present invention is applied; and
[0024] FIG. 6 is a circuit diagram of a second embodiment of a display apparatus for a conveyor according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Embodiments of a display device for a conveyor according to the present invention are described below with reference to the drawings.
[0026] FIG. 5 shows a platform and its vicinity of an escalator to which the present invention is applied. In FIG. 5 , the reference number 10 indicates an end part of a handrail panel. A handrail panel of an escalator can be formed of a plate glass or a stainless plate, both of which the present invention can be applied to. FIG. 5 shows a handrail panel end portion 10 of a left handrail panel relative to a platform, with a right handrail panel end portion being omitted. A handrail 11 is moved and folded back at the handrail panel end portion 10 to turn its advancing direction. The reference number 12 indicates an end skirt portion as a whole. The end skirt portion 12 is mounted on each end of a deck cover 13 . A step is indicated by the reference number 14 . A yellow demarcation line 14 a is applied to a periphery of a surface of the step 14 .
[0027] A belt entrance 15 is formed on a front surface of the end skirt portion 12 . A display device 16 is attached below the end skirt portion 12 to display operation conditions of the escalator such as a moving direction. The display device 16 may either be disposed on both of the end skirt portions 12 on both sides of the platform, or may be disposed on one of the end skirt portions 12 .
[0028] Various switches and auxiliary instruments such as an operation board 17 , an inlet switch 18 , a passenger detection sensor 19 of the elevator are disposed on an inside surface of the end skirt portion 12 where an operating function and a safety function are concentrated.
[0029] FIG. 1 is a circuit diagram of an operation condition display apparatus of the embodiment. FIG. 2 shows contactors disposed on a switch circuit of a motor driving circuit for a crive motor of the escalator.
[0030] In FIG. 1 , the reference number 20 indicates a controller for controlling an operation of the escalator, while the reference number 21 indicates a display controller for controlling the display apparatus 16 . A power unit is indicated by the reference number 22 . In FIG. 2 , the reference numbers 23 indicates a contactor for switching an operation of the escalator to a DOWN move, while the reference number 24 indicates a contactor for switching an operation of the escalator to an UP move. The reference number 25 Indicates a switch for switching the DOWN move to the UP move and vice versa. When the switch 25 is changed to an UP position, the UP operation contactor 24 becomes ON whereby an a contact 24 a of the UP operation contactor 24 becomes ON and a b contact 24 b thereof becomes OFF. Thus, the DOWN operation contactor 23 , which has been ON until then, becomes OFF. When the switch 25 is switched on a DOWN position, the proceedings are reversely carried out.
[0031] In FIG. 1 , the reference numbers 1 A to 1 P indicate contacts of safety devices that are disposed on various points of the escalator. The contacts 1 A to 1 P of the safety devices are constructed as b contacts which are opened when the safety devices are actuated. The contacts 1 A to 1 P of the safety devices are respectively connected in parallel to input ports # 1 to # 15 of the controller 20 . Contacts # 1 to # 4 are connected in parallel to output ports # 1 to # 4 of the controller 20 . ON/OFF signals of the contacts are respectively transmitted to input ports # 1 to # 4 of the display control unit 21 .
[0032] In the display control unit 21 , an a contact 23 a of the DOWN operation contactor 23 is connected to an input port # 5 of the display control device 21 , the a contact 24 a of the UP operation contactor 24 is connected to an input port # 6 thereof, and an a contact 28 a of a detection relay 28 for detecting an malfunction of the controller, which is described in detail below, is connected to an input port # 7 thereof. These contacts are connected to the respective input ports in parallel to a wiring connecting an output COM port of the controller 20 to an input COM port of the display control unit 21 .
[0033] In FIG. 1 , the reference number 30 indicates a malfunction detection circuit including the controller malfunction detecting relay 28 . The a contact 28 a of the controller malfunction detecting relay 28 is disposed on the wiring junction in which the output COM port of the controller 20 is connected to the input COM port of the display control device 21 , and on a power supply circuit of a monitoring panel. The reference number 32 indicates a safety device detection relay. An a contact 32 a of the safety device detection relay 32 is disposed on a switch circuit of the motor driving circuit shown in FIG. 2 . When any of the safety devices is actuated, the a contact 32 a makes the contactors 23 and 24 off. The reference number 34 indicates a normally ON relay which maintains an ON position as long as the controller 20 is normally operated.
[0034] An process for displaying operation conditions of the escalator is described with reference to FIGS. 1 to 3 . FIG. 3 is a reference chart showing a relationship between input signals fed to the display control unit 21 and messages to be displayed.
[0035] When the escalator is running in an upward direction, the UP operation contactor 24 is ON. In FIG. 1 , since the a contact 24 a of the UP operation contactor 24 connected to the input port # 6 of the display control unit 21 is ON, the input port # 6 is ON. While an operation of the escalator is suitably carried out and none of the safety devices 26 A to 26 P are actuated, potentials of the input ports # 1 to # 15 of the controller 20 are all ON at the H level. Based on the input information, the controller 20 switches off the output ports # 1 to # 4 , as shown in the reference chart of FIG. 3 . Thus, only the input port # 6 of the display control unit 21 is ON and other input ports are OFF. Then, the display control unit 21 causes the display device 16 to indicate an arrow mark shown in FIG. 4 ( a ) representing that the escalator is available.
[0036] When the escalator is running in a downward direction, the a contact 23 a of the DOWN operation contactor 23 is ON, and only the input port # 5 of the display control unit 21 is ON while all the other input ports are OFF. In this case, the display device 16 indicates a mark shown in FIG. 4 ( b ) representing a forbiddance of entering the escalator.
[0037] A display operation upon an operation of the safety devices in the course of the upward operation is described. Suppose that any of the safety devices is actuated to cause the contact 1 A to become OFF. Since an opening of the contact 1 A causes the safety device operation detection relay 32 to become OFF, the a contact 32 a shown in FIG. 2 is opened so that the contactor 24 becomes OFF. As a result, an running operation of the escalator is stopped.
[0038] In the controller 20 , since the contact 1 A is opened, potentials of the input ports # 1 to # 15 are all OFF at the L level. As shown in FIG. 3 , the controller 20 switches on the output port # 1 based on the input information. Thus, only the input port # 1 of the display control unit 21 becomes ON. In compliance with the chart of FIG. 3 , the display control device 21 receiving the same signal causes the display device 16 to alternately display a mark shown in FIG. 4 ( c ) representing a position of the actuated safety device and the mark shown in FIG. 4 ( b ) representing a forbiddance of entering, with certain intervals therebetween.
[0039] Similarly, when the contact 1 B of the safety devices is actuated, only the input port # 1 of the controller 20 becomes ON. As shown in FIG. 3 , when such a signal is introduced, the controller 20 makes only the output port # 2 ON. The display control unit 21 receiving the same signal causes the display device 16 to display a predetermined message in compliance with the chart of FIG. 3
[0040] In this way, the controller 20 converts information denoting an actuation of any of the safety devices 1 A to 1 P to 2 4 patterns of binary signals formed by a combination of ON/OFF of the four input ports # 1 to # 4 , and outputs the binary signals to the display control unit 21 . In the display control unit 21 , inputs provided from the controllers 20 are assigned to the input ports # 1 . to # 4 , while ON/OFF signals of the respective contacts of the DOWN operation contactor 23 , the UP operation contactor 24 , and the controller malfunction detection relay 28 are transmitted to the input ports # 5 to # 7 . As a result, as shown in FIG. 3 , when ON/OFF combinations are previously set, it is possible for the display device 16 to display messages corresponding to all the operations.
[0041] A display operation when the controller 20 is not normally operated is described.
[0042] The normally ON relay 34 maintains an ON position as long as the controller 20 is working. However, when the controller 20 is failed for some reason, an always ON contact of the always ON relay 34 becomes OFF.
[0043] In the malfunction detection circuit 30 on which the controller malfunction detection relay 28 is disposed, a b contact 34 b of the always ON relay 34 becomes ON whereby the controller malfunction detection relay 28 becomes ON. At the same time, in an input portion of the controller 20 , an a contact 34 a of the normally ON relay 34 becomes OFF whereby the safety device detection relay 32 becomes OFF. Accordingly, the DOWN operation contactor 23 or the UP operation contactor 24 becomes OFF to thereby immediately stop a running operation of the escalator.
[0044] In the controller malfunction detection circuit 30 , since the a contact 23 a of the DOWN operation contactor 23 or the a contact 24 a of the UP operation contactor 24 becomes OFF, the controller malfunction detection relay 28 is self-maintained.
[0045] The self-maintaining of the controller malfunction detection relay 28 maintains an opened position of the b contact 28 b of the controller malfunction detection relay 28 which is disposed on the wiring connecting the COM output port of the controller 20 to the COM input port of the display control unit 21 . Thus, an input from the controller 20 to the display control unit 21 is interrupted. Accordingly, wrong messages irrelevant to the present running condition, which may be caused based on a signal from the malfunctioned controller 20 , are prevented from being displayed. That is, since the a contact 28 a of the controller malfunction relay 28 is ON, only the input port # 7 of the input ports # 1 to # 7 of the display control unit 21 is ON. In compliance with the chart of FIG. 3 , the display device 16 alternately displays characters “CNT” representing that the controller 20 is failed, and a mark representing a forbiddance of entering.
[0046] On the other hand, since the a contact 28 a of the controller malfunction detection relay 28 disposed on a circuit of the monitoring panel becomes ON, a outbreak of the malfunction is displayed on the monitoring panel. Consequently, an operator can surely be aware of the malfunction of the controller 20 .
[0047] In the above embodiment, the display device 16 displays messages corresponding to the operation conditions of the safety devices in compliance with the chart of FIG. 3 . Alternatively, as shown in the rightmost column in the chart of FIG. 3 , encrypted characters and marks relating to the operation conditions of the safety devices can be shown, whereby the displayed messages are comprehensible by only operators and maintenance workers. Thus, details of breakdown are not understood by outsiders, which can ease the anxiety of passengers.
[0048] A second embodiment of the present invention is described with reference to FIG. 6 .
[0049] According to the second embodiment, a memory 40 of the controller 20 stores malfunction history data in the past fes years. Thus, the malfunction history data stored in the memory 40 can be utilized when the escalator is maintained.
[0050] The power unit 22 is provided with a battery 42 . Thus, if a customer power source is blocked, an electric power necessary to display a malfunction of the controller 20 can be reserved by using the battery 42 . Consequently, when the customer power source is blocked, the memory 40 of the controller 20 stores new breakdown history data, which can facilitate a work for restoration of the elevator. | A display device for conveyor according to the present invention: a plurality of safety device disposed on various points of a conveyor; a display for displaying information such as operation conditions of the conveyor or broken locations thereof by means of predetermined display patterns; a contactor for intermittently charging current to a motor driving part of the conveyor, or switching UP and DOWN operations; a safety device operation detection relay for blocking a power source of the contactor, when any of the safety devices is operated; a binarization means for binarizing a signal which specifies the operation condition of the conveyor or the operated safety device; and a display controller for receiving the binarized signal, determining a message to be displayed in compliance with a combination of binary signals, and outputting the determined display signal to the display device. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to miniature tools and, in particular, to pocket driver tools for storing and providing both a holder for drivers and a handle for operating the drivers, and to such pocket driver tools having illuminating devices.
2. Description of the Prior Art
U.S. Pat. No. 4,283,757 (Nalbandian et al., 1981), U.S. Pat. No. 5,515,249 (Shiao, 1996), U.S. Pat. No. 5,772,308 (Lin, 1998) and D592,930 (Cai, 2009) all disclose illuminated screw drivers. A number of screw driver tools are known incorporating storage compartments for the drivers, but where the socket is not on the longitudinal axis of the tool. Tools are known having storage compartments where drivers or other components are stored in the tool, but where the drivers or other components are not transverse to and are disposed on the longitudinal axis of the tool, including U.S. Pat. No. 5,515,249 (Shiao, 1996), U.S. Pat. No. 5,967,641 (Sung et al., 1999), U.S. Pat. No. 6,216,858 (Chiu, 2001), U.S. Pat. No. 6,431,034 (Chen, 2002), U.S. Pat. No. 6,640,675 (Chuang, 2003), U.S. Pat. No. 7,032,483 (Liu, 2006), U.S. Design Pat. No. Des. 385,172 (Bramsiepe et al., 1997), and U.S. Patent Publications Nos. 2008/0083304 (Finn) and 2011/0226098 (Zhang). U.S. Pat. No. 1,309,281 (Forbes, 1919) discloses a tool whose handle is also a tool kit. Other disclosures of driver tools for holding more than one driver can be found in U.S. Pat. No. 5,704,260 (Huang, 1998), U.S. Pat. No. 5,782,150 (Huang, 1998), U.S. Pat. No. 5,887,306 (Huang, 1999), U.S. Pat. No. 5,896,606 (Huang, 1999), U.S. Publication Nos. 2007/0251355 (Kao, 2007) and 2008/0041746 (Hsiao), and U.S. Design Pat. Des. 385,172 (Bramsiepe et al., 1997), Des. 400,775 (Hsu, 1998), D580,655 (Kao, 2008) and D592,930 (Cai, 2009). Included in the foregoing are disclosures of such driver tools for holding a plurality of drivers that also have work-place illumination devices, such as U.S. Pat. No. 5,515,249 (Shiao, 1996) and U.S. Pat. No. 5,772,308 (Lin, 1998). An illuminated screwdriver is described in U.S. Pat. No. 4,283,757 (Nalbandian et al., 1981). The assignee of the present application has on the market a product called “XDrive Compact Driver Tool” wherein drivers are stored in the tool and extend in directions that are parallel with the longitudinal axis of the tool.
SUMMARY OF THE INVENTION
An object of the invention is to provide a driver tool that is small enough to be stored in a user's pocket, perhaps on a key chain, in a handbag, attached to a handle or other part of a larger object, or stored in a desk, tool box, accessory box or the like.
Another object of the present invention is to provide a pocket driver tool which can store a plurality of drivers in a compact, secure but easily accessible manner.
A further object of the present invention is the provision of a pocket driver tool for holding elongated drivers having a working end and a holding end, the working end being a socket into which drivers can be inserted.
It is also a provision of the present invention to provide a pocket driver tool as discussed above having an illumination device for selectively illuminating a work place.
A yet further object of the present invention is to provide a pocket driver tool with an illumination device which fully illuminates a work place.
It is also an object of the present invention to provide a pocket driver tool which is extremely thin, while still being able to store a plurality of drivers and cell batteries for powering an illumination device forming part of the pocket driver tool.
An additional object of the invention is to provide a pocket driver tool with an illumination device having an easily accessible actuating button.
It is yet still another object of the invention to provide a pocket driver tool which is of short length, of narrow width and being flat across its broader surfaces, yet is still able to perform its intended function.
A general object of the present invention is to provide a pocket driver tool which is efficient and effective in operation, is attractive in appearance and can be produced in a precise manner at a low cost.
These and other objects will be apparent from the description to follow and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are perspective views of a pocket driver tool according to the preferred embodiment of invention, showing the front and rear portions thereof in a vertical position with the forward end of the pocket driver tool disposed at the lower part of the respective figures, with a spring clip which is not a component of the preferred embodiment.
FIGS. 3 and 4 are respective front and back views of the embodiment of the invention shown in FIGS. 1 and 2 .
FIGS. 5 and 6 are respective views of opposite sides of the preferred embodiment of the invention shown in FIGS. 1-4 .
FIGS. 7 and 8 are respective forward and rearward views of the preferred embodiment of the invention as shown in FIGS. 1-6 .
FIG. 9 is a perspective view of the preferred embodiment of the invention as shown in FIGS. 1-8 , with the storage compartment cover in its open position revealing the drivers in their respective stalls.
FIG. 10 is a perspective view like that shown in FIG. 9 with the drivers raised above the pocket driver tool.
FIGS. 11 , 12 and 13 are front, side and forward views of the preferred embodiment of the invention shown in FIGS. 1-10 with the storage compartment cover in its open position.
FIGS. 14 , 15 , 16 , 17 and 18 are perspective, front, side, rear and forward end views of a housing top used in the preferred embodiment of the invention shown in FIGS. 1-13 .
FIGS. 19 , 20 , 21 , 22 and 23 are perspective, front, side, rear and forward end views of a housing bottom used in the preferred embodiment of the invention shown in FIGS. 1-13 .
FIG. 24 is a perspective view of a battery contact for use in the preferred embodiment of the invention.
FIGS. 25 and 26 are respectively perspective and bottom plan views of an actuating button for use in the preferred embodiment of the invention.
FIG. 27 is an exploded view of the preferred embodiment of the invention as shown in FIGS. 1-23 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The foregoing objects of the invention are accomplished by means of the preferred embodiment of the invention discussed below. A pocket driver tool 10 is shown in FIGS. 1-13 and 27 . Pocket driver tool 10 includes a longitudinal housing 2 composed of a housing top 3 and a housing bottom 5 . Pocket driver tool 10 further includes a removable tool door 7 for opening and closing a driver storage compartment 8 , an illumination device actuating button 9 and a battery door 11 as most of its externally visible parts. Pocket driver tool 10 has a central longitudinal axis L. Housing 2 has a forward end portion 4 , a rearward end portion 6 , and opposing side portions 14 and 16 . Housing top 3 is composed of a flat front face 12 , with an actuating button orifice 13 , generally flat (although slightly concave and slightly outwardly flared with respect to longitudinal axis L) opposing side walls 15 , 17 , a housing top, slightly convex forward end wall 19 and a forward socket and portion 20 including a multisided socket 21 which is preferably a hexagonal socket 21 . Axis L is the central longitudinal axis of socket 21 . Housing top 3 has a housing top curved rearward section 23 with a convexly curved, housing top rearward end wall 25 and a key ring-receiving orifice 27 having an imaginary axis perpendicular to longitudinal axis L. A pair of opposing housing top side walls 29 , 31 interconnects a forward section 30 of housing top 3 and rearward section 32 of housing top 3 . Respective forward and rearward screw bosses 33 and 35 include threaded screw holes for receiving screws to construct pocket tool holder 10 as discussed below. Housing top 3 is depicted in detail in FIGS. 14-18 .
Tool door 7 is positioned over a tool storage opening 37 in housing top 3 . Tool door 7 has a pair of hinge arms 39 having outwardly extending hinge pins 41 which are received in receptacle bosses 43 in housing top 3 to form a pair of hinges 45 . Tool door 7 also has a latch arm 47 and housing top 3 has a latch receptacle 49 , latch arm 47 and latch receptacle 49 forming a snap latch 51 . Tool door 7 has a flat front face 53 and opposing side walls 55 and 57 which cooperate with parts of the respective opposing sides portions 14 and 16 of pocket driver tool 10 as discussed below.
Housing top 3 includes on its front face 12 a pair of opposing side walls 59 and 61 of which side walls 55 and 57 of tool door 7 are respective continuations to provide this portion of pocket driver tool 10 , a continuous and sleek appearance. Opposing side walls 59 and 61 also cooperate with the side walls of housing bottom 5 as explained hereinbelow. Side walls 55 , 57 , 59 and 61 are slightly concave with respect to longitudinal axis L as explained below. Housing top 3 has a convexly curved housing top forward end wall 62 opposite rearward end wall 25 . Pocket driver tool 10 includes an illumination device 200 . Illumination device 200 is located at forward socket end portion 20 . Forward section 30 of housing top 3 further includes upper portions 64 and 65 of a pair of lens mounts 67 and 69 on opposite sides of an upper socket portion 70 of socket 21 for, as explained below, directing illumination to the work place for a driver inserted in socket 21 . Socket 21 and lens mounts 67 , 69 are located in a forwardly extending nose portion 71 further discussed below.
Reference is now made to housing bottom 5 which is attached to housing top 3 as discussed later. The details of housing bottom 5 are shown in FIGS. 19-22 . Housing bottom 5 has a forward portion 73 and a rearward portion 75 . Housing bottom 5 includes a housing bottom flat back face 77 with a battery door orifice 79 , opposing housing bottom side walls 81 and 83 which correspond in configuration (including the concave curve and the outward flare) to opposing housing top side walls 15 and 17 of housing top 3 to form, when housing top 3 and housing bottom 5 are attached, continuous, closed sleek and attractive opposing sides 85 and 87 of pocket driver tool 10 . Housing bottom 5 further includes a convexly curved, housing bottom forward end wall 89 and a convexly curved, housing bottom rearward end wall 91 , each configured to match and be continuous of respective forward and rearward end wall 62 and 25 of housing top 3 to also form respective continuous, closed sleek forward and rearward end walls 19 and 25 of pocket driver tool 10 . Housing bottom 5 includes in its forward portion 73 a lower socket portion 90 and a pair of lower portions 92 and 94 of lens mounts 67 and 69 . A pair of cell battery compartments 95 is in forward portion 73 , but rearward of lower socket portion 90 and lower portions 92 and 94 . A PCB-LED compartment 97 has appropriate walls to firmly support a PCB-LED assembly 99 as explained further. Extending between side walls 81 and 83 are opposing forward driver end stall wall 101 and rearward driver stall end wall 103 , and three intermediate driver stall walls 105 , 107 and 109 , for forming a series of driver stalls 111 , 113 , 115 and 117 . Driver stalls 111 , 113 , 115 and 117 are transverse to longitudinal axis L. Housing top 3 has in the bottom of its side walls 31 and 33 , a set of opposing slots 119 , 121 and 123 for receiving the upper ends of driver stall walls 105 , 107 and 109 . Housing bottom 5 also has a finger slot 125 to enable a user to slip the end of the user's finger in slot 125 to open tool door 7 . Tool door 7 thus selectively covers and uncovers driver stalls 111 , 113 , 115 and 117 . This enables the withdrawal of one or more drivers from said respective driver stalls and for enabling the putting of drivers in driver stalls when the stalls are empty. Housing bottom 5 has in its housing bottom rearward portion 75 a centrally located boss 127 with a portion 128 of key ring-receiving orifice 27 having an imaginary axis which is perpendicular to longitudinal axis L. Housing bottom rearward portion 75 and housing top rear section 23 cooperate to form a rear housing portion 130 . Key ring-receiving orifice 27 has a portion 126 of housing top 3 and portion 128 of key ring-receiving orifice 27 of housing bottom 5 are in alignment and cooperate to form housing key ring-receiving orifice 27 . Housing bottom 5 further is further comprised of forward screw hole bosses 129 and rearward screw hole bosses 131 , each located symmetrically of longitudinal axis L for cooperating with respective tool bosses 33 and 35 in housing top 3 to receive screws in their respective screw holes for holding housing top 3 and housing bottom 5 together.
PCB-LED assembly 99 includes a base 133 from which extend a set of electrical leads 135 to which are connected light emitting diodes (LEDs) 137 . A mounting block 139 also extends from base 133 with a button protrusion 141 to be engaged by button 9 as explained below. LEDs 137 are respectively disposed in the rearward portions of lens mounts 67 and 69 . LEDs 137 are preferably 10,000 MCD, 50,000 LED bulbs for two hours of continuous use.
A battery contact 143 , shown alone in FIG. 24 , is disposed between battery door 11 and cell battery compartments 95 for electrically connecting cell batteries C when the latter are mounted in compartments 95 . Battery contact 143 is made of an electrically conducting material such as a tin nickel alloy, and has a hole 145 in its mid-portion for receiving a captive screw 146 extending through a conical post 147 extending inwardly from the center of battery door 11 , perpendicular to longitudinal axis L. Battery contact 143 has inwardly flared side portions 149 for being compressed against cell batteries C by battery door 11 to assure contact with batteries C. Batteries C are preferably 2 CR 1025 lithium batteries.
Battery door 11 has an interior battery contact lip 151 for pressing battery contact 143 against cell batteries C disposed in battery compartments 85 , and a recess 153 for receiving a lip 155 in housing bottom 5 to firmly seat battery door 11 in housing bottom 5 across battery door orifice 79 . Housing bottom 5 has a screw boss 157 with a screw hole 159 for receiving captive screw 146 to firmly and releasably attached battery door 11 to pocket driver tool 10 .
FIGS. 25 and 26 illustrate illumination device actuating button 9 . Illumination device actuating button 9 has a generally oblong outer periphery with straight opposing sides 162 , and a flat exterior face 161 . It has a peripheral shoulder 163 on a lip 165 for engaging an interior shoulder on housing top 3 to retain button 9 in housing top 3 . There is an interior recessed cross 167 for engaging button protrusion 141 , which button 9 depresses to engage PCB-LED assembly 99 with cell batteries C to actuate LEDs 137 .
Driver stalls 111 , 113 , 115 and 117 extend across driver tool compartment 8 perpendicular to longitudinal axis 11 . The base of compartment 8 is the interior surface of the forward portion of housing bottom 5 , and the top of compartment 8 is the interior surface of front face 53 of tool door 7 . Driver tools found to be important to users of this type of tool are a flat head driver 169 , a relatively large Phillips head driver 171 , a relatively small Phillips head driver 173 and an Allen driver 175 . The preferred forms of drivers other than a flat head driver are a #2 Phillips driver 177 , a #1 Phillips driver 179 and a 5/32 inch Allen driver 175 . These drivers are preferably 24.85 mm long. The driven end of each of drivers 169 , 171 , 173 and 175 are each preferably hexagonal as is socket 21 , and have a cross dimension between the flats of 6.250 mm. Socket 21 is dimensioned to receive and drive drivers 169 , 171 , 173 and 175 . The respective drivers 169 , 171 , 173 and 175 each have a multisided driver end dimensioned and configured to be received in socket 21 in a fitting relationship. One of drivers 169 , 171 , 173 and 175 , when received in socket 21 , is used to drive a fastener by the manual rotation of pocket driver tool 10 about longitudinal axis L. The fitting relationship prevents the rotation of the driver with respect to multisided socket 21 .
A tool magnet 181 is provided at an interior closed end of socket 21 in order to releasably hold ferromagnetic drivers 169 , 171 , 173 and 175 , respectively, held in socket 21 . The foregoing drivers can easily be removed from storage compartment 8 and held in socket 21 , and likewise be removed from socket 21 by the user of pocket tool 10 .
Housing bottom 5 is attached to housing top 3 by means of housing screws 183 which are inserted in screw holes in each of screw bosses 33 and 35 in housing top 3 , and screw bosses 129 and 131 in housing bottom 5 . A quick clip 185 or other key ring can be inserted through key ring orifice 27 .
Pocket driver tool 10 is extremely flat and hence easy to store. Battery compartments 95 hold cell batteries C in a general plane parallel with the flat faces 12 and 53 of housing top 3 and tool door 7 , and flat face 77 of housing bottom 5 , with their imaginary central longitudinal axes in an imaginary plane perpendicular to an imaginary plane incorporating longitudinal axis L and perpendicular to flat faces 12 , 53 and 77 . Drivers 169 , 171 , 173 and 175 extend across tool compartment 8 , and are short enough as described above to render pocket driver tool 10 to have a short width between side walls 15 and 17 . Since parts to be held by pocket driver tool 10 are the latter drivers, and since their respective widths are of a small dimension as noted above, the thickness of tool 10 is also small enough to assist in making tool 10 easy to store. Likewise the length of tool 10 between opposing curved end walls 19 and 25 is very small as well. In the preferred embodiment of the invention, pocket driver tool 10 has a width w of 33.133 mm (or about 1.3 inches), a length l of 65.237 mm (or about 2.6 inches) and a thickness t of 6.350 mm (or about 0.4 inch).
Pocket driver tool 10 is also effective in use. Even though its width is small, a user can insert a driver in socket 21 , insert the driver in a screw or other fastener, hold the opposing side walls 15 and 17 with the thumb on one side and index finger on the other side and apply torsion to tool 10 to obtain the desired twisting action. Curved side walls 15 and 17 assist in preventing slipping of the fingers along the latter walls during use. Actuating button 9 can be easily operated with one of the user's fingers while pocket driver tool 10 is in use, possibly requiring an easy manipulation of the user's fingers.
Pocket driver tool 10 is a precision tool, which nevertheless can be made inexpensively for a current retail selling price of less than ten dollars (US). Pocket driver tool 10 is attractive in appearance, and effective and efficient in use.
The invention has been described in detail with particular reference to its preferred embodiment, but variations and modifications within the spirit and scope of the invention may appear to those skilled in the art from the foregoing description and from the appended claims. | A pocket driver tool having a longitudinal housing with a multisided socket at one end of the tool and extending along part of a longitudinal axis of the pocket driver tool, and stalls for drivers extending transversely to the longitudinal axis. A lumination device can illuminate the work place in which the pocket driver tool is to drive a fastener into or out of a workpiece. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a division of U.S. Ser. No. 09/419,345 filed on Oct. 15, 1999 now U.S. Pat. No. 6,355,092.
BACKGROUND
1. Field of the Invention
The present invention relates generally to cleaning systems, and more specifically to substrate cleaning systems, such as textile cleaning systems, utilizing an organic cleaning solvent and a pressurized fluid solvent.
2. Related Art
A variety of methods and systems are known for cleaning substrates such as textiles, as well as other flexible, precision, delicate, or porous structures that are sensitive to soluble and insoluble contaminants. These known methods and systems typically use water, perchloroethylene, petroleum, and other solvents that are liquid at or substantially near atmospheric pressure and room temperature for cleaning the substrate.
Such conventional methods and systems generally have been considered satisfactory for their intended purpose. Recently, however, the desirability of employing these conventional methods and systems has been questioned due to environmental, hygienic, occupational hazard, and waste disposal concerns, among other things. For example, perchloroethylene frequently is used as a solvent to clean delicate substrates, such as textiles, in a process referred to as “dry cleaning.” Some locales require that the use and disposal of this solvent be regulated by environmental agencies, even when only trace amounts of this solvent are to be introduced into waste streams.
Furthermore, there are significant regulatory burdens placed on solvents such as perchloroethylene by agencies such as the EPA, OSHA and DOT. Such regulation results in increased costs to the user, which, in turn, are passed to the ultimate consumer. For example, filters that have been used in conventional perchloroethylene dry cleaning systems must be disposed of in accordance with hazardous waste or other environmental regulations. Certain other solvents used in dry cleaning, such as hydrocarbon solvents, are extremely flammable, resulting in greater occupational hazards to the user and increased costs to control their use. In addition, textiles that have been cleaned using conventional cleaning methods are typically dried by circulating hot air through the textiles as they are tumbled in a drum. The solvent must have a relatively high vapor pressure and low boiling point to be used effectively in a system utilizing hot air drying. The heat used in drying may permanently set some stains in the textiles. Furthermore, the drying cycle adds significant time to the overall processing time. During the conventional drying process, moisture adsorbed on the textile fibers is often removed in addition to the solvent. This often results in the development of undesirable static electricity and shrinkage in the garments. Also, the textiles are subject to greater wear due to the need to tumble the textiles in hot air for a relatively long time. Conventional drying methods are inefficient and often leave excess residual solvent in the textiles, particularly in heavy textiles, components constructed of multiple fabric layers, and structural components of garments such as shoulder pads. This may result in unpleasant odors and, in extreme cases, may cause irritation to the skin of the wearer. In addition to being time consuming and of limited efficiency, conventional drying results in significant loss of cleaning solvent in the form of fugitive solvent vapor. Finally, conventional hot air drying is an energy intensive process that results in relatively high utility costs and accelerated equipment wear.
Traditional cleaning systems may utilize distillation in conjunction with filtration and adsorption to remove soils dissolved and suspended in the cleaning solvent. The filters and adsorptive materials become saturated with solvent, therefore, disposal of some filter waste is regulated by state or federal laws. Solvent evaporation especially during the drying cycle is one of the main sources of solvent loss in conventional systems. Reducing solvent loss improves the environmental and economic aspects of cleaning substrates using cleaning solvents. It is therefore advantageous to provide a method and system for cleaning substrates that utilize a solvent having less adverse attributes than those solvents currently used and reduces solvent losses.
As an alternative to conventional cleaning solvents, pressurized fluid solvents or densified fluid solvents have been used for cleaning various substrates, wherein densified fluids are widely understood to encompass gases that are pressurized to either subcritical or supercritical conditions so as to achieve a liquid or a supercritical fluid having a density approaching that of a liquid. In particular, some patents have disclosed the use of a solvent such as carbon dioxide that is maintained in a liquid state or either a subcritical or supercritical condition for cleaning such substrates as textiles, as well as other flexible, precision, delicate, or porous structures that are sensitive to soluble and insoluble contaminants.
For example, U.S. Pat. No. 5,279,615 discloses a process for cleaning textiles using densified carbon dioxide in combination with a non-polar cleaning adjunct. The preferred adjuncts are paraffin oils such as mineral oil or petrolatum. These substances are a mixture of alkanes including a portion of which are C 16 or higher hydrocarbons. The process uses a heterogeneous cleaning system formed by the combination of the adjunct which is applied to the textile prior to or substantially at the same time as the application of the densified fluid. According to the data disclosed in U.S. Pat. No. 5,279,615, the cleaning adjunct is not as effective at removing soil from fabric as conventional cleaning solvents or as the solvents described for use in the present invention as disclosed below.
U.S. Pat. No. 5,316,591 discloses a process for cleaning substrates using liquid carbon dioxide or other liquefied gases below their critical temperature. The focus of this patent is on the use of any one of a number of means to effect cavitation to enhance the cleaning performance of the liquid carbon dioxide. In all of the disclosed embodiments, densified carbon dioxide is the cleaning medium. This patent does not describe the use of a solvent other than the liquefied gas for cleaning substrates. While the combination of ultrasonic cavitation and liquid carbon dioxide may be well suited to processing complex hardware and substrates containing extremely hazardous contaminants, this process is too costly for the regular cleaning of textile substrates. Furthermore, the use of ultrasonic cavitation is less effective for removing contaminants from textiles than it is for removing contaminants from hard surfaces.
U.S. Pat. No. 5,377,705 discloses a process for cleaning precision parts utilizing a liquefied pressurized gas in the supercritical state and an environmentally acceptable co-solvent. During this process, the parts to be cleaned are pre-treated with the co-solvent and then placed in the cleaning vessel. Afterwards, the contaminants and co-solvent are removed from the parts by circulating a pressurized gas in its supercritical state through the vessel. Redeposition of co-solvent and contaminants is controlled by the amount of pressurized gas that is pumped through the vessel. Co-solvents specified for use in conjunction with the cleaning solvent include aliphatics, terpenes, acetone, laminines, isopropyl alcohol, Axarel (DuPont), Petroferm (Petroferm, Inc.), kerosene and Isopar-m (Exxon). During the cleaning process, the cleaning solvent (supercritical carbon dioxide) flows through a vessel containing the parts to be treated, through a filter or filters and directly to a separator in which the solvent is evaporated and recondensed. The disclosed co-solvents for use in this patent have high evaporation rates and low flash points. The use of such co-solvents results in high solvent losses, and high fire risks. Furthermore, many of the co-solvents are not compatible with common dyes and fibers used in textile manufacture. Also, the use of supercritical carbon dioxide necessitates the use of more expensive equipment.
U.S. Pat. No. 5.417,768 discloses a process for precision parts cleaning using a two-solvent system. One solvent can be liquid at room temperature and pressure while the second solvent can be supercritical carbon dioxide. The objectives of this invention include using two or more solvents with minimal mixing of the solvents and to incorporate ultrasonic cavitation in such a way as to prevent the ultrasonic transducers from coming in contact with the first-mentioned solvent. An apparatus is described which consists of an open top vessel within a covered pressurized vessel. The primary fluid is pumped into the open top vessel. After cleaning with the primary fluid, it is pumped from the open top vessel. Pressurized carbon dioxide is then pumped into the open top vessel and flushed through the vessel until the level of contaminants within the vessel are reduced to the desired level. The co-solvents disclosed in this patent are the same solvents specified in U.S. Pat. No. 5,377,705. Use of these solvents would introduce a high risk of fire, high levels of solvent loss and potential damage to a wide range of textiles.
U.S. Pat. No. 5,888,250 discloses the use of a binary azeotrope comprised of propylene glycol tertiary butyl ether and water as an environmentally attractive replacement for perchlorethylene in dry cleaning and degreasing processes. While the use of propylene glycol tertiary butyl ether is attractive from an environmental regulatory point of view, its use as disclosed in this invention is in a conventional dry cleaning process using conventional dry cleaning equipment and a conventional evaporative hot air drying cycle. As a result, it has many of the same disadvantages as conventional dry cleaning processes described above.
Several of the pressurized fluid solvent cleaning methods described in the above patents may lead to recontamination of the substrate and degradation of efficiency because the contaminated solvent is not continuously purified or removed from the system. Furthermore, pressurized fluid solvent alone is not as effective at removing some types of soil as are conventional cleaning solvents. Consequently, pressurized fluid solvent cleaning methods require individual treatment of stains and heavily soiled areas of textiles, which is a labor-intensive process. Furthermore, systems that utilize pressurized fluid solvents for cleaning are more expensive and complex to manufacture and maintain than conventional cleaning systems. Finally, few if any conventional surfactants can be used effectively in pressurized fluid solvents. The surfactants and additives that can be used in pressurized fluid solvent cleaning systems are much more expensive than those used in conventional cleaning systems.
There thus remains a need for an efficient and economic method and system for cleaning substrates that incorporates the benefits of prior systems, and minimizes the difficulties encountered with each. There also remains a need for a method and system in which the hot air drying time is eliminated, or at least reduced, thereby reducing the wear on the substrate and preventing stains from being permanently set on the substrate.
SUMMARY
In the present invention, certain types of organic solvents, such as glycol ethers and, specifically, poly glycol ethers including dipropylene glycol n-butyl ether, tripropylene glycol n-butyl ether or tripropylene glycol methyl ether, or similar solvents or mixtures of such solvents are used. Any type of organic solvent that falls within the range of properties disclosed hereinafter may be used. However, unlike conventional cleaning systems, in the present invention, a conventional drying cycle is not necessary. Instead, the system utilizes the solubility of the organic solvent in pressurized fluid solvents, as well as the physical properties of pressurized fluid solvents, to dry the substrate being cleaned.
As used herein, the term “pressurized fluid solvent” refers to both pressurized liquid solvents and densified fluid solvents. The term “pressurized liquid solvent” as used herein refers to solvents that are liquid at between approximately 600 and 1050 pounds per square inch and between approximately 5 and 30 degrees Celsius, but are gas at atmospheric pressure and room temperature. The term “densified fluid solvent” as used herein refers to a gas or gas mixture that is compressed to either subcritical or supercritical conditions so as to achieve either a liquid or a supercritical fluid having density approaching that of a liquid. Preferably, the pressurized fluid solvent used in the present invention is an inorganic substance such as carbon dioxide, xenon, nitrous oxide, or sulfur hexafluoride. Most preferably, the pressurized fluid solvent is densified carbon dioxide.
The substrates are cleaned in a perforated drum within a vessel in a cleaning cycle using an organic solvent. A perforated drum is preferred to allow for free interchange of solvent between the drum and vessel as well as to transport soil from the substrates to the filter. After substrates have been cleaned in the perforated drum, the organic solvent is extracted from the substrates by rotating the cleaning drum at high speed within the cleaning vessel in the same way conventional solvents are extracted from substrates in conventional cleaning machines. However, instead of proceeding to a conventional evaporative hot air drying cycle, the substrates are immersed in pressurized fluid solvent to extract the residual organic solvent from the substrates. This is possible because the organic solvent is soluble in the pressurized fluid solvent. After the substrates are immersed in pressurized fluid solvent, which may also serve as a cleaning solvent, the pressurized fluid solvent is transferred from the drum. Finally, the vessel is de-pressurized to atmospheric pressure to evaporate any remaining pressurized fluid solvent, yielding clean, solvent-free substrates.
Glycol ethers, specifically poly glycol ethers, used in the present invention tend to be soluble in pressurized fluid solvents such as supercritical or subcritical carbon dioxide so that a conventional hot air drying cycle is not necessary. The types of poly glycol ethers used in conventional cleaning systems must have a reasonably high vapor pressure and a low boiling point because they must be removed from the substrates by evaporation in a stream of hot air. However, solvents, particularly non-halogenated solvents, that have a high vapor pressure and a low boiling point generally also have a low flash point. From a safety standpoint, organic solvents used in cleaning substrates should have a flash point that is as high as possible, or preferably, it should have no flash point. By eliminating the conventional hot air evaporative drying process, a wide range of solvents can be used in the present invention that have much lower evaporation rates, higher boiling points and higher flash points than those used in conventional cleaning systems.
Thus, the cleaning system described herein utilizes solvents that are less regulated and less combustible, and that efficiently remove different soil types typically deposited on textiles through normal use. The cleaning system reduces solvent consumption and waste generation as compared to conventional dry cleaning systems. Machine and operating costs are reduced as compared to currently used pressurized fluid solvent systems, and conventional additives may be used in the cleaning system.
Furthermore, one of the main sources of solvent loss from conventional dry cleaning systems, which occurs in the evaporative hot air drying step, is substantially reduced or eliminated altogether. Because the conventional evaporative hot air drying process is eliminated, there are no heat set stains on the substrates, risk of fire and/or explosion is reduced, the cleaning cycle time is reduced, and residual solvent in the substrates is substantially reduced or eliminated. Substrates are also subject to less wear, less static electricity build-up and less shrinkage because there is no need to tumble the substrates in a stream of hot air to dry them.
While systems according to the present invention utilizing pressurized fluid solvent to remove organic solvent can be constructed as wholly new systems, existing conventional solvent systems can also be converted to utilize the present invention. An existing conventional solvent system can be used to clean substrates with organic solvent, and an additional pressurized chamber for drying substrates with pressurized fluid solvent can be added to the existing system.
Therefore, according to the present invention, textiles are cleaned by placing the textiles to be cleaned into a cleaning drum within a cleaning vessel, adding an organic solvent to the cleaning vessel, cleaning the textiles with the organic solvent, removing a portion of the organic solvent from the cleaning vessel, rotating the cleaning drum to extract a portion of the organic solvent from the textiles, placing the textiles into a drying drum within a pressurizable drying vessel, adding a pressurized fluid solvent to the drying vessel, removing a portion of the pressurized fluid solvent from the drying vessel, rotating the drying drum to extract a portion of the pressurized fluid solvent from the textiles, depressurizing the drying vessel to remove the remainder of the pressurized fluid solvent by evaporation, and removing the textiles from the depressurized vessel.
These and other features and advantages of the invention will be apparent upon consideration of the following detailed description of the presently preferred embodiment of the invention, taken in conjunction with the claims and appended drawings, as well as will be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a cleaning system utilizing separate vessels for cleaning and drying.
FIG. 2 is a block diagram of a cleaning system utilizing a single vessel for cleaning and drying.
DETAILED DESCRIPTION
Reference will now be made in detail to embodiments of the invention, examples of which are illustrated in the accompanying drawings. The steps of each method for cleaning and drying a substrate will be described in conjunction with the detailed description of the system.
The methods and systems presented herein may be used for cleaning a variety of substrates. The present invention is particularly suited for cleaning substrates such as textiles, as well as other flexible, precision, delicate, or porous structures that are sensitive to soluble and insoluble contaminants. The term “textile” is inclusive of, but not limited to, woven or non-woven materials, as well as articles therefrom. Textiles include, but are not limited to, fabrics, articles of clothing, protective covers, carpets, upholstery, furniture and window treatments. For purposes of explanation and illustration, and not limitation, exemplary embodiments of a system for cleaning textiles in accordance with the invention are shown in FIGS. 1 and 2.
As noted above, the pressurized fluid solvent used in the present invention is either a pressurized liquid solvent or a densified fluid solvent. Although a variety of solvents may be used, it is preferred that an inorganic substance such as carbon dioxide, xenon, nitrous oxide, or sulfur hexafluoride, be used as the pressurized fluid solvent. For cost and environmental reasons, liquid, supercritical, or subcritical carbon dioxide is the preferred pressurized fluid solvent.
Furthermore, to maintain the pressurized fluid solvent in the appropriate fluid state, the internal temperature and pressure of the system must be appropriately controlled relative to the critical temperature and pressure of the pressurized fluid solvent. For example, the critical temperature and pressure of carbon dioxide is approximately 31 degrees Celsius and approximately 73 atmospheres, respectively. The temperature may be established and regulated in a conventional manner, such as by using a heat exchanger in combination with a thermocouple or similar regulator to control temperature. Likewise, pressurization of the system may be performed using a pressure regulator and a pump and/or compressor in combination with a pressure gauge. These components are conventional and are not shown in FIGS. 1 and 2 as placement and operation of these components are known in the art.
The system temperature and pressure may be monitored and controlled either manually, or by a conventional automated controller (which may include, for example, an appropriately programmed computer or appropriately constructed microchip) that receives signals from the thermocouple and pressure gauge, and then sends corresponding signals to the heat exchanger and pump and/or compressor, respectively. Unless otherwise noted, the temperature and pressure is appropriately maintained throughout the system during operation. As such, elements contained within the system are constructed of sufficient size and material to withstand the temperature, pressure, and flow parameters required for operation, and may be selected from, or designed using, any of a variety of presently available high pressure hardware.
In the present invention, the preferred organic solvent should have a flash point of greater than 200° F. to allow for increased safety and less governmental regulation, have a low evaporation rate to minimize fugitive emissions, be able to remove soils consisting of insoluble particulate soils and solvent soluble oils and greases, and prevent or reduce redeposition of soil onto the textiles being cleaned.
Preferably, the organic solvent in the present invention is a glycol ether, and specifically a poly glycol ether such as dipropylene glycol n-butyl ether, tripropylene glycol n-butyl ether or tripropylene glycol methyl ether, or any combination of one or more of these. Additionally, any organic solvent or mixture of organic solvents exhibiting the following physical properties is suitable for use in the present invention: (1) soluble in carbon dioxide at a pressure of between about 600 and about 1050 pounds per square inch and at a temperature of between about 5 and about 30 degrees Celsius; (2) specific gravity of greater than about 0.7 (the higher the density, the better the organic solvent); and (3) Hansen solubility parameters of about 7.2-8.1 (cal/cm 3 ) ½ for dispersion, about 2.0-4.8 (cal/cm 3 ) ½ for polar, and about 4.0-7.3 (cal/cm 3 ) ½ for hydrogen bonding (based on values cited in Publication No. M-167P from Eastman Chemical Products). Preferably, in addition to the above three physical properties, the organic solvent used in the present invention should also exhibit one or more of the following physical properties: (4) flash point greater than about 200 degrees Fahrenheit; and (5) evaporation rate of lower than about 30 (where n-butyl acetate=100). Most preferably, the organic solvent used in the present invention exhibits each of the foregoing characteristics (i.e., those identified as (1) through (5)).
The Hansen solubility parameters were developed to characterize solvents for the purpose of comparison. Each of the three parameters (i.e., dispersion, polar and hydrogen bonding) represents a different characteristic of solvency. In combination, the three parameters are a measure of the overall strength and selectivity of a solvent. The above Hansen solubility parameter ranges identify solvents that are good solvents for a wide range of substances and also exhibit a degree of solubility in liquid carbon dioxide. The Total Hansen solubility parameter, which is the square root of the sum of the squares of the three parameters mentioned previously, provides a more general description of the solvency of the organic solvents.
Dipropylene glycol n-butyl ether, tripropylene glycol n-butyl ether and tripropylene glycol methyl ether all fall within all of the above parameters; however, any organic solvent or mixture of organic solvents that meet at least properties 1 through 3, and preferably all 5 properties, is suitable for use in the present invention. Furthermore, the organic solvent should also have a low toxicity and a low environmental impact. Table 1 below shows the physical properties of a number of organic solvents that may be suitable for use in the present invention.
TABLE 1
Evaporation
Soluble
Rate
Hansen Solubility Parameters
in
Specific
Flash
(n-butyl
Hydrogen
carbon
Gravity
Point
acetate =
Dispersion
Polar
Bonding
Total
Solvent
dioxide
(20° C./20° C.)
(° F.)
100)
(cal/cm 3 ) 1/2
(cal/cm 3 ) 1/2
(cal/cm 3 ) 1/2
(cal/cm 3 ) 1/2
Ethylene
Yes
0.931
110
30
7.9
4.5
7.0
11.5
Glycol Ethyl
Ether
Ethylene
Yes
0.973
130
20
7.8
2.3
5.2
9.7
Glycol Ethyl
Ether Acetate
Diethylene
Yes
0.956
222
0.3
7.8
3.4
5.2
10.0
Glycol Butyl
Ether
Propylene
Yes
0.872
113
25
7.5
3.0
5.3
9.6
Glycol t-butyl
(25° C./25° C.)
Ether
Dipropylene
Yes
0.951
167
2
7.6
2.8
5.5
9.8
Glycol Methyl
Ether
Tripropylene
Yes
0.962
232
0.2
7.4
3.0
5.7
9.8
Glycol Methyl
Ether
Dipropylene
Yes
0.912
214
0.4
7.4
2.2
5.5
9.5
Glycol n-Butyl
Ether
Dipropylene
Yes
0.922
190
1.3
7.4
2.4
5.7
9.6
Glycol n-
Propyl Ether
Tripropylene
Yes
0.934
255
0.029
7.4
2.4
5.1
9.3
Glycol n-Butyl
Ether
In Table 1, the solvents are soluble in carbon dioxide between 570 psig/5° C. and 830 psig/20° C. The flash point was measured using Tag Closed Cup for ethylene glycol ethyl ether and ethylene glycol ethyl ether acetate; using SETA Flash for diethylene glycol butyl ether, propylene glycol t-butyl ether, dipropylene glycol methyl ether, tripropylene glycol methyl ether, dipropylene glycol n-butyl ether, and dipropylene glycol n-propyl ether; and using Pensky Martens Closed Cup for tripropylene glycol n-butyl ether. The values for the evaporation rate are based on n-butyl acetate=100. Finally, the specific gravity, flash point, evaporation rate and Hansen solubility parameters were obtained from Publication No. M-167P from Eastman Chemical Products for ethylene glycol ethyl ether, ethylene glycol ethyl ether acetate, diethylene glycol butyl ether, and propylene glycol t-butyl ether; from “Products for Cleaners and the Personal Care Industry,” Arco Chemicals (1997), for dipropylene glycol methyl ether, tripropylene glycol methyl ether, dipropylene glycol n-butyl ether, and dipropylene glycol n-propyl ether; and from Lyondell Chemical Company for tripropylene glycol n-butyl ether.
Referring now to FIG. 1, a block diagram of a cleaning system having separate vessels for cleaning and drying textiles is shown. The cleaning system 100 generally comprises a cleaning machine 102 having a cleaning vessel 110 operatively connected to, via one or more motor activated shafts (not shown), a perforated rotatable cleaning drum or wheel 112 within the cleaning vessel 110 with an inlet 114 to the cleaning vessel 110 and an outlet 116 from the cleaning vessel 110 through which cleaning fluids can pass. A drying machine 104 has a drying vessel 120 capable of being pressurized. The pressurizable drying vessel 120 is operatively connected to, via one or more motor activated shafts (not shown), a perforated rotatable drying drum or wheel 122 within the drying vessel 120 with an inlet 124 to the drying vessel 120 and an outlet 126 from the drying vessel 120 through which pressurized fluid solvent can pass. The cleaning vessel 110 and the drying vessel 120 can either be parts of the same machine, or they can comprise separate machines. Furthermore, both the cleaning and drying steps of this invention can be performed in the same vessel, as is described with respect to FIG. 2 below.
An organic solvent tank 130 holds any suitable organic solvent, as previously described, to be introduced to the cleaning vessel 110 through the inlet 114 . A pressurized fluid solvent tank 132 holds pressurized fluid solvent to be added to the pressurizable drying vessel 120 through the inlet 124 . Filtration assembly 140 contains one or more filters that continuously remove contaminants from the organic solvent from the cleaning vessel 110 as cleaning occurs.
The components of the cleaning system 100 are connected with lines 150 - 156 , which transfer organic solvents and vaporized and pressurized fluid solvents between components of the system. The term “line” as used herein is understood to refer to a piping network or similar conduit capable of conveying fluid and, for certain purposes, is capable of being pressurized. The transfer of the organic solvents and vaporized and pressurized fluid solvents through the lines 150 - 156 is directed by valves 170 - 176 and pumps 190 - 193 . While pumps 190 - 193 are shown in the described embodiment, any method of transferring liquid and/or vapor between components can be used, such as adding pressure to the component using a compressor to force the liquid and/or vapor from the component.
The textiles are cleaned with an organic solvent such as those previously described or mixtures thereof. The textiles may also be cleaned with a combination of organic solvent and pressurized fluid solvent, and this combination may be in varying proportions from about 50% by weight to 100% by weight of organic solvent and 0% by weight to 50% by weight of pressurized fluid solvent. In the cleaning process, the textiles are first sorted as necessary to place the textiles into groups suitable to be cleaned together. The textiles may then be spot treated as necessary to remove any stains that may not be removed during the cleaning process. The textiles are then placed into the cleaning drum 112 of the cleaning system 100 . It is preferred that the cleaning drum 112 be perforated to allow for free interchange of solvent between the cleaning drum 112 and the cleaning vessel 110 as well as to transport soil from the textiles to the filtration assembly 140 .
After the textiles are placed in the cleaning drum 112 , an organic solvent contained in the organic solvent tank 130 is added to the cleaning vessel 110 via line 152 by opening valve 171 , closing valves 170 , 172 , 173 and 174 , and activating pump 190 to pump organic solvent through the inlet 114 of the cleaning vessel 110 . The organic solvent may contain one or more co-solvents, water, detergents, or other additives to enhance the cleaning capability of the cleaning system 100 . Alternatively, one or more additives may be added directly to the cleaning vessel 110 . Pressurized fluid solvent may also be added to the cleaning vessel 110 along with the organic solvent to enhance cleaning. Pressurized fluid solvent can be added to the cleaning vessel 110 via line 154 by opening valve 174 , closing valves 170 , 171 , 172 , 173 , and 175 , and activating pump 192 to pump pressurized fluid solvent through the inlet 114 of the cleaning vessel 110 . Of course, if pressurized fluid solvent is included in the cleaning cycle, the cleaning vessel 110 will need to be pressurized in the same manner as the drying vessel 120 , as discussed below.
When a sufficient amount of the organic solvent, or combination of organic solvent and pressurized fluid solvent, is added to the cleaning vessel 110 , the motor (not shown) is activated and the perforated cleaning drum 112 is agitated and/or rotated within cleaning vessel 110 . During this phase, the organic solvent is continuously cycled through the filtration assembly 140 by opening valves 170 and 172 , closing valves 171 , 173 and 174 , and activating pump 191 . Filtration assembly 140 may include one or more fine mesh filters to remove particulate contaminants from the organic solvent passing therethrough and may alternatively or in addition include one or more absorptive or adsorptive filters to remove water, dyes and other dissolved contaminants from the organic solvent. Exemplary configurations for filter assemblies that can be used to remove contaminants from either the organic solvent or the pressurized fluid solvent are described more fully in U.S. application Ser. No. 08/994,583 incorporated herein by reference. As a result, the organic solvent is pumped through outlet 116 , valve 172 , line 151 , filter assembly 140 , line 150 , valve 170 and re-enters the cleaning vessel 110 via inlet 114 . This cycling advantageously removes contaminants, including particulate contaminants and/or soluble contaminants, from the organic solvent and reintroduces filtered organic solvent to the cleaning vessel 110 and agitating or rotating cleaning drum 112 . Through this process, contaminants are removed from the textiles. Of course, in the event the cleaning vessel 110 is pressurized, this recirculation system will be maintained at the same pressure/temperature levels as those in cleaning vessel 110 .
After sufficient time has passed so that the desired level of contaminants is removed from the textiles and organic solvent, the organic solvent is removed from the cleaning drum 112 and cleaning vessel 110 by opening valve 173 , closing valves 170 , 171 , 172 and 174 , and activating pump 191 to pump the organic solvent through outlet 116 via line 153 . The cleaning drum 112 is then rotated at a high speed, such as 400-800 rpm, to further remove organic solvent from the textiles. The cleaning drum 112 is preferably perforated so that, when the textiles are rotated in the cleaning drum 112 at a high speed, the organic solvent can drain from the cleaning drum 112 . Any organic solvent removed from the textiles by rotating the cleaning drum 112 at high speed is also removed from the cleaning drum 112 in the manner described above. After the organic solvent is removed from the cleaning drum 112 , it can either be discarded or recovered and decontaminated for reuse using solvent recovery systems known in the art. Furthermore, multiple cleaning cycles can be used if desired, with each cleaning cycle using the same organic solvent or different organic solvents. If multiple cleaning cycles are used, each cleaning cycle can occur in the same cleaning vessel, or a separate cleaning vessel can be used for each cleaning cycle.
After a desired amount of the organic solvent is removed from the textiles by rotating the cleaning drum 112 at high speed, the textiles are moved from the cleaning drum 112 to the drying drum 122 within the drying vessel 120 in the same manner textiles are moved between machines in conventional cleaning systems. In an alternate embodiment, a single drum can be used in both the cleaning cycle and the drying cycle, so that, rather than transferring the textiles between the cleaning drum 112 and the drying drum 122 , a single drum containing the textiles is transferred between the cleaning vessel 110 and the drying vessel 120 . If the cleaning vessel 110 is pressurized during the cleaning cycle, it must be depressurized before the textiles are removed. Once the textiles have been placed in the drying drum 122 , pressurized fluid solvent, such as that contained in the carbon dioxide tank 132 , is added to the drying vessel 120 via lines 154 and 155 by opening valve 175 , closing valves 174 and 176 , and activating pump 192 to pump pressurized fluid solvent through the inlet 124 of the drying vessel 120 via lines 154 and 155 . When pressurized fluid solvent is added to the drying vessel 120 , the organic solvent remaining on the textiles dissolves in the pressurized fluid solvent.
After a sufficient amount of pressurized fluid solvent is added so that the desired level of organic solvent has been dissolved, the pressurized fluid solvent and organic solvent combination is removed from the drying vessel 120 , and therefore also from the drying drum 122 , by opening valve 176 , closing valve 175 and activating pump 193 to pump the pressurized fluid solvent and organic solvent combination through outlet 126 via line 156 . If desired, this process may be repeated to remove additional organic solvent. The drying drum 122 is then rotated at a high speed, such as 150-350 rpm, to further remove the pressurized fluid solvent and organic solvent combination from the textiles. The drying drum 122 is preferably perforated so that, when the textiles are rotated, in the drying drum 122 at a high speed, the pressurized fluid solvent and organic solvent combination can drain from the drying drum 122 . Any pressurized fluid solvent and organic solvent combination removed from the textiles by spinning the drying drum 122 at high speed is also pumped from the drying vessel 120 in the manner described above. After the pressurized fluid solvent and organic solvent combination is removed from the drying vessel 120 , it can either be discarded or separated and recovered for reuse with solvent recovery systems known in the art. Note that, while preferred, it is not necessary to include a high speed spin cycle to remove pressurized fluid solvent from the textiles.
After a desired amount of the pressurized fluid solvent is removed from the textiles by rotating the drying drum 122 , the drying vessel 120 is depressurized over a period of about 5-15 minutes. The depressurization of the drying vessel 120 vaporizes any remaining pressurized fluid solvent, leaving dry, solvent-free textiles in the drying drum 122 . The pressurized fluid solvent that has been vaporized is then removed from the drying vessel 120 by opening valve 176 , closing valve 175 , and activating pump 193 . As a result, the vaporized pressurized fluid solvent is pumped through the outlet 126 , line 156 and valve 176 , where it can then either be vented to the atmosphere or recovered and recompressed for reuse.
While the cleaning system 100 has been described as a complete system, an existing conventional dry cleaning system may be converted for use in accordance with the present invention. To convert a conventional dry cleaning system, the organic solvent described above is used to clean textiles in the conventional system. A separate pressurized vessel is added to the conventional system for drying the textiles with pressurized fluid solvent. Thus, the conventional system is converted for use with a pressurized fluid solvent. For example, the system in FIG. 1 could represent such a converted system, wherein the components of the cleaning machine 102 are conventional, and the pressurized fluid solvent tank 132 is not in communication with the cleaning vessel 100 . In such a situation, the drying machine 104 is the add-on part of the conventional cleaning machine.
Furthermore, while the system shown in FIG. 1 comprises a single cleaning vessel, multiple cleaning vessels could be used, so that the textiles are subjected to multiple cleaning steps, with each cleaning step carried out in a different cleaning vessel using the same or different organic solvents in each step. The description of the single cleaning vessel is merely for purposes of description and should not be construed as limiting the scope of the invention.
Referring now to FIG. 2, a block diagram of an alternate embodiment of the present invention, a cleaning system having a single chamber for cleaning and drying the textiles, is shown. The cleaning system 200 generally comprises a cleaning machine having a pressurizable vessel 210 . The vessel 210 is operatively connected to, via one or more motor activated shafts (not shown), a perforated rotatable drum or wheel 212 within the vessel 210 with an inlet 214 to the vessel 210 and an outlet 216 from the vessel 210 through which dry cleaning fluids can pass.
An organic solvent tank 220 holds any suitable organic solvent, such as those described above, to be introduced to the vessel 210 through the inlet 214 . A pressurized fluid solvent tank 222 holds pressurized fluid solvent to be added to the vessel 210 through the inlet 214 . Filtration assembly 224 contains one or more filters that continuously remove contaminants from the organic solvent from the vessel 210 and drum 212 as cleaning occurs.
The components of the cleaning system 200 are connected with lines 230 - 234 that transfer organic solvents and vaporized and pressurized fluid solvent between components of the system. The term “line” as used herein is understood to refer to a piping network or similar conduit capable of conveying fluid and, for certain purposes, is capable of being pressurized. The transfer of the organic solvents and vaporized and pressurized fluid solvent through the lines 230 - 234 is directed by valves 250 - 254 and pumps 240 - 242 . While pumps 240 - 242 are shown in the described embodiment, any method of transferring liquid and/or vapor between components can be used, such as adding pressure to the component using a compressor to force the liquid and/or vapor from the component.
The textiles are cleaned with an organic solvent such as those previously described. The textiles may also be cleaned with a combination of organic solvent and pressurized fluid solvent, and this combination may be in varying proportions of 50-100% by weight organic solvent and 0-50% by weight pressurized fluid solvent.
In the cleaning process, the textiles are first sorted as necessary to place the textiles into groups suitable to be cleaned together. The textiles may then be spot treated as necessary to remove any stains that may not be removed during the cleaning process. The textiles are then placed into the drum 212 within the vessel 210 of the cleaning system 200 . It is preferred that the drum 212 be perforated to allow for free interchange of solvent between the drum 212 and the vessel 210 as well as to transport soil from the textiles to the filtration assembly 224 .
After the textiles are placed in the drum 212 , an organic solvent contained in the organic solvent tank 220 is added to the vessel 210 via line 231 by opening valve 251 , closing valves 250 , 252 , 253 and 254 , and activating pump 242 to pump organic solvent through the inlet 214 of the vessel 210 . The organic solvent may contain one or more co-solvents, detergents, water, or other additives to enhance the cleaning capability of the cleaning system 200 . Alternatively, one or more additives may be added directly to the vessel. Pressurized fluid solvent may also be added to the vessel 210 along with the organic solvent to enhance cleaning. The pressurized fluid solvent is added to the vessel 210 via line 230 by opening valve 250 , closing valves 251 , 252 , 253 and 254 , and activating pump 240 to pump the pressurized fluid solvent through the inlet 214 of the vessel 210 .
When the desired amount of the organic solvent, or combination of organic solvent and pressurized fluid solvent as described above, is added to the vessel 210 , the motor (not shown) is activated and the drum 212 is agitated and/or rotated.
During this phase, the organic solvent, as well as pressurized fluid solvent if used in combination, is continuously cycled through the filtration assembly 224 by opening valves 252 and 253 , closing valves 250 , 251 and 254 , and activating pump 241 . Filtration assembly 224 may include one or more fine mesh filters to remove particulate contaminants from the organic solvent and pressurized fluid solvent passing therethrough and may alternatively or in addition include one or more absorptive or adsorptive filters to remove water, dyes, and other dissolved contaminants from the organic solvent. Exemplary configurations for filter assemblies that can be used to remove contaminants from either the organic solvent or the pressurized fluid solvent are described more fully in U.S. application Ser. No. 08/994,583 incorporated herein by reference. As a result, the organic solvent is pumped through outlet 216 , valve 253 , line 233 , filter assembly 224 , line 232 , valve 252 and reenters the vessel 210 via inlet 214 . This cycling advantageously removes contaminants, including particulate contaminants and/or soluble contaminants, from the organic solvent and pressurized fluid solvent and reintroduces filtered solvent to the vessel 210 . Through this process, contaminants are removed from the textiles.
After sufficient time has passed so that the desired Jevel of contaminants is removed from the textiles and solvents, the organic solvent is removed from the vessel 210 and drum 212 by opening valve 254 , closing valves 250 , 251 , 252 and 253 , and activating pump 241 to pump the organic solvent through outlet 216 and line 234 . If pressurized fluid solvent is used in combination with organic solvent, it may be necessary to first separate the pressurized fluid solvent from the organic solvent. The organic solvent can then either be discarded or, preferably, contaminants may be removed from the organic solvent and the organic solvent recovered for further use. Contaminants may be removed from the organic solvent with solvent recovery systems known in the art. The drum 212 is then rotated at a high speed, such as 400-800 rpm, to further remove organic solvent from the textiles. The drum 212 is preferably perforated so that, when the textiles are rotated in the drum 212 at a high speed, the organic solvent can drain from the cleaning drum 212 . Any organic solvent removed from the textiles by rotating the drum 212 at high speed can also either be discarded or recovered for further use.
After a desired amount of organic solvent is removed from the textiles by rotating the drum 212 , pressurized fluid solvent contained in the pressurized fluid tank 222 is added to the vessel 210 by opening valve 250 , closing valves 251 , 252 , 253 and 254 , and activating pump 240 to pump pressurized fluid solvent through the inlet 214 of the pressurizable vessel 210 via line 230 . When pressurized fluid solvent is added to the vessel 210 , organic solvent remaining on the textiles dissolves in the pressurized fluid solvent.
After a sufficient amount of pressurized fluid solvent is added so that the desired level of organic solvent has been dissolved, the pressurized fluid solvent and organic solvent combination is removed from the vessel 210 by opening valve 254 , closing valves 250 , 251 , 252 and 253 , and activating pump 241 to pump the pressurized fluid solvent and organic solvent combination through outlet 216 and line 234 . Note that pump 241 may actually require two pumps, one for pumping the low pressure organic solvent in the cleaning cycle and one for pumping the pressurized fluid solvent in the drying cycle.
The pressurized fluid solvent and organic solvent combination can then either be discarded or the combination may be separated and the organic solvent and pressurized fluid solvent separately recovered for further use. The drum 212 is then rotated at a high speed, such as 150-350 rpm, to further remove pressurized fluid solvent and organic solvent combination from the textiles. Any pressurized fluid solvent and organic solvent combination removed from the textiles by spinning the drum 212 at high speed can also either be discarded or retained for further use. Note that, while preferred, it is not necessary to include a high speed spin cycle to remove pressurized fluid solvent from the textiles.
After a desired amount of the pressurized fluid solvent is removed from the textiles by rotating the drum 212 , the vessel 210 is depressurized over a period of about 5-15 minutes. The depressurization of the vessel 210 vaporizes the pressurized fluid solvent, leaving dry, solvent-free textiles in the drum 212 . The pressurized fluid solvent that has been vaporized is then removed from the vessel 210 by opening valve 254 , closing valves 250 , 251 , 252 and 253 , and activating pump 241 to pump the vaporized pressurized fluid solvent through outlet 216 and line 234 . Note that while a single pump is shown as pump 241 , separate pumps may be necessary to pump organic solvent, pressurized fluid solvent and pressurized fluid solvent vapors, at pump 241 . The remaining vaporized pressurized fluid solvent can then either be vented into the atmosphere or compressed back into pressurized fluid solvent for further use.
As discussed above, dipropylene glycol n-butyl ether, tripropylene glycol n-butyl ether and tripropylene glycol methyl ether are the preferred organic solvents for use in the present invention, as shown in the test results below. Table 2 shows results of detergency testing for each of a number of solvents that may be suitable for use in the present invention. Table 3 shows results of testing of drying and extraction of those solvents using densified carbon dioxide.
Detergency tests were performed using a number of different solvents without detergents, co-solvents, or other additives. The solvents selected for testing include organic solvents and liquid carbon dioxide. Two aspects of detergency were investigated—soil removal and soil redeposition. The former refers to the ability of a solvent to remove soil from a substrate while the latter refers to the ability of a solvent to prevent soil from being redeposited on a substrate during the cleaning process. Wascherei Forschungs Institute, Krefeld Germany (“WFK”) standard soiled swatches that have been stained with a range of insoluble materials and WFK white cotton swatches, both obtained from TESTFABRICS, Inc., were used to evaluate soil removal and soil redeposition, respectively.
Soil removal and redeposition for each solvent was quantified using the Delta Whiteness Index. This method entails measuring the Whiteness Index of each swatch before and after processing. The Delta Whiteness Index is calculated by subtracting the Whiteness Index of the swatch before processing from the Whiteness Index of the swatch after processing. The Whiteness Index is a function of the light reflectance of the swatch and in this application is an indication of the amount of soil on the swatch. More soil results in a lower light reflectance and Whiteness Index for the swatch. The Whiteness indices were measured using a reflectometer manufactured by Hunter Laboratories.
Organic solvent testing was carried out in a Launder-Ometer while the densified carbon dioxide testing was carried out in a Parr Bomb. After measuring their Whiteness Indices, two WFK standard soil swatches and two WFK white cotton swatches were placed in a Launder-Ometer cup with 25 stainless steel ball bearings and 150 mL of the solvent of interest. The cup was then sealed, placed in the Launder-Ometer and agitated for a specified length of time. Afterwards, the swatches were removed and placed in a Parr Bomb equipped with a mesh basket. Approximately 1.5 liters of liquid carbon dioxide between 5° C. and 25° C. and 570 psig and 830 psig was transferred to the Parr Bomb. After several minutes the Parr Bomb was vented and the dry swatches removed and allowed to reach room temperature. Testing of densified carbon dioxide was carried out by placing the swatches in a Parr Bomb, transferring liquid carbon dioxide at 20° C. and 830 psig to the Parr Bomb. The swatches were fastened to a wire frame attached to a rotatable shaft to enable the swatches to be agitated while immersed in the liquid carbon dioxide. The Whiteness Index of the processed swatches was determined using the reflectometer. The two Delta Whiteness Indices obtained for each pair of swatches were averaged. The results are presented in Table 2.
Because the Delta Whiteness Index is calculated by subtracting the Whiteness Index of a swatch before processing from the Whiteness Index value after processing, a positive Delta Whiteness Index indicates that there was an increase in Whiteness Index as a result of processing. In practical terms, this means that soil was removed during processing. In fact, the higher the Delta Whiteness Value, the more soil was removed from the swatch during processing. Each of the organic solvents tested exhibited significant soil removal. Densified carbon dioxide alone, on the other hand, exhibited no soil removal. The WFK white cotton swatches exhibited a decrease in Delta Whiteness Indices indicating that the soil was deposited on the swatches during the cleaning process. Therefore, a “less negative” Delta Whiteness Index suggests that less soil was redeposited. It should be noted that the seemingly excellent result obtained for densified carbon dioxide is an anomaly and resulted from the fact that essentially no soil removal took place and therefore essentially no soil was present in the solvent which could be deposited on the swatch. The organic solvents on the other hand, exhibited good soil redeposition results.
TABLE 2
Delta Whiteness Values
Cleaning Time
Insoluble Soil
Insoluble Soil
Solvent
(minutes)
Removal
Redeposition
Densified Carbon
20
0.00
−0.54
Dioxide (at 20° C.
and 830 psig)
Ethylene Glycol
12
13.87
−5.10
Ethyl Ether
Ethylene Glycol
12
16.10
−11.40
Ethyl Ether
Acetate
Diethylene Glycol
12
12.80
−5.11
Butyl Ether
Propylene Glycol
12
14.35
−13.50
t-butyl Ether
Dipropylene Glycol
20
11.84
−5.64
Methyl Ether
Tripropylene Glycol
12
13.48
−5.60
Methyl Ether
Dipropylene Glycol
12
13.97
−6.22
n-Butyl Ether
Dipropylene Glycol
12
13.15
−7.50
n-Propyl Ether
Tripropylene Glycol
12
13.24
−4.35
n-Butyl Ether
To evaluate the ability of densified carbon dioxide to extract organic solvent from a substrate, WFK white cotton swatches were used. One swatch was weighed dry and then immersed in an organic solvent sample. Excess solvent was removed from the swatch using a ringer manufactured by Atlas Electric Devices Company. The damp swatch was re-weighed to determine the amount of solvent retained in the fabric. After placing the damp swatch in a Parr Bomb densified carbon dioxide was transferred to the Parr Bomb. The temperature and pressure of the densified carbon dioxide for all of the trials ranged from 5° C. to 20° C. and from 570 psig-830 psig. After five minutes the Parr Bomb was vented and the swatch removed. The swatch was next subjected to Soxhlet extraction using methylene chloride for a minimum of two hours. This apparatus enables the swatch to be continuously extracted to remove the organic solvent from the swatch. After determining the concentration of the organic solvent in the extract using gas chromatography, the amount of organic solvent remaining on the swatch after exposure to densified carbon dioxide was calculated by multiplying the concentration of the organic solvent in the extract by the volume of the extract. A different swatch was used for each of the tests. The results of these tests are included in Table 3. As the results indicate, the extraction process using densified carbon dioxide is extremely effective.
TABLE 3
Weight of
Percentage
Weight of Solvent
Densified
by Weight
on Test Swatch
Carbon
of Solvent
(grams)
Dioxide
Removed
Before
After
Used
from
Solvent
Extraction
Extraction
(kilograms)
Swatch
Ethylene Glycol Ethyl
1.8718
0.0069
1.35
99.63
Ether
Ethylene Glycol Ethyl
1.9017
0.0002
1.48
99.99
Ether Acetate
Diethylene Glycol
1.9548
0.0033
1.72
99.83
Butyl Ether
Propylene Glycol
2.0927
0.0010
1.24
99.95
t-butyl Ether
Dipropylene Glycol
2.1209
0.0005
1.31
99.98
Methyl Ether
Tripropylene Glycol
1.9910
0.0022
1.71
99.89
Methyl Ether
Dipropylene Glycol
1.8005
0.0023
1.77
99.87
n-Butyl Ether
Dipropylene Glycol
1.7096
0.0034
1.59
99.80
n-Butyl Ether
Dipropylene Glycol
1.7651
0.0018
3.36
99.90
n-Butyl Ether
Dipropylene Glycol
1.7958
0.0012
1.48
99.94
n-Propyl Ether
Tripropylene Glycol
1.8670
0.0034
1.30
99.82
n-Butyl Ether
It is to be understood that a wide range of changes and modifications to the embodiments described above will be apparent to those skilled in the art and are contemplated. It is, therefore, intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of the invention. | A cleaning system that utilizes an organic cleaning solvent and pressurized fluid solvent is disclosed. The system has no conventional evaporative hot air drying cycle. Instead, the system utilizes the solubility of the organic solvent in pressurized fluid solvent as well as the physical properties of pressurized fluid solvent. After an organic solvent cleaning cycle, the solvent is extracted from the textiles at high speed in a rotating drum in the same way conventional solvents are extracted from textiles in conventional evaporative hot air dry cleaning machines. Instead of proceeding to a conventional drying cycle, the extracted textiles are then immersed in pressurized fluid solvent to extract the residual organic solvent from the textiles. This is possible because the organic solvent is soluble in pressurized fluid solvent. After the textiles are immersed in pressurized fluid solvent, pressurized fluid solvent is pumped from the drum. Finally, the drum is de-pressurized to atmospheric pressure to evaporate any remaining pressurized fluid solvent, yielding clean, solvent free textiles. The organic solvent is preferably dipropylene glycol n-butyl ether, tripropylene glycol n-butyl ether or tripropylene glycol methyl ether, a mixture thereof, or a similar solvent and the pressurized fluid solvent is preferably densified carbon dioxide. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to the control of data to a two-dimensional display screen, e.g., on a computer monitor. More particularly, the present invention is directed to a technique for providing a variable resolution display.
Computers commonly operate in different display modes with different display characteristics, in accordance with the requirements of the data being displayed. For example, a typical computer may operate its display in either a text or graphics mode, and may be capable of several different types of graphics modes. Bit plane graphics provides the least expensive way of displaying information on the screen, simply storing one bit for each pixel. However, the versatility of the display is not very good, since the allocation of only one bit per pixel means that no shading can be shown.
Gray scale level displays require more memory to store an image of the same resolution. E.g., by allocating four bits per pixel, each pixel can be shown in sixteen different levels of shading, thus increasing the versatility in what kinds of displays can be provided. For the same resolution, however, a gray level display with four bits per pixel will require a frame buffer which is four times as large as that required for a bit plane graphics display.
Finally, color displays typically allocate between four and eight bits per pixel to allow any given pixel to be represented in a large number of different color shades. To provide the same level of resolution as above, the frame buffer for a color display would necessarily be four to eight time larger than for a bit plane graphics system.
It would be desirable to provide a universal display controller capable of operating in each of the three different modes, but a number of problems are encountered. If the same spatial resolution is required for each different mode, the only approach would be to provide a frame buffer of maximum size which could provide high resolution images even in a color display having a "depth" of eight bits per pixel. Such an arrangement, however, would be expensive not only due to the cost and size of the frame buffer, but also as a result of the very high cost of high resolution color monitors as compared with gray level or black-and-white (B&W) monitors of the same resolution. As a practical matter, there is not often a requirement for equal resolution in both B&W and color modes. Moderately priced systems may include a high resolution B&W monitor and lower resolution color monitor. Higher priced systems may also utilize monitors with different resolutions, since B&W monitors in general provide higher resolution than the best color monitors. It is therefore desirable to provide a means for operating at different display resolutions.
Examples of display controllers adaptable to different resolutions are disclosed in U.S. Pat. Nos. 4,500,875 to Schmitz and 4,236,228 to Nagashima et al. The latter discloses a technique whereby a slow addressing method is used to assist the microprocessor in appropriately addressing a memory location, but this is not practical for providing fast video refresh. The former reference discloses a technique wherein a plurality of gates are provided in the video data path between the frame buffer and color map memory. This is disadvantageous not only due to the complexity of the gate array but also in that the different propagation paths through the gate array must be very short and of equal propagation delay, requiring further complex hardware to ensure satisfaction of the timing requirements.
A display controlling with a permanent frame buffer configuration requires a very large frame buffer size to handle both requirements of high resolution and of maximum pixel depth. It is possible to provide additional hardware to reconfigure the frame buffer structure for particular applications, but such additional hardware would be quite expensive.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a display controller capable of variable spatial resolution and variable pixel data depth.
It is a further object of this invention to provide such a system which avoids the use of costly additional frame buffer reconfiguration hardware.
It is a feature of the present invention that the frame buffer is software-reconfigurable using a Video Look-up Table (VLT). Briefly, the present invention employs a frame buffer configured for the maximum pixel data depth data mode, and a VLT for receiving the frame buffer output data and providing appropriate pixel data through a digital-to-analog (D/A0 converter to the monitor. If a color monitor is used, separate VLTs may be used for each color. All VLTs are divided into partitions which are programmed identically. A plurality of shift registers are used to pass the data from the frame buffer to the VLTs. The shift registers are arranged such that their collective outputs at any given time will represent a multi-bit address word to the VLT. The shift registers are provided with separately controllable Clear inputs so that the effective depth of the pixel data can be varied in accordance with the display mode. For example, with a maximum pixel depth of eight bits per pixel, all eight shift registers may be used to provide data to the VLTs. In a higher resolution mode, the pixel depth may be four bits per pixel. This is accomplished by reading through a column or row of the frame buffer twice, the first time utilizing half of the shift registers to provide half of the data to the VLTs, and the second time using the other half of the shift registers to provide the other half of the frame buffer data to the VLTs. For a frame buffer configured for a pixel depth of eight bits, it is possible to increase the display resolution by a factor of eight by reading out only one bit per pixel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood from the following description in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram of a display controller in accordance with a first embodiment of the present invention;
FIG. 2 is a block diagram of a display controller in accordance with a second embodiment of the present invention; and
FIG. 3 is a block diagram of a display controller in accordance with a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A relatively simple implementation of the present invention is represented by the embodiment of FIG. 1. In this embodiment, the frame buffer having an organization of 1024 (horizontal)×512 (vertical) by 8 (depth) can be also used to provide a resolution of 1024×1024 with a depth of 4 bits per pixel.
The system of FIG. 1 is a conventional display controlled with three VLTs (red, green and blue), a frame buffer, eight N-bit shift registers SHR0-SHR7. D/A converters for the outputs of each of the VLTs, and a line counter. The frame buffer may be a μpD 41264 video RAM made by NEC Corporation. The line counter provides nine bits (0-8) of its output as the vertical video-refresh address to the frame buffer. Each successive address from the bits 0-8 of the line counter addresses one of the 512 lines, or rows, of the frame buffer, with each row including 1024 8-bit pixel data values. In a known manner, the 8 bits of each pixel data value can be read out in parallel, with each bit going to a respective one of the shift registers SHR0-SHR7. These N-bit shift registers are loaded in response to a signal (VCLK/N) applied to their load terminals LD, so that N pixel values are taken from the frame buffer at each load signal (VCLK/N), where N is a ratio between the video clock VCLK frequency and the frame buffer video refresh read-out period. Between each load signal, N pulses of the video clock VCLK occur, shifting out in parallel the contents of all registers SHR0-SHR7, with the collective outputs of the shift registers at any given time representing one of the 8-bit pixel data values provided in common to all of the VLTs.
In addition to the conventional structure, the device includes a one-bit Mode Register, two NAND gates and one inverter INV. In addition, the line counter includes an extra bit LC<9>. The "clear" inputs CLR of the shift registers SHR0-SHR3 are connected in common to the output of the gate NAND1, and the "clear" inputs of the registers SHR4-SHR7 are connected in common to the output of gate NAND2. For 512×1024 resolution, the mode register is set to a value of "0". This will cause the outputs of each of the gates NAND1 and NAND2 to be continually high, so that none of the shift registers SHR0-SHR7 are cleared. Once each count of the line counter, a new line in the frame buffer is accessed. Once each cycle of the load signal (VCLK/N), N 8-bit pixel data values are loaded in parallel into the registers SHR0-SHR7. The register contents are then shifted out in response to the video clock signal VCLK, with the collective outputs of the shift registers SHR0-SHR7 at any time representing one 8-bit pixel value. These 8-bit values are provided in common to all three VLTs. With each pixel value having a depth of 8-bits, the VLTs can cooperate to provide 256 different shades of color for each pixel. Alternatively, a B&W monitor may be used, e.g., operated in accordance with a gray scale.
If higher resolution is desired, this can be easily accomplished by effectively dividing the frame buffer into halves. More particularly, instead of operating the frame buffer as though each line includes 1024 columns which are 8-bits deep, the frame buffer is operated as two different 512×1024×4 buffers.
To operates in the 1024×1024 mode, the mode register is set to a value of "1". During a first pass through the frame buffer, the output bits 0-8 from the line counter sequentially step through all 512 lines of the frame buffer. At this time, the additional bit LC<9> is low, so that the output of NAND1 is high and the output of NAND2 is low. As a consequence, registers SHR4-SHR7 are kept cleared. Thus, when the 8-bit words are loaded in parallel across the 8 registers SHR0SHR7, the bits 4-8 are effectively ignored, with the 8-bit word subsequently provided to the VLTs comprising the output bits from SHR0-SHR3 as its four most significant bits and a value of "0" as its four least significant bits. During the next pass through the 512 lines of the frame buffer, the additional bit LC<9> has a value of "1", so that the output of NAND1 is low and the output of NAND2 is high. This time through, the registers SHR0-SHR3 are maintained cleared, while the bits 4-7 from each column of the frame buffer are provided through the registers SHR4-SHR7 as the four least significant bits of the address word to be provided to the VLTs. In this higher resolution mode, the four upper bits of the pixel data are equal to 0 during the first half of the frame period, and the four lower bits are equal to 0 during the second half. If VLT R is loaded in accordance with Table 1 set forth below, the data value provided at the output of the VLT will be determined in accordance with only those four bits from the shift registers SHR which are not cleared. The frame buffer data stored in bits 0-3 corresponds to the pixel values for the raster lines 0-511, while the data stored in the bits 4-7 correspond to the pixel values for the raster lines 512-1023. In this way, the output of VLT R is exactly the same as if the frame buffer would have been organized as a 1024×1024×4 memory.
The A(O) . . . A(F) data provided at the output of VLT R may represent image transformation data (e.g.,
TABLE 1______________________________________Address7 . . . 4 3 . . . 0 Data______________________________________0 0 A(0)0 1 A(1)0 2 A(2). . .. . .. . .0 F A(F)1 0 A(1)2 0 A(2). . .. . .. . .F 0 A(F)______________________________________
gama correction data), or in the simplest case may simply be equal to the VLT location address (proportional output). As a result, the output of the D/A converter connected to VLT R can be used for a B&W monitor with double resolution. Of course, the vertical sync parameters should be mode-dependent as well, and this can be accomplished in a straightforward manner which need not be described in detail here.
No additional hardware is required for communication with the host processor. When the desired resolution is 512×1024, data can be written in complete 8-bit bytes. If the resolution is changed to 1024×1024, a read-modify-write mode can be used in order to write either the upper or lower four bits as desired.
As can be seen from the above description, a value of "0" in the mode register allows the frame buffer to perform as a 512×1024×8 buffer, thus giving a resolution of 512×1024 with 8 bits of depth per pixel. A mode register value of "1" permits the buffer to operate as a 1024×1024×4 buffer for a resolution of 1024×1024 and four bits of "depth" per pixel. The embodiment of FIG. 1 is thus easily implemented without excessive frame buffer storage requirements and without costly additional hardware, while providing a simple and effective technique for alternately operating a different resolutions.
FIG. 2 illustrates a second embodiment of the invention which is useful if there exists a speed limitation which will not permit the use of a read-modify-write mode to separately maintain the upper and lower halves of the frame buffer during 1024×1024 operation. In FIG. 2, the frame buffer address register FBADREG serves the same function as the line counter in FIG. 1, with the first 9 bits (0-8) providing the line address to the frame buffer. The mode signal is provided from a mode register (not shown) as in the embodiment of FIG. 1. In this embodiment, the read signal FBRD is high during a frame buffer read operation, and the write signal FBWR is high during a frame buffer write operation. In addition, transceivers T1, T2 and T3 are provided between the frame buffer data I/O ports and the host data bus, with the direction of data transmission through the transceivers being controlled in accordance with the signal at the direction terminal D. (In some cases where it is unnecessary to change the width of the host data path to the frame buffer from 8 bits to 4 bits, these additional transceivers may be unnecessary.)
For MODE=0 operation for 512×1024 resolution with 8 bits of depth per pixel, the outputs of NAND1 and NAND2 are always high, and the transceiver T3 is disabled through the inverter INV2. During a read operation, the outputs of gates NAND3 and NAND4 are low so that each of transceivers T1 and T2 will pass data in the direction from the frame buffer to the host data bus. For a write operation, the outputs of gates NAND5 and NAND6 are both low, enabling the writing of data into all 8 bits of the frame buffer depth. The outputs of gates NAND3 and NAND4 are high, so that transceivers T1 and T2 pass all 8 bits of data in the direction from the host data bus to the frame buffer. For 1024×1024 resolution with a depth of 4 bits per pixel, the MODE signal is set to a value of "1", thus disabling transceiver T2 and enabling transceiver T3. For a read operation, the signals FBRD and FBWR are high and low, respectively. During the first 512-count cycle of the frame buffer address register bits 0-8, the additional bit will have a value of "0", so that the outputs of NAND1 and NAND2 will be high and low, respectively. As a consequence, the outputs of gates NAND3 and NAND4 will be low and high, respectively. Transceiver T1 will pass the frame buffer bits 0-3 to the host data bus. Transceiver T3 will pass the same bits back to the I/O ports for bits 4-7, but this will be of no consequence since the writing of data into the frame buffer will be disabled. During a second pass through the frame buffer, the additional bit in the frame buffer address register will be high, so that the outputs of gates NAND3 and NAND4 will be high and low, respectively. During this half of the frame period, the frame buffer output bits 4-7 are provided to the host data bus through the transceiver T3. Thus, the bits 0-3 on the host data bus will always represent the pixel data, and the frame buffer will appear to the host processor to operate as a 1024×1024×4 structure.
For a write operation in the high resolution mode, the signals FBRD and FBWR are low and high, respectively, so that the outputs of both of gates NAND3 and NAND4 will be high and the transceivers T1 and T3 will both pass data in the direction from the host data bus to the frame buffer data I/O ports. During a first pass through the 512 lines of the frame buffer, the additional bit in the frame buffer address register will have a low value, so that the outputs of gates NAND1 and NAND2 will be high and low, respectively, and the outputs of gates NAND5 and NAND6 will consequently be low and high, respectively. Thus, the four bits 0-3 of pixel data provided from the host data bus in common through the transceivers T1 and T3 can only be written into the bits 0-3 of the frame buffer. During the second half of the frame period, the additional bit in the frame buffer address register will have a high value, so that the outputs of gates NAND5 and NAND6 will be high and low, respectively, thereby permitting the four bits of data provided from the host data bus to be written only into the bits 4-7 of the frame buffer.
The embodiment of FIG. 2 is similar to that of FIG. 1 in that it is relatively easily implemented and provides an effective technique for operating in either a 512×1024×8 mode or 1024×1024×4 mode, without requiring either an excessive frame buffer storage capacity or complicated hardware for switching between different modes of operation. It should also be noted that the displayable image could be selected between these lower and higher resolution modes, e.g., 1024×800×4. This could be achieved by simply changing sync parameters and through corresponding adjustment of the sequence of the video refresh addresses.
Turning now to FIG. 3, a third embodiment of the invention is illustrated for controlling spatial resolution in either direction. In the example of FIG. 3, the frame buffer structure is 512×512×8 bits, an again the buffer may be the NEC upD 41264 video RAM. As before, the frame buffer output is provided in parallel across 8 shift registers SHR0-SHR7 each having a separately controllable clear terminal CLR. The embodiment of FIG. 3 further includes an 8-bit clear data register CLR, and a combinational shifter SHIFT the shift amount of which is controlled by a 3-bit shift signal SH.
In this embodiment, the mode register MODR is a three-bit register. As before, the line counter LCNT includes 9 bits (0-8) which provide the line count portion of the video refresh address to the frame buffer. The scan generator multiplexer SGMUX provides any one of the bits 8-10 of the pixel counter PCNT to the count input of the line counter LCNT, and the shift multiplexer SHMUX provides an appropriate 3-bit control signal SH to the shifter SHIFT. Both of the muliplexers SGMUX and SHMUX are controlled by the three-bit output from the mode register MODR.
The following Table 2 shows the various resolutions which are available, the data depth at each resolution, the corresponding mode register value and CLR data value.
TABLE 2______________________________________Resolution Data Depth MODR CLRHor Vert bits hex hex______________________________________ 512 512 8 0 FF 512 1024 4 1 0F1024 512 4 2 0F1024 1024 2 3 031024 2048 1 4 012048 1024 1 5 01______________________________________
For 512×512×8 operation, the data in the clear data register CLR is FF (hex), i.e., all zeros. Thus, regardless of the value of the shift signal SH, all outputs of the shifter SHIFT will be 0, and none of the registers SHR0-SHR7 will be cleared. Under control of the line counter, clocked by PCNT<8> byte-wide data will be read out of the frame buffer into the registers SHR0-SHR7 and will be provided from there to the VLTs.
For 512×1024×4 operation, the mode register is set to a value of 1 and the register CLR is set to a value of OF (hex), i.e., 00001111. Each line is read out once due to clocking of the line counter by PCNT<8>, but two passes are made through the lines to simulate 1024 vertical resolution. To read a different four bits during each pass through the 512 lines, the shift control signal SH is controlled by LCNT<9>. For example, when the first 512 lines are being displayed, LCNT<9>=0 so that the shift control signal SH is zero and SHR4-SHR7 are cleared. When the next 512 lines are being displayed, LCNT<9>=1 so that the shift control signal SH is 4 (hex) and SHR0-SHR3 are cleared.
For 1024×512×4 operation, the mode registration is set to a value of 2 (i.e., "010"), and the register CLR is again set to a value of OF (hex). With the mode register MODR having a value of "010", the shift control signal SH will be determined by PCNT<9>. The scan generator multiplexer SGMUX will pass PCNT<9> to the count input of the line counter LCNT so that each line will be read twice in succession during a single pass of the line counter through the 512 lines of the buffer this will simulate a buffer line length of 1024.
For 1024×1024 resolution, the pixel data depth is reduced to two bits, and the mode register MODR is set to a value of 3 (i.e., "011"), with the clear data register CLR being set to a value of 03 (hex), i.e., 00000011. The line counter LCNT is again clocked by PCNT<9> so that a line is read twice in succession for each LCNT output, and the SH signal to the shift register SHIFT will be represented by [LCNT9, PCNT9,, 0]. A timing sequence of the CLR signals and video refresh addresses corresponding to the 1024×1024×2 reorganization of the frame buffer is shown in the following Table 3. The row address is represented by the lower 9 bits of the line counter LCNT, with the column address being internally generated by the frame buffer. As can be seen from Table 3, a first pass through the 512 lines of the frame buffer is made, with each line being read out twice. During the first reading of each line, only SHR0 and SHR1 are used, with the remainder of the registers SHR2-SHR7 being kept cleared. During the second reading of each line, only registers SHR2 and SHR3 are not cleared. Next, a second pass through the 512 lines of the frame buffer is made, with each line again being read out twice. During the first reading of each line, only the registers SHR4 and SHR5 are not cleared, and during the second reading of each line only the registers SHR6 and SHR7 are not cleared. Thus, with two readings of each line, and two passes through the 512 lines, the 512×512×8 frame buffer is effectively operated as a 1024×1024×2 structure.
For 1024×2048×1 operation, the mode register MODR is set to a value of "100" with the clear data register CLR set to a value of 00000001. In this mode, each line is read twice to simulate a horizontal resolution of 1024, and four passes are made through the 512 lines of the frame buffer to simulate a vertical resolution of 2048. The shift signal SH is controlled by LCNT<10>, LCNT<9> and PCNT<9>.
Finally, for 2048×1024×1 operation, the mode register MODR is set to a value of "101" with the clear data register CLR having a value of 00000001. During a first pass through the 512 lines of the frame buffer, each line is read four times, passing a single different bit each of those four times. During a second pass through the 512 lines of the frame buffer, each line is again read four times, each time passing a single one of the remaining four bits of the buffer depth. This effectively goes through the 512 line of memory twice to simulate a vertical resolution of 1024, while reading each line four separate times to simulate a horizontal resolution of 2048.
As can be seen from the above description, the present invention provides a frame buffer architecture that can be used with a wide variety of monitors with different resolutions. The solution is most suitable for systems already using a video look-up table (VLT) for conventional purposes, e.g., gamma correction, color transformations, 2.5D graphics, etc. In such cases, the implementation requires very little additional hardware.
TABLE 3__________________________________________________________________________LCNT PCNT<9> SHR's CLR signals Video --refr --add<9 . . . 0> <0> 0 1 2 3 4 5 6 7 RA CA__________________________________________________________________________ 0 0 1 1 0 0 0 0 0 0 0 0 . . . 511 0 1 0 0 1 1 0 0 0 0 0 0 . . . 511 1 0 1 1 0 0 0 0 0 0 1 0 . . . 511 1 1 0 0 1 1 0 0 0 0 1 0 . . . 511 2 0 1 1 0 0 0 0 0 0 2 0 . . . 511 2 1 0 0 1 1 0 0 0 0 2 0 . . . 511. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .511 0 1 1 0 0 0 0 0 0 511 0 . . . 511511 1 0 0 1 1 0 0 0 0 511 0 . . . 511512 0 0 0 0 0 1 1 0 0 0 0 . . . 511512 1 0 0 0 0 0 0 1 1 0 0 . . . 511513 0 0 0 0 0 1 1 0 0 1 0 . . . 511513 1 0 0 0 0 0 0 1 1 1 0. . . 511. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .1023 0 0 0 0 0 1 1 0 0 511 0 . . . 5111023 1 0 0 0 0 0 0 1 1 511 0 . . . 511__________________________________________________________________________
It should be noted that the embodiments disclosed above are by way of example only, and that various changes and modifications can be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims. | A display controller provides multiple different resolutions by selectively enabling different combinations of shift registers between the frame buffer and video look-up tables (VLTs). The VLTs are partitioned, with different partitions being programmed identically in accordance with the values of only the number of address bits which will be active from the shift registers at any one time. | 6 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to corner beads for drywall construction and in particular to corner beads that are affixed directly to drywall framework and projected outwardly to match drywall thicknesses before the drywall is attached to the drywall framework.
[0002] Conventional drywall beads at corners and edges of drywall are formed after drywall has been attached to drywall framework. This has required a further finishing function that is expensive in addition to its being delayed until after official approval of insulation behind the drywall framework, which increases total construction time and costs.
[0003] There are numerous known devices and methods for forming drywall-corner beads. None, however, provide a bead wall having a corner-bead base that is affixed directly to drywall framework for extending the bead wall outwardly to where outside surfaces of the drywall will be when the drywall is added later after the corner-bead base has been affixed securely to drywall framework in a manner taught by this invention.
[0004] Examples of most-closely related known but different devices without a corner bead having a corner-bead base affixed directly to drywall framework and other features of this invention are described in the following patent documents:
U.S. Patent No. Inventor Issue Date 5,544,463 Bergin Aug. 13, 1996 6,148,573 Smythe, Jr. Nov. 21, 2000 6,212,836 Larson Apr. 10, 2001 6,189,273 Larson Feb. 20, 2001 5,752,353 Koenig, et al. May 19, 1998 6,223,486 Dunham May 01, 2001 5,131,198 Ritchie, et al. Jul. 21, 1992 5,613,335 Rennich, et al. Mar. 25, 1997 6,295,776 Kunz, et al. Oct. 02, 2001 1,634,862 Yoder Jul. 05, 1927 6,352,382 Hatlan, et al. Mar. 05, 2002
SUMMARY OF THE INVENTION
[0005] Objects of patentable novelty and utility taught by this invention are to provide a drywall-frame-affixable corner bead and method which:
[0006] provides a strong corner bead for drywall construction;
[0007] is adaptable to a plurality of known classes of drywall corners including without limitation, bullnose-shaped corners;
[0008] can be affixed directly to drywall framework before the drywall is applied to decrease construction time waiting for inspection approval of drywall framework and wall insulation prior to attachment of drywall to the drywall framework;
[0009] avoids need for finishing or optionally can be finished easily with painting or other covering;
[0010] can be protected with an adhered covering prior to use; and
[0011] prevents unevenness and joint lines at drywall corners.
[0012] This invention accomplishes these and other objectives with a drywall-frame-affixable corner bead having a corner-bead wall with a corner-bead base that is affixed directly to drywall framework. Positional framework extends the corner-bead wall outwardly to where outside surfaces of the drywall will be when the drywall is added later after the corner-bead base has been affixed securely to drywall framework. The corner-bead wall can be shaped arcuately or otherwise as desired.
[0013] The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0014] This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are explained briefly as follows:
[0015] [0015]FIG. 1 is a partially cutaway top view of the drywall-frame-affixable corner bead having a single corner-bead wall affixed to drywall framework behind ninety-degree corner walls and having bendable surfacing material adhered to a face of the corner-bead wall and to orthogonal edges of corner sheets of drywall;
[0016] [0016]FIG. 2 is an enlarged top view of the drywall-frame-affixable corner bead separately and having the bendable surfacing material, which can include paper, cloth-like or plastic sheeting, bent outwardly from adhered attachment to either a curved surface of the corner-bead wall or to positional framework to which the corner-bead wall is connected;
[0017] [0017]FIG. 3 is an enlarged top view of the FIG. 1 embodiment showing detail of affixment of the drywall-frame-affixable corner bead to the drywall framework behind drywall that is attached to the drywall framework and having the bendable surfacing material adhered to the curved face of the corner-bead wall and to the drywall adjacent to the corner-bead wall;
[0018] [0018]FIG. 4 is the FIG. 2 illustration showing detail of adherence of the bendable surfacing material to the positional framework of the corner-bead wall and showing fasteners for fastening a corner-bead base to the drywall framework;
[0019] [0019]FIG. 5 is the FIG. 4 illustration with the bendable surfacing material adhered to the corner-bead wall that is shown with dashed lines;
[0020] [0020]FIG. 6 is a side view of the drywall-frame-affixable corner bead as seen from a top side of the FIG. 4 illustration to show a convenient plurality of fastener orifices and a fastener in one of them for affixing the corner-bead wall to drywall framework;
[0021] [0021]FIG. 7 is a bottom view of the drywall-frame-affixable corner bead as seen from a bottom side of the FIG. 4 illustration to show the plurality of fastener orifices and showing the bendable surfacing material on the positional framework;
[0022] [0022]FIG. 8 is the bottom view of the drywall-frame-affixable corner bead as seen from the bottom side of the FIG. 4 illustration;
[0023] [0023]FIG. 9 is a partially cutaway front view of the drywall-frame-affixable corner bead and a domed-bead joint having three corner-bead walls attached to a top corner of three drywall surfaces;
[0024] [0024]FIG. 10 is a partially cutaway top view of the domed-bead joint having three corner-bead walls for attachment to a top corner of the three drywall surfaces;
[0025] [0025]FIG. 11 is a fragmentary end view of an arcuate corner-bead wall in relationship to the positional framework and base walls;
[0026] [0026]FIG. 12 is a fragmentary end view of a straight corner-bead wall in relationship to the positional framework and base walls;
[0027] [0027]FIG. 13 is a fragmentary end view of an angled corner-bead wall in relationship to the positional framework and base walls;
[0028] [0028]FIG. 14 is a partially cutaway side view of the drywall-frame-affixable corner bead affixed over drywall and having the surfacing material adhered to the drywall;
[0029] [0029]FIG. 15 is a partially cutaway side view of the drywall-frame-affixable corner bead and the domed bead joint in position for being assembled to be affixed over three surfaces of the drywall;
[0030] [0030]FIG. 16 is a top end view of the corner-bead wall positioned at an orthogonal corner of drywall sheets by the positional framework which is attached to drywall framework with an attachment base having a locator base wall;
[0031] [0031]FIG. 17 is a top end view of the corner-bead wall positioned on a wall edge or protrusion such as sides of an archway;
[0032] [0032]FIG. 18 is the FIG. 17 illustration with addition of an under-surface material; and
[0033] [0033]FIG. 19 a top end view of a corner of drywall sheets covered by the corner-bead wall at a side of a window.
DESCRIPTION OF PREFERRED EMBODIMENT
[0034] Listed numerically below with reference to the drawings are terms used to describe features of this invention. These terms and numbers assigned to them designate the same features throughout this description.
1. Corner-bead wall 2. Outside surfaces 3. Drywall 4. Drywall framework 5. First base wall 6. Second base wall 7. First bead edge 8. Second bead edge 9. First framework extension 10. Second framework extension 11. Filler support 12. Connector lip 13. Covering 14. Covering extension 15. Fastener aperture 16. Fastener 17. Domed bead joint 18. Joint ends 19. First bead wall 20. Second bead wall 21. Third bead wall 22. First edge plate 23. Second edge plate 24. Third edge plate 25. First corner-base wall 26. Second corner-base wall 27. Third corner-base wall 28. First edge wall 29. Second edge wall 30. Third edge wall 31. Corner slants 32. Convex arc 33. Plain surface 34. Angled corner 35. Attachment base wall 36. Locator base wall 37. Bead flat 38. Rigid support 39. Bead flat 40. Wall edge 41. Wall-edge extension 42. Window structure 43. Undersurface material
[0035] Referring to FIGS. 1 - 3 , a drywall-affixable corner bead has at least one corner-bead wall 1 with shape and size for being extended intermediate edges of outside surfaces 2 of drywall 3 and related structure that is attachable to drywall framework 4 . The drywall framework 4 can be metallic, wooden, plastic, other material or combinations thereof that may be devised and provided from-time-to-time for construction of inside walls for buildings.
[0036] At least one corner-bead base is affixable directly to the drywall framework 4 . The corner-bead base has one or more base walls that can include a first base wall 5 and a second base wall 6 . The corner-bead wall 1 can include a first bead edge 7 and a second bead edge 8 .
[0037] Positional framework is extended predeterminedly intermediate the corner-bead base and the corner-bead wall 1 . The positional framework for a large portion of applications can include a first framework extension 9 and a second framework extension 10 . The first framework extension 9 is extended intermediate the first base wall 5 and the first bead edge 7 . The second framework extension 10 is extended intermediate the second base wall 6 and the second bead edge 8 .
[0038] Optionally, the positional framework can include a filler support 11 that can be flexible in combination with or in lieu of the first framework extension 9 and the second framework extension 10 as shown in FIG. 5.
[0039] The corner-bead wall 1 can include a convex arc 32 as shown in FIG. 11, a plane surface 33 as shown in FIG. 12 or an angled corner 34 as shown in FIG. 13. Either can include a connector lip 12 as a bead-alignment member as shown in FIGS. 10 - 13 and 15 .
[0040] The corner-bead wall 1 can be predeterminedly finished with coloring, covering or texture or a combination thereof that does not require further treatment or coloring. Optionally, the corner-bead wall 1 can be textured to receive coloring that includes painting.
[0041] As shown in FIGS. 1 - 5 and 7 , the corner-bead wall 1 can be predeterminedly covered with covering 13 intermediate the first bead edge 7 and the second bead edge 8 . The covering 13 can include covering extensions 14 having covering adhesive on drywall sides of the covering extension 14 . The covering extensions 14 can be adherent or can be made adherent to outside surfaces 2 of the drywall 3 . Prior to being adhered to the outside surfaces 2 of the drywall 3 , the covering extension 14 can be positioned against either the first framework extension 9 and the second framework extension 10 , against the outside surface of the corner-bead wall 1 or not against either. FIG. 2 shows the covering extensions 14 without being fixed against either the corner-bead wall 1 and the first bead edge 7 and the second bead edge 8 , or after being removed therefrom to be adhered to the outside surfaces 2 of the drywall 3 .
[0042] As shown in FIGS. 6 - 8 , the first base wall 5 and the second base wall 6 can include a plurality of fastener apertures 15 into which fasteners 16 can be inserted conveniently for affixing the corner-bead wall 1 directly to the drywall framework 4 .
[0043] Referring to FIGS. 9 - 10 , the at least one corner-bead wall 1 can include a domed bead joint 17 having a plurality of three corner-bead walls 1 . The three corner-bead walls 1 each include the first bead edge 7 and the second bead edge 8 . The three corner-bead walls 1 have joint ends 18 which are affixed to the domed bead joint 17 from which a first bead wall 19 , a second bead wall 20 and a third bead wall 21 comprising the three corner-bead walls 1 are extended. The first bead edge 7 of the first bead wall 19 is orthogonal to the second bead edge 8 of the second bead wall 20 . The first bead edge 7 of the second bead wall 20 is orthogonal to the second bead edge 8 of the third bead wall 21 . The first bead edge 7 of the third bead wall 21 is orthogonal to the second bead edge 8 of the first bead wall 19 .
[0044] As shown most clearly in FIG. 10, a first edge plate 22 is extended intermediate the first bead edge 7 of the first bead wall 19 and the second bead edge 8 of the second bead wall 20 . A second edge plate 23 is extended intermediate the first bead edge 7 of the second bead wall 20 and the second bead edge 8 of the third bead wall 21 . A third edge plate 24 is extended intermediate the first bead edge 7 of the third bead wall 21 and the second bead edge 8 of the first bead wall 19 .
[0045] Also shown most clearly in FIG. 10, the corner-bead base includes a first corner-base wall 25 , a second corner-base wall 26 and a third corner-base wall 27 that are affixable directly to the drywall framework 4 . The positional framework for the domed bead joint 17 includes a first edge wall 28 extended from the first edge plate 22 to the first corner-base wall 25 , a second edge wall 29 extended from the second edge plate 23 to the second corner-base wall 26 and a third edge wall 30 extended from the third edge plate 24 to the third corner-base wall 27 .
[0046] The drywall-frame-affixable corner bead having a single corner-bead wall 1 is affixed to two-wall corners of drywall 3 as shown separately in FIG. 14 or below the drywall-frame-affixable corner bead having the three corner bead walls 19 - 21 extending from the domed bead joint 17 as shown in FIG. 15. For affixing the three corner bead walls 19 - 21 extending from the domed bead joint 17 , corner slants 31 on the drywall 3 are shaped to match wall slants of the first edge wall 28 , the second edge wall 29 and the third edge wall 30 .
[0047] Referring to FIG. 16, the plurality of base walls of the corner-bead base 1 can include an attachment base wall 35 and a locator base wall 36 . The locator base wall 36 is extended at a predetermined angle from a base end of the attachment base wall 35 . The first framework extension 9 and the second framework extension 10 can be attached directly to the attachment base wall 35 proximate the locator base wall 36 .
[0048] Referring to FIGS. 17 - 19 , the positional framework can include a rigid support 38 that is extended intermediate the corner-bead base and an inside surface of the corner-bead wall 1 . The rigid support 38 can be attached to the drywall framework 4 with the fasteners 16 .
[0049] Embodiments with the rigid support 38 are intended primarily for irregular corners that are characteristic of windows, archways and doors.
[0050] As shown in FIG. 17, the corner-bead wall 1 can include a bead flat 39 having oppositely disposed sides extended from the rigid support 38 . The rigid support 38 is extended at a predetermined angle from an attachment side of the bead flat 39 predeterminedly intermediate the oppositely disposed sides. The covering extension 14 can be extended from at least one side of the bead flat 39 for covering a wall edge 40 at an archway or similar structure.
[0051] As shown in FIG. 18, the corner-bead wall 1 can include a wall-edge extension 41 that is extended over subsurface material 43 predeterminedly intermediate a first rigid support 38 that is attachable to a first side of a wall edge 40 and a second rigid support 38 that is attachable to a second side of the wall edge 40 .
[0052] Referring to FIG. 19, the bead flat 39 attached to the rigid support 38 can be positioned on the drywall 3 at an edge of window structure 42 .
[0053] A method is provided with steps for using a drywall-frame-fixable corner bead with at least one corner-bead wall having shape and size for being extended intermediate edge positions of outside surfaces of corners of drywall that is attachable to drywall framework; at least one corner-bead base that is affixable directly to the drywall framework; positional framework with extensions extended predeterminedly intermediate the corner-bead base and the corner-bead wall; and the positional framework having shape and size for positioning the corner-bead wall proximate the edge positions of the outside surfaces of the corners of the drywall predeterminedly.
[0054] The steps comprise:
[0055] affixing the corner-bead base 5 , 6 directly to corners of the drywall framework 4 of a building under construction; and
[0056] attaching wall-corner edges of drywall 3 to the drywall framework 4 with the wall-corner edges of the drywall 3 being over the positional framework 9 , 10 and the corner-bead base 5 , 6 being intermediate the drywall 3 and the drywall framework 4 .
[0057] The use method can relate to the drywall-frame-affixable corner bead wherein the bead corner includes a three-sided drywall corner and the drywall-frame-affixable corner bead includes a domed bead joint having a plurality of three corner-bead walls; the three corner-bead walls each include a first bead edge and a second bead edge; the three corner-bead walls have joint ends which are affixed to the domed bead joint from which a first bead wall, a second bead wall and a third bead wall comprising the three corner-bead walls are extended; the first bead edge of the first bead wall is orthogonal to the second bead edge of the second bead wall; the first bead edge of the second bead wall is orthogonal to the second bead edge of the third bead wall; the first bead edge of the third bead wall is orthogonal to the second bead edge of the first bead wall; a first edge plate is extended intermediate the first bead edge of the first bead wall and the second bead edge of the second bead wall; a second edge plate is extended intermediate the first bead edge of the second bead wall and the second bead edge of the third bead wall; a third edge plate is extended intermediate the first bead edge of the third bead wall and the second bead edge of the first bead wall; the corner-bead base includes a first corner-base wall, a second corner-base wall and a third corner-base wall that are affixable directly to the drywall framework; and the positional framework includes a first edge wall extended from the first edge plate to the first corner-base wall, a second edge wall extended from the second edge plate to the second corner-base wall and a third edge wall extended from the third edge plate to the third corner-base wall.
[0058] The steps include:
[0059] affixing the first corner-base wall 25 to the drywall framework 4 ;
[0060] affixing the second corner-base wall 26 to the drywall framework 4 ;
[0061] affixing the third corner-base wall 27 to the drywall framework 4 ;
[0062] shaping a corner slant 31 of a first panel of drywall 3 to match congruently and to fit against the first edge wall 28 of the positional framework;
[0063] attaching the first panel of drywall 3 to the drywall framework 4 with the first corner-base wall 25 being intermediate the first panel of drywall 3 and the drywall framework 4 ;
[0064] shaping the corner slant 31 of a second panel of the drywall 3 to match congruently and to fit against the second edge wall 29 of the positional framework;
[0065] attaching the second panel of the drywall 3 to the drywall framework 4 with the second corner-base wall 26 being intermediate the second panel of the drywall 3 and the drywall framework 4 ;
[0066] shaping the corner slant 31 of a third panel of the drywall 3 to match congruently and to fit against the third edge wall 30 of the positional framework; and
[0067] attaching the third panel of the drywall 3 to the drywall framework 4 with the third corner-base wall 27 being intermediate the third panel of the drywall 3 and the drywall framework.
[0068] A new and useful drywall-frame-affixable corner bead and method having been described, all such foreseeable modifications, adaptations, substitutions of equivalents, mathematical possibilities of combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims and not precluded by prior art are included in this invention. | A drywall-frame-affixable corner bead has a corner-bead wall ( 1 ) with a corner-bead base that is affixed directly to corners of drywall framework ( 4 ) for extending the corner-bead wall outwardly to where outside surfaces of drywall ( 3 ) will be when the drywall is added later after the corner-bead base has been affixed securely to drywall framework. The corner bead can be shaped arcuately or otherwise as desired. Positional framework is extended intermediate the corner-bead wall and the corner-bead base for positioning the corner-bead walls at outside edges of drywall that is attached over the corner-bead base. A domed bead joint ( 17 ) is provided for three-sided bead corners. A use method includes affixing the corner-bead base to the drywall framework prior to attaching the drywall in order to position the corner-bead base intermediate the drywall and the drywall framework. A method for using the domed bead joint for three-sided drywall corners includes shaping corner slants ( 31 ) of the drywall to match edge walls of positional framework of the domed bead joints prior to attaching the three sides of drywall corners. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 08/488,344 filed Jun. 7, 1995 which is a continuation-in-part of PCT application Ser. No. PCT/US94/01577 filed Feb. 9, 1994 which designated the United States as a continuation-in-part of U.S. application Ser. No. 160,544, filed Dec. 1, 1993, now issued on Sep. 26, 1995 as U.S. Pat. No. 5,452,622, which is a continuation-in-part of U.S. application Ser. No. 08/015,332, filed Feb. 9, 1993, now issued on May 3, 1994 as U.S. Pat. No, 5,307,705; this application is also directly a continuation-in-part of U.S. application Ser. No. 160,544, filed Dec. 1, 1993, now issued on Sep. 26, 1995 as U.S. Pat. No. 5,452,622, which is a continuation-in-part of U.S. application Ser. No. 08/015,332, filed Feb. 9, 1993, now issued on May 3, 1994 as U.S. Pat. No., 5,307,705; all of these are incorporated by reference herewithin.
BACKGROUND OF THE INVENTION
This invention relates generally to rotatable apparatuses and specifically to a rotatable apparatus having a pair of rotatable members joined by a stress dissipating structure and a rotatable apparatus having enlarged and decreased rpm driven and pinion gear portions for use with a worm drive and a smaller motor.
The primary function of a gear is to transmit power from a power generating source to an operating device. This is achieved through the intermeshing and continuity of action between the teeth of a driving gear which is associated with the power source and the teeth of the mating gear which is associated with the operating device. Since a gear is a rotating body, a state of dynamic equilibrium must be attained. Therefore, to be in dynamic equilibrium all of the reactions from the rotating gear must be neutralized by equal and opposite forces supporting the gear shaft.
Traditional gear design comprises a central hub, a web extending radially outward therefrom which is, in turn, peripherally bordered by an integral radial rim having geared teeth thereupon. Gear failure can occur if manufacturing tolerances, material type, and gear design are not matched to the service application. Furthermore, since gears have historically been manufactured from a single homogeneous material, the bulk rigidity and strength of the web is generally greater than or equal to that of the hub and rim. Thus, torsional stresses created through start-up, shut-down, overload, or through cyclical fatigue are localized in the teeth and hub areas. As a result, gears typically fail at the root of the teeth or in the hub region. Such failures include excessive wear, plastic flow or creep, tooth bending fatigue, contact fatigue (pitting and spalling), thermal fatigue, tooth bending impact, tooth shear, tooth chipping, case crushing, torsional shear and stress ruptures. Many of these failures are due primarily to overload, cycling fatigue, and/or start-up and shut-down rotational shock referenced above that is especially prevalent in gears that perform in non-constant rotation service applications.
Additionally, most, if not all, motors and gears used in automotive window lift applications tend to be rather large in a transverse direction (i.e., perpendicular to the armature shaft rotational axis) primarily due to the inefficiently constructed conventional driven gear coupled thereto. This largeness in size adds to packaging problems within the doors thereby reducing occupant shoulder room. These motors also add unnecessary weight which adversely affects the vehicle's gas/mileage performance.
An alternative gear design that has been used is a compliant gear having a rigid one-piece hub and web, and a separate rim member with a rubber-like insert or ring located between the outer radial edge of the web and the inner radial edge of the rim. An example of this configuration is disclosed in U.S. Pat. No. 2,307,129 entitled "Shock Proof Gear", issued to Hines et al. on Jan. 5, 1943, which is incorporated by reference herewithin. Although the rubber-like insert of Hines is supposed to dampen audible vibrations and somewhat reduce resultant stresses within the gear, under load the rim is capable of compressing one side of the rubber-like insert such that the rotational axis of the rim could become axially offset from the rotational axis of the hub. This misalignment can cause partial or complete disengagement of the gear teeth of the compliant gear from those of its mating gear. In addition, gears having this type of rubber-like insert strictly between the web and the rim are subject to the rim torquing away from the hub in a transverse direction normal to the direction of rotation. Under load this transverse movement may also cause misalignment of the mating gear teeth which will localize stresses upon distinct portions of each tooth. Moreover, the hub and rim may not provide an adequate attachment, and thus force transfer, surface for the rubber-like insert in extreme torque situations. A similar design using elastomeric laminates with a shim therebetween is disclosed in U.S. Pat. No. 4,674,351 entitled "Compliant Gear", issued to Byrd on Jun. 23, 1987.
Another compliant rotating member configuration is disclosed in FIG. 8 of U.S. Pat. No. 3,216,267 entitled "Rotary Motion Transmitting Mechanism For Internal Combustion Engines And The Like", issued to Dolza on Nov. 9, 1965. The Dolza sprocket/gear design contains a stamped cup-shaped hub which has an outward radially extending flange and a cushioning member fully attached to the side thereof. The rim of the sprocket/gear has a generally L-shaped cross section with the radial inward leg being fully attached to the opposite side of the cushioning member. In that design there are gaps between the outer circumference of the cushioning member and the inside radial surface of the rim and also a gap between the radially inward surface of the cushioning member and the radially outward horizontal edge of the cup-shaped hub section. While the sprocket/gear is designed to maintain angular torsional rigidity while having radial flexibility, under load the rim of the sprocket/gear may become elliptical and thus encroach upon the gaps created above and below the cushioning member. Moreover, the rotational axis of the rim may also become offset from the rotational axis of the hub under working conditions.
It is also known to provide a sunroof motor with a conventional gear having a unitary polymeric rim, offset web and hub. This gear further has a receptacle and an inner set of rim channels for receiving a metallic cup in an interlocking fashion. A Belleville washer frictionally rides against an outer surface of the metal cup and is interlocked to a pinion shaft. The gear is also journalled freely about the shaft. The amount of frictional force exerted by the Belleville washer against the cup is controlled by the amount of torque supplied to a pinion shaft engaging nut; thus, the Belleville washer acts as a clutch mechanism. However, this traditional sunroof motor is not provided with a rotational stress dissipating structure beyond the coaxial Belleville washer. This sunroof motor and gear system also suffers from being large in transverse size and heavy in weight.
Furthermore, many conventional clutches employ rotation dampening devices and spring biasing devices. For instance, reference should be made to the following U.S. Pat. No.: 5,333,713 entitled "Friction Clutch" which issued to Hagnere et al. on Aug. 2, 1994; U.S. Pat. No. 5,322,141 entitled "Damped Driven Disk Assembly" which issued to Szadkowski on Jun. 21, 1994; U.S. Pat. No. 5,310,025 entitled "Aircraft Brake Vibration Damper" which issued to Anderson on May 10, 1994; U.S. Pat. No. 5,308,282 entitled "Pressure Plate for a Vibration Damper Assembly having Built-In Lash" which issued to Hansen et al. on May 3, 1994; U.S. Pat. No. 5,273,145 entitled "Hydraulic Clutch Control Means, In Particular For A Motor Vehicle" which issued to Corral et al. on Dec. 28, 1993; U.S. Pat. No. 5,186,077 entitled "Torque Variation Absorbing Device" which issued to Nakane on Feb. 16, 1993; U.S. Pat. No. 5,161,660 entitled "Clutch Plate with Plural Dampers" which issued to Huber on Nov. 10, 1992; RE Pat. No. 34,105 entitled "Internal Assisted Clutch" which issued to Flotow et al. on Oct. 20, 1992; and U.S. Pat. No. 4,996,892 entitled "Flywheel Assembly" which issued to Yamamoto on Mar. 5, 1991; all of which are incorporated by reference herewithin. While many of these clutch constructions recognize an unsatisfied need for rotational stress reduction devices therein, and propose various supposed improvements therein, further improvement in performance, cost and assembly would be desirable. For example, the rotationally oriented compression springs utilized in some of these constructions can be easily overcompressed beyond their elasticity limit, thus, leading to poor subsequent performance. By themselves, these compression springs are not well suited for repeated, high load, full compression.
SUMMARY OF THE INVENTION
In accordance with the present invention, the preferred embodiment of a rotatable apparatus includes a pair of rotatable members joined by a stress dissipating structure. The stress dissipating structure can be employed in a gear, sprocket, clutch or the like. In one embodiment of the present invention, antibuckling plates generally spanning between a hub and rim define a hollow cavity. In another embodiment of the present invention, the stress dissipating structure includes specifically configured sets of nodules moving with the hub and rim. An additional aspect of the present invention provides a stress dissipating structure employing various anti-buckling plate attachment constructions. In still another embodiment of the present invention, a uniquely sized and packaged gear, gear housing and/or motor are employed in order to maximize output force per pound of material efficiencies. An additional advantage of the present invention over conventional systems is that the present invention allows for a worm drive system coupled to a pinion gear to be vastly improved regarding weight and size and, hence, power density (i.e., pounds torque achieved per pound of material utilized). This is realized by recognizing that torque is directly proportional to force times distance and to horsepower divided by speed. Thus, by using a reduced size motor with worm gear attached to power a ring or driven gear with an integrally attached pinion, power density efficiencies greater than 50% over conventional systems are achievable.
The configurations of the apparatus of the present invention are advantageous over conventional systems in that the present invention allows the stress dissipating structure to absorb structural stresses between the hub and the rim due to instantaneous shocks created by apparatus rotational start-up or shut-down, cyclical fatigue, and/or overload. Furthermore, the stress dissipating resilient structure, especially when coupled with anti-buckling plates, provides significant lateral planar rigidity thereby resisting angular torsional deformation in a direction normal to the rotational axis between the rim and the hub while also discouraging rotational axis misalignment between the rim and the hub (i.e., the center to center distances between driven and drive gears are always maintained). By matching the bulk torsional rigidity and allowed torsional deformations of the stress dissipating structure, which can be a function of its modulus of elasticity, its dimensional thickness, or the specific formations chosen, to that of the output coupling performance proportions, the beneficial characteristics of a conventional single piece homogenous gear, sprocket and clutch are maintained while the resilient structure acts to synergistically dissipate stresses between the rim and the hub.
The apparatus of the present invention is also much thinner in a transverse (or crosscar) direction than conventional apparatuses thereby providing packaging benefits. Furthermore, the present invention is significantly lighter in weight than conventional systems while still increasing the output force per pound of material efficiencies. Additional objects, advantages, and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side elevational view showing the preferred embodiment of a stress dissipation apparatus of the present invention employed in an automotive vehicle window lift mechanism;
FIG. 2 is a partially exploded perspective view showing the preferred embodiment of the present invention stress dissipation apparatus;
FIG. 3 is a side elevational view showing the preferred embodiment of the present invention stress dissipation apparatus, with portions broken away therefrom;
FIG. 4 is a cross sectional view, taken along line 4--4 of FIG. 3, showing the preferred embodiment of the present invention stress dissipation apparatus;
FIG. 5 is an enlarged sectional view, taken within circle 5--5 of FIG. 4, showing snap-fit attachments employed with the preferred embodiment of the present invention stress dissipation apparatus;
FIG. 6 is an enlarged sectional view, taken within circle 6--6 of FIG. 4, showing another snap-fit attachment employed with the preferred embodiment of the present invention stress dissipation apparatus;
FIG. 7 is a diagrammatic side elevational view showing the relationship of nodules within the preferred embodiment stress dissipation apparatus of the present invention; and
FIGS. 7a and 7b are fragmentary cross-sectional views, taken along lines 7a--7a and 7b--7b, respectively, showing the relationship of the nodules to the anti-buckling plates;
FIG. 8 is a diagrammatic view showing an alternate embodiment apparatus of the present invention; and
FIG. 8a is a cross-sectional view, taken along line 8a--8a taken from FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of a stress dissipation apparatus of the present invention can be employed in combination with an automotive vehicle door 9 window lift regulator or mechanism 11 as is shown in FIG. 1. In this window lift application, the stress dissipation apparatus includes a fractional horsepower dc electric motor 13 which drives a driven gear 15 coupled to a scissor arm linkage. The scissor arm linkage raises and lowers a window 17 coupled thereto. The stress dissipation apparatus of the present invention can also be employed with other types of automotive window lift mechanisms such as, for example, that disclosed within the following U.S. Pat. No.: 5,351,443 entitled "Automotive Door with Window Pane lifter Module" which issued to Kimura et al. on Oct. 4, 1994; U.S. Pat. No. 5,255,470 entitled "Vehicle Door Glass Regulator" which issued to Dupuy on Oct. 26, 1993; U.S. Pat. No. 5,226,259 entitled "Automotive Door with Power Window" which issued to Yamagata et al. on Jul. 13, 1993; U.S. Pat. No. 4,222,202 entitled "Automotive Tape Drive Window Regulator" which issued to Pigeon on Sep. 16, 1980; and U.S. Pat. No. 3,930,339 entitled "Window Regulator, Especially for Automobiles, with a Threaded Cable Moving in a Guide" which issued to Jander on Jan. 6, 1976; all of which are incorporated by reference herewithin.
Now referring to FIGS. 2 and 3, electric motor 13 includes an armature or motor housing 31, an armature 33, an armature shaft 35, permanent fixed magnets 37, a commutator 39 and a brush card assembly 41. Armature 33 includes copper wire windings 43 wrapped inside of a plurality of armature pack slots which are juxtaposed between a plurality of magnetically conductive armature teeth 45. A helically wound worm gear portion 47 is located upon armature shaft 35. Worm gear portion 47 is juxtaposed within a worm housing portion 49 of a driven gear housing 61. Armature housing 31 has a longitudinal dimension "D L " and transverse dimensions "D T ." When electric motor 13 is installed in door 9 (see FIG. 1), the crosscar transverse dimension of motor 13, the lateral direction of driven gear housing 61 and the lateral direction of driven gear 15, are all taken in a direction that is perpendicular to the plane of the side views shown in FIGS. 1 and 3.
While electric motor 13 may have a variety of configurations and components, the electric motor illustrated as part of the present invention stress dissipation apparatus has similar characteristics to that disclosed in U.S. Pat. No. 5,440,186 entitled "Motor with Isolated Brush Card Assembly" which issued to Forsell et al. on Aug. 8, 1995, and is also incorporated by reference herewithin. However, as will be further discussed hereinafter, the electric motors of the present invention and of U.S. Pat. No. 5,440,186 have significantly differing sizes and weights due to the driven stress dissipating gear 15 and driven gear housing constructions of the present invention.
Referring to FIGS. 3 and 4, driven stress dissipation gear 15 includes a hub 71, a first annular antibuckling plate 73, a second annular antibuckling plate 75, a rim 77 and a rotational stress dissipation device 79. All of these driven gear elements rotatably surround a driven gear rotational axis 81. First antibuckling plate 73 is integrally molded as part of a laterally offset wall of hub 71 while second antibuckling plate 75 is integrally molded as part of a section of rim 77. An auxiliary hub 91 is integrally formed from an end of second antibuckling plate 75 opposite that of an edge adjoining rim 77. Lateral edges of auxiliary hub 91 are provided with rounded corners to minimize surface area contact against the adjacent first antibuckling plate 73 and driven gear housing 61. A radially projecting annular foot 93 inwardly depends from a median portion of an auxiliary hub internal surface 95. A curved edge 97 of foot 93, curved edge 99 of auxiliary hub 91, and a curved end 101 of a finger 103 laterally project from rim 77 and act as bearing surfaces against driven gear housing 61. An inner surface 111 of hub 71 also has a pair of curved fingers 113 which act as bearing surfaces against driven gear housing 61.
A generally cylindrical leg 131 inwardly extends, in a lateral direction, from an inside face 132, of first antibuckling plate 73. A pointed barb 135, outwardly extending from a distal end of leg 131, engages a V-shaped receptacle 135 disposed in auxiliary hub 91. Barb 133 and receptacle 135 achieve a snap-fit attachment between antibuckling plates 73 and 75. This can best be observed by reference to FIG. 6.
Returning to FIG. 4, an outer edge 141 of first antibuckling plate 73 is placed in snap-fit engagement within a V-shaped receptacle 143 of rim 77. Thus, first antibuckling plate 73 is prevented from laterally moving relative to rim 77 while first antibuckling plate 73 can be rotated somewhat independently of rim 77.
As can be observed in FIGS. 2 and 3, rim 77 has a set of geared teeth 145 outwardly projecting therefrom for engagement with worm gear portion 47 of motor 13. Additionally, as is shown in FIGS. 2 through 5, a steel pinion gear 147, having outwardly extending spur gear teeth 149, is pressfit or otherwise affixed upon an outer surface 151 of hub 71. A knurled pattern may be provided upon an interior surface of pinion gear 147 to ensure proper frictional engagement with hub 71. Pinion gear 147 may also be attached to hub 71 through sonic welding, remelting of the hub through pinion gear heating or the like. Hub 71, first antibuckling plate 73, second antibuckling plate 75 and rim 77 are all preferably injection molded from an engineering grade thermoplastic material such as polyacetyl, a modified PBT, or a modified polyamide.
FIGS. 2, 4 and 5 illustrate driven gear housing 61 as being an injection molded engineering grade material (or alternately, suitable die cast metals such as zinc, aluminum or magnesium) with a cup-shaped cross section defined by a generally cylindrical interior wall 171, a generally cylindrical exterior wall 173 and a generally annular bottom wall 175. An inner surface of interior wall 171 defines a substantially cylindrical opening 181. As can be observed in FIG. 4, cylindrical opening 181 has a diameter "D O " relatively larger than a radial distance "D G " of one side of the gear (i.e., the difference between the radii of the rim and the hub). Therefore, even though the present invention gear has a much larger outer diameter as compared to conventional gears, the enlarged cylindrical opening 181, coupled with a slightly thinner lateral dimension in combination with a proportionally reduced motor size, result in overall weight reduction as compared to conventional gears and drives.
Returning again to FIGS. 2, 4 and 5, an injection molded polymeric cover plate 201, having an annular configuration, is screwed onto flanges (not shown) with bosses extending from exterior wall 173 of driven gear housing 61. A flexible moisture seal, such as a nylon or teflon O-ring may be employed between an inner edge of cover plate 201 and the adjacent antibuckling plate 73. An injection molded polymeric retaining plate 203 is attached to interior wall 171 of driven gear housing 61 through a pointed snap-fit barb 205 disposed along a side leg mating with a V-shaped receptacle 207. Along an adjoining perpendicular top leg of retaining plate 203, there is a laterally oriented and pointed snap-fit barb 209 which slidably engages into a V-shaped receptacle 211 of a distal edge of hub 71. A sealing O-ring or the like may be provided between retaining plate and driven gear housing 61 or between retaining plate 203 and hub 71.
Within the gear, a hollow and substantially annular cavity 221 is bordered by first antibuckling plate 73, auxiliary hub 91 of second antibuckling plate 75, foot 93 of second antibuckling plate 75 and interior wall 171 of driven gear housing 61. Other hollow and annular cavities 223 and 225 are also provided between portions of second antibuckling plate 75 and driven gear housing 61. All of these cavities further contribute to the weight reduction achieved by the present invention system while also allowing for their bordering plate segments to act as a strong box-like structure.
Rotational stress dissipation device 79 is best illustrated in FIGS. 4 and 7. A first set of nodules 301 radially extends outward from an inner member defined as either a modified form of the hub or the first antibuckling plate. A second set of nodules 303 radially extends inward from an outer member defined as the rim or the second antibuckling plate. Each first nodule 301 has a proximal end 305 with a relatively constricted rotational direction dimension as compared to an expanded rotational direction dimension disposed at a distal end 307. Tapered surfaces 309 and 311 extend between the proximal and distal ends.
Second nodules 303 have a distal end 321 with a relatively constricted rotational direction dimension as compared to an expanded rotational direction dimension disposed at a proximal end 323. Tapered surfaces 325 and 327 extend between the proximal and distal ends. An elastomeric material 341 such as Santoprene® 55 acts as a resilient member disposed between the first and second sets of nodules 301 and 303, respectively, for reducing differential rotational movements between the hub and rim. Elastomeric material 341 can be injection molded or, alternately, reaction injection molded in-place with the hub 71 and rim 77 preassembled or elastomeric material 341 can be separately molded and then manually inserted between the hub 71 and rim 77. While the resilient member is preferably shown as being elastomeric material, it may alternately comprise springs, flexible spokes or the like. The design structure employed with the present invention allows for utilization of increased diameter driven and pinion gears in combination with smaller electric motors. This results in overall reduced weight and provides for improved dynamics with worm gear, driven gear and pinion gear speeds being drastically reduced. These reduced gear speeds provide for, in addition to other things, reduced wear, quietness and shock loads.
The amount of taper of each of the nodules 301 and 303 and the amount of elastomeric material ("E") disposed between each pair of adjacent nodules 301 and 303 can be generally characterized by the following formula: ##EQU1## where E 2 is a rotational direction dimension between the proximal end of one of the second set of nodules and the distal end of an adjacent one of the first set of nodules;
E 1 is a rotational direction dimension between the distal end of the one of the second set of nodules and the proximal end of the adjacent one of the first set of nodules;
D 2 is a diameter of the rim teeth 145; and
D 1 is a diameter of the hub teeth 149;
whereby generally uniform strain is imparted upon the elastomeric material 79 during deformation due to differing rotational movement between the rim 77 and the hub 71.
An alternate embodiment enlarged diameter driven gear can also be employed in combination with the reduced size motor. In this embodiment a single web spans between an integrally formed hub and web. Thus, the hub, web and rim all rotate the same amount as a solid gear. Due to the enlarged driven and pinion gear diameters, a stress dissipating structure may not be required since the gears will rotate at significantly slower speeds and thus be less susceptible to shocks and stress. Since the cylindrical opening within the driven gear housing is of a large size, overall part weight is minimized. The driven and pinion gears can be die cast from a metallic material or can be injection molded from a reinforced nylon or reinforced polyester polymeric material.
The following Table 1 sets forth the theoretical values and sizes of a selected present invention system as compared to an existing conventional automotive window lift system. It is significant to note that the total system weight reduction is 300 grams (approximately 30% less than conventional systems) while the overall system output torque is maintained. Thus, very significant efficiencies in power density are achieved (i.e., 61 inch-pounds per pound for traditional systems versus 91 inch-pounds per pound for one version of the present invention; this amounts to greater than 50% improvement) while the lateral size and system weight are reduced. Furthermore, due to the smaller motor size (e.g., requiring less copper wire windings, smaller permanent magnets and the like) very significant cost savings are also achieved.
TABLE 1______________________________________ CONVENTIONAL PRESENT INVENTION SYSTEM SYSTEM______________________________________Electric Motor Weight = 525 grams* Weight = 200 grams*and Armature Armature housing length = Armature housing size =Housing 23/4 inches (D.sub.L) × 2 11/2 inches (D.sub.L) × 11/2 inches (D.sub.T) inches (D.sub.T) Worm RPM = 6000-8000 Worm RPM = 2400 Motor horsepower = 0.25 Motor horsepower = 0.041Worm Gear Driven gear housing Driven gear diameter =Portion and diameter = 2.5 inches 4.8 inchesWorm Housing Weight = 275 grams Weight = 325 gramsand Driven GearHousingDriven Gear Diameter = 2.4 inches Diameter = 4.9 inches Weight = 95 grams Weight = 45 gramsPinion Gear Diameter = 9/16 inch Diameter = 4 inches Weight = 30 grams Weight = 55 gramsSystem Torque 125 inch-pounds 125 inch-poundsTotal Weight 925 grams 625 grams______________________________________
The following formulas, Table 2, and discussion thereafter, are designed to allow one skilled in the art to utilize the present invention in systems having various sized driven gears, pinion gears and output torques:
Horsepower=[(Torque)(RPM)]/Constant
Horsepower=[(Torque)(RPM)]/63025, where torque is measured in inches-pounds.
Torque=(Distance)(Force).
TABLE 2__________________________________________________________________________EXEMPLARYGEAR NO. 1 2 3 4 5 6__________________________________________________________________________WEIGHT (GRAMS) 925 775 725 750 625 575WINDOW SPEED* 20 20 20 20 20 20(FEET/MINUTE)PINION GEAR** RPM 125 625 62.5 27.7 20.8 13.3PINION GEAR** 9 18 18 32 54 72NO. OF TEETHDRIVEN GEAR - RPM 125 62.5 62.5 27.7 20.8 13.3DRIVEN GEAR 2.4 2.4 2.4 3.6 4.8 6.0DIAMETER (INCHES)DRIVEN GEAR -- 0 0 50 100 150DIAMETER %INCREASEWORM GEAR - RPM 7200 3650 3600 2400 2400 1920MOTOR 0.248 0.124 0.124 0.055 0.041 0.026HORSEPOWERPINION GEAR 125 125 125 125 125 125TORQUE(INCHES-POUNDS)__________________________________________________________________________ Gear No. 1 A conventional arrangement as listed in Table 1. Gear No. 2 A solid hub, web, and rim arrangement (as shown in FIG. 8) with the pinion gear size increased and the motor horsepower reduced. Gear No. 5 The present invention as listed in Table 1 and shown in FIGS. 2-4. Gear Nos. 3, 4, 5, 6 The present invention with a gear having a hollow hub with annular spacing as shown in FIGS. 2-4. *Approximate Speed **Note all gear teeth have identical size and shape.
The present invention system, which employs the enlarged diameter driven and pinion gears 147 in combination with the reduced size motor 13, is also well suited for automotive vehicle powered moving panels such as door windows, sunroof windows, sliding minivan doors or the like. These powered moving panels must meet FMVSS 118 which mandates that the motor must stall at twenty-two pounds of force in order to prevent occupant finger pinching. Therefore, as can be observed in FIG. 8, an electrical current sensor 401 is electrically connected to commutator 39 of motor 13 by way of brushes for sensing if a sudden current rise is present (excluding initial energization and deenergization current spikes) which indicate that the closure force and motor torque has increased. Thus, the motor can be deenergized and/or reversed. Sensor 401 can be a voltage divider, resistor or the like, which operates in conjunction with a mosfet or microprocessor electrically connected therewith. An enlarged diameter ("D DG ") of driven gear 403 and an enlarged diameter ("D P ") of pinion gear 405, shown in FIG. 8 as having a solidly and integrally formed hub 407, laterally central web 409 and rim 411, allow for slower rotational speeds of the gears 403 and 405 and commutator 39. These slower rotational speeds further provide the ability to more accurately sense motor induced current rises as a relation of time and panel movement distance. Depending upon the specific application, the larger diameter gears 403 and 405 and smaller motor 13 are sized in accordance with the theoretical calculations of Table 1.
Referring to FIGS. 2 and 8, the size relations of the driven gear 403 and motor 13 can be characterized as follows:
D DG <(1.5)(D P ), where "D P " is the diameter of the pinion gear 405. Accordingly, an outer diameter D DG of the driven gear 403 is less than one and one-half times the outer diameter D P of the pinion gear 405 while the relationship between the armature housing volume divided by the outer diameter D DG of the driven gear 403 is less than two inches squared. Although it is preferable to provide a large cylindrical opening 181 (see FIG. 4) within the driven gear housing 61 and hub 71 in order to save weight, it is also envisioned that the presently discussed alternate gears may not necessarily need this opening to realize the size and speed relationships and advantages of the present invention.
While the preferred embodiment of this stress dissipation apparatus has been disclosed, it will be appreciated that various modifications may be made without departing from the present invention. For example, the nodule construction disclosed can be employed with other hub and rim configurations. Furthermore, the pinion gear teeth 149 can be integrally formed upon the hub 71. Also, the hub 71 need not be necessarily offset from the rim 77. A more centralized web may alternately be employed between the hub and rim, instead of outer antibuckling plates, while harnessing the other novel aspects of the present invention. Many other snap-fit means, such as separated cantilevered beams, tongue and groove formations, dovetail formations, rounded barbs or squared barbs can also be provided. Various materials have been disclosed in an exemplary fashion, however, other materials may of course be employed. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention. | A rotatable apparatus includes a pair of rotatable members joined by a stress dissipating structure. The stress dissipating structure can be employed in a gear, sprocket, clutch or the like. In one embodiment of the present invention, antibuckling plates generally spanning between a hub and rim define a hollow cavity. In another embodiment of the present invention, the stress dissipating structure includes a specifically configured sets of nodules moving the hub and rim. An additional aspect of the present invention provides a stress dissipating structure employing various anti-buckling plate attachment constructions. In still another embodiment of the present invention, a uniquely sized and packaged gear, gear housing and/or motor are employed in order to maximize output force per pound of material efficiencies. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a photographing system constituted by a lens apparatus and an image pickup apparatus, and more particularly to a controlling apparatus for controlling a zoom operation in a photographing system such as a video camera, a still camera, or a monitoring camera.
[0003] 2. Related Background Art
[0004] In many cases, a photographing system includes an optical-zooming function which changes a photographing field angle by moving a lens. In addition, some of the photographing systems have a digital-zooming function which electronically magnifies and reduces photographed image data. Besides, a photographing system has been proposed in which a zoom magnification virtually larger than a zoom magnification obtained in a case where an optical-zoom only is employed is obtained by using both the optical-zoom and the digital-zoom. In this regard, in Japanese Patent Application Laid-Open No. H09-243899 (paragraphs 0042 through 0046, FIG. 8, and the like), a technology in an interchangeable lens type photographing system in which zooming is carried out by smoothly shifting the optical-zoom and the digital-zoom from each other is proposed.
[0005] On the other hand, there is a professional-use photographing system which is equipped with a so-called preset zoom function (see Japanese Patent No. 3387889 (paragraphs 0027 through 0030, FIGS. 1 and 2, and the like)). The preset zoom function is a function in which an optical-zoom position is stored in a memory in advance and a zoom operation to the stored optical-zoom position is performed when a preset zoom switch is operated at an arbitrary optical-zoom position. The preset zoom function is convenient in a case where a zoom operation to a prescribed zooming position at a constant speed is repeated many times.
[0006] In addition, in Japanese Patent No. 3372912 (paragraph 0036, FIG. 1, and the like), the photographing system including a so-called shuttle shot zoom function is disclosed. The shuttle shot zoom function is an enhanced preset zoom function. That is, with the shuttle shot zoom function, when the preset zoom switch is operated at an arbitrary optical-zoom position, the arbitrary optical-zoom position is stored in the memory. After that, in accordance with the termination of preset zoom operation to a zoom position which is preset or an interruption of operation of the preset zoom switch during the preset zoom operation, the zooming operation to an original zoom position is performed by inverting the direction of zooming.
[0007] This function is used, for example, in a case where a tele-photo end is stored in the memory in advance, and a photographer wants to check whether a lens is focused or not after determining a composition at the arbitrary zoom position. In other words, the shuttle shot zoom function is convenient in a case where the zooming is performed once to the tele-photo end to confirm whether or not the lens is focused and then the zoom position is returned to an original position to start photographing, and where the photographing is performed alternately at arbitrary two zoom positions.
[0008] However, the preset zoom function and the shuttle shot zoom function which are mentioned above (hereinafter, both of them are referred to collectively as memory zoom function; and the operation thereof is hereinafter referred to as a memory zoom operation) are functions related to the optical-zoom. In the memory zoom function, the digital-zoom is not considered.
[0009] In this regard, it is inconvenient that the memory zoom function mentioned above can be used only in an optical-zoom region in the photographing system in which a large zoom magnification can be obtained by a combination of the optical-zoom and the digital-zoom.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a photographing system in which the memory zoom function can be effectively used regardless of whether the zooming is operated in the optical-zoom region or the digital zoom region.
[0011] In order to achieve the above-described object, the present invention provides a controlling apparatus for a photographing system having an optical-zoom region and a digital zoom region, including zoom controlling means in which the photographing system performs a memory zoom operation which is a zoom operation to a zoomed state stored in storage means. In addition, the zoom controlling means controls the photographing system to perform the memory zoom operation from a first zoomed state within one of the optical-zoom region and the digital zoom region to a second zoomed state within the other zoom region and stored in the storage means.
[0012] Note that the memory zoom operation includes a preset zoom operation, a shuttle shot zoom operation, and the like.
[0013] According to the present invention, regardless of whether each of a start position and a stop position of the memory zoom operation (the position stored in the memory) is in the optical-zoom region or in the digital zoom region, the memory zoom function can be utilized. In other words, a photographer can utilize the memory zoom function without being aware of whether the zoom is performed in the optical-zoom region or in the digital-zoom region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a block diagram showing a constitution of a lens-incorporated video camera (a photographing system) according to a first embodiment of the present invention;
[0015] FIG. 2 is a diagram showing a constitution of the preset zoom operation portion according to the first embodiment of the present invention;
[0016] FIG. 3 is comprised of FIGS. 3A and 3B showing flow charts explaining a processing of the preset zoom operation according to the first embodiment of the present invention;
[0017] FIG. 4 is a graph showing a relationship of a lens position in an inner focusing system zoom lens;
[0018] FIGS. 5A and 5B are diagrams explaining a preset, zoom operation from an optical-zoom region to a digital zoom region according to the first embodiment of the present invention;
[0019] FIGS. 6A and 6B are diagrams explaining a preset zoom operation from the digital zoom region to the optical-zoom region according to the first embodiment of the present invention;
[0020] FIGS. 7A and 7B are diagrams explaining an operation of a digital-zooming invalidation processing according to the first embodiment of the present invention;
[0021] FIG. 8 is a flow chart explaining a digital-zooming invalidation processing according to the first embodiment of the present invention;
[0022] FIG. 9 is a flow chart explaining a storing processing of a preset position according to the first embodiment of the present invention;
[0023] FIG. 10 is a diagram showing a constitution of a shuttle shot zoom operation portion according to a second embodiment of the present invention;
[0024] FIG. 11 is comprised of FIGS. 11A and 11B showing flow charts explaining a processing of the shuttle shot zoom operation according to the second embodiment of the present invention;
[0025] FIG. 12 is comprised of FIGS. 12A and 12B showing flow charts explaining a processing of the shuttle shot zoom operation according to the second embodiment of the present invention;
[0026] FIG. 13 is a flow chart explaining a processing of the shuttle shot zoom operation according to the second embodiment of the present invention;
[0027] FIG. 14 is a block diagram showing a constitution of an interchangeable lens type video camera (photographing system) according to a third embodiment of the present invention;
[0028] FIG. 15 is a flow chart explaining an operation of the camera microcomputer according to the third embodiment of the present invention;
[0029] FIG. 16 is a flow chart explaining an operation of the lens microcomputer according to the third embodiment of the present invention;
[0030] FIG. 17 is a flow chart explaining an operation of the lens microcomputer according to the third embodiment of the present invention;
[0031] FIG. 18 is a block diagram showing a constitution of an interchangeable lens type video camera (photographing system) according to a fourth embodiment of the present invention;
[0032] FIG. 19 is a flow chart explaining an operation of the camera microcomputer according to the fourth embodiment of the present invention;
[0033] FIG. 20 is a flow chart explaining an operation of the lens microcomputer according to the fourth embodiment of the present invention;
[0034] FIG. 21 is a flow chart explaining an operation of the camera microcomputer according to the fourth embodiment of the present invention; and
[0035] FIG. 22 is a diagram showing a zoom range in a photographing system according to a fifth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Embodiments of the present invention will be described in detail below with reference to the drawings.
First Embodiment
[0037] Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 shows a constitution of a photographing system of a first embodiment of the present invention. In the first embodiment, a preset zoom function in a lens-incorporated video camera is explained.
[0038] The photographing system includes a so-called rear focus type photographing optical system. Light from an object OBJ incident into the optical system passes through a first lens 102 , which is fixed; a second lens (variator lens) 103 for zooming; an iris 104 for adjusting light quantity; a third lens 105 , which is fixed; and a fourth lens (focus lens) 106 for focusing to form an image on an image sensor 107 such as a CCD sensor and CMOS sensor.
[0039] An electric signal generated by a photoelectric conversion operation by the image sensor 107 is sent to a camera signal processing means 108 . The electric signal is converted into an analog video signal by a signal processing of such as signal amplification. Further, the analog video signal is converted into a digital video signal by means of an A/D converter 109 . The digital video signal is sent to a memory 110 . The memory 110 temporarily stores the video signal.
[0040] Here, a digital-zoom circuit 111 carries out a zoom processing of the digital video signal stored in the memory 110 , on the basis of a zoom magnification signal by a microcomputer 112 . In order to obtain a zoom magnification not less than 1, the digital-zoom circuit 111 thins out image signals stored in the memory 110 , and carries out the zoom processing by interpolating the image signals which are thinned out by means of various methods.
[0041] By carrying out the zoom processing like this by altering a magnification smoothly in terms of time, it becomes possible to obtain a moving image which is zoomed in or zoomed out.
[0042] The video signal in the memory 110 which is processed into a video of an appropriate magnification by the digital-zoom circuit 111 is then subjected to processings such as a color correction processing and a white balance processing. After that, the video signal is outputted to a recording medium (such as a semiconductor memory, an optical disk, or a magnetic tape) or an external device such as a personal computer or a television monitor.
[0043] The microcomputer 112 reads a zoom command signal outputted from a zoom operation portion 118 , which is operated in order to change an amount of zooming (magnification).
[0044] Here, an explanation will be made as to a case where the microcomputer 112 carries out an optical-zoom control. In a rear focus type optical system as in this embodiment, the lens cannot be focused by merely moving a variator lens 103 in order to perform zooming. This is because the relationship between a position of the variator lens 103 (zoom lens) and the position of a focus lens 106 for keeping a focused state varies in a complicated manner depending on an object distance as shown in FIG. 4 . Accordingly, the microcomputer 112 detects the position of the variator lens 103 and the focus lens 106 by means of a zoom lens position detection device 113 and a focus lens position detection device 114 . In addition, the microcomputer 112 moves the zoom lens 103 and the focus lens 106 by means of a zoom lens driving portion 115 and a focus lens driving portion 116 , respectively, so that a lens positional relationship as shown in FIG. 4 can be established when a zoom command is outputted by a zoom operation portion 118 .
[0045] In addition, the video camera is provided with a preset zoom operation portion 117 , as an exclusive operation member of the preset zoom function, which is one of the memory zoom functions as a zoom auxiliary function. The preset zoom operation portion 117 includes, as shown in FIG. 2 , a zoom position memory 201 for storing a present zoom position as a preset position; a preset execution switch 202 for executing a preset zoom operation which is one of memory zoom operations which are zoom operations to the zoom position stored in the zoom position memory 201 ; and a speed selection volume 203 for selecting a zooming speed in the preset zoom operation by a user. The preset execution switch 202 and the speed selection volume 203 are electrical parts. The microcomputer 112 detects output signals from the preset execution switch 202 and the speed selection volume 203 .
[0046] As described above, the video camera of this embodiment is capable of carrying out the optical-zoom which is performed by moving the variator lens 103 and the focus lens 106 in conjunction with each other, and the digital-zoom in which the zooming is performed by means of image processing of the video signal. More specifically, the zooming in a low magnification region is carried out by means of the optical-zoom, and the zooming by the digital-zoom is carried out in a region of larger magnification than optical-zoom limit (tele-photo end). That is, as shown in FIG. 5A , the zooming within a region of a low magnification (wide-angle end) is carried out by means of the optical-zoom, and the zoom operation by means of the digital-zoom is not performed up to the maximum magnification of the optical-zoom. The zoom operation by means of the digital-zoom is performed when the zoom operation to tele-photo direction exceeding the maximum magnification of the optical-zoom is performed.
[0047] Note that in FIG. 5B , the zoom position of which the magnification of the digital-zoom is set to 1 is indicated as a digital wide-angle end, and the marginal position on a high magnification side of the digital-zoom is indicated as a digital tele-photo end. In a case of the digital-zoom, the marginal value can be changed to any value through image processing. However, in FIG. 5B , a marginal magnification at which a deterioration of image quality occurs within tolerance is determined as the digital tele-photo end. In addition, a zooming region obtained by the optical-zoom is called as an optical-zoom region and a zooming region obtained by the digital-zoom is called as the digital zoom region.
[0048] In addition, this embodiment is constituted so that the optical-zoom region and the digital zoom region do not overlap each other and that the zoom position belongs only to either one of the optical-zoom region and the digital zoom region. However, in order to smoothly carry out shifting between the optical-zoom region and the digital zoom region (that is, in order to make any joint between the zoom regions inconspicuous), a region in which the optical-zoom region and the digital zoom region overlap each other may be provided (see Japanese Patent Application Laid-Open No. H09-243899 (paragraphs 0042 through 0046, FIG. 8, etc.)).
[0049] Next, a control of the preset zoom operation in the microcomputer 112 will be explained. The preset zoom operation (function) is an operation such that when the preset execution switch 202 is operated while the zoom position is at a desired position, the zoom position is stored in the zoom position memory 201 , and after that, the zoom operation is performed to the zoom position stored in the zoom position memory 201 in advance in accordance with the operation of the preset execution switch 202 in a state in which the zooming position is located at an arbitrary zoom position.
[0050] FIG. 9 is a flow chart explaining a registration processing (preset processing of S 900 ) of the zoom position for the preset zoom operation. In FIG. 9 , first, in a step (abbreviated as S hereafter) 901 , the microcomputer 112 determines whether an operation for storing the zoom position in the zoom position memory 201 (an operation of the preset execution switch 202 ) has been performed or not. In a case where the operation has been performed, in S 902 , it is checked whether a digital-zoom use flag is currently set or not. When the digital-zoom use flag is set (TRUE), it shows that the present zoom position is in the digital zoom region, and when the digital-zoom use flag is not set (FALSE), it shows that the present zoom position is in the optical-zoom region.
[0051] When the digital-zoom use flag is not set, the processing proceeds to S 903 . In S 903 , the microcomputer 112 stores information on the zoom lens position obtained by a zoom lens position detection device 113 in the zoom position memory 201 . In addition, when the digital-zoom use flag is set, the processing proceeds to S 904 . In S 904 , a digital-zoom magnification which is sent to the digital-zooming circuit 111 is read and the digital-zoom magnification is stored in the zoom position memory 201 . A series of the registration processing (S 900 ) is carried out at regular time intervals and the zoom position stored in the zoom position memory 201 is sequentially updated.
[0052] Here, in the above explanation, the explanation is made as to a case where the zoom position is stored in the zoom position memory 201 , but the stored zoomed state may take any form. For example, an optical-zoom state may be stored as an encoder value of an actual zoom lens position or as a focal distance of a photography optical system which is calculated from the encoder value. In addition, the form may be different between a rear focus type and a front focus type. Besides, the zoomed state in the digital zoom region may be a state expressed as the digital-zoom magnification which is sent from the microcomputer 112 to the digital-zooming circuit 111 , a ratio of an output image range in relation to an effective image pickup region of the image pickup element, a thinning amount of scanning lines, and the like.
[0053] Further, the zoomed state can be expressed by the focal distance corresponding to a synthesis zoom magnification, which is calculated by multiplying an optical focal distance by the digital-zoom magnification. This is effective in a case, for example, of a zooming system having a region in which, the optical-zoom region and the digital zoom region mentioned above are overlapping each other. This will be explained later.
[0054] Next, a zoom operation processing (S 300 ) to a zoom position which has been preset (hereafter referred to as a preset position) will now be explained with reference to the flow charts of FIGS. 3 A and 3 B.
[0055] First, in S 301 , the microcomputer 112 determines whether the preset zoom operation has been executed or not, by a preset flag which is to be described later. If the preset zoom operation has already been executed, the processing proceeds to S 304 . If the preset zoom operation has not been executed yet, the processing proceeds to S 302 , and it is determined whether the preset execution switch 202 has been operated or not.
[0056] In a case where the preset execution switch 202 is not operated, the processing (S 300 ) is ended and after a predetermined period of time, the processing of S 300 is started again.
[0057] In a case where it is determined in S 302 that the preset zoom operation is being executed, the preset flag is changed to TRUE to show that the preset zoom operation is currently being executed. Then, the processing proceeds to the next processing, S 304 .
[0058] In S 304 , the microcomputer 112 determines whether the zoom operation is being performed in a zoom operation portion 118 or not. In a case where the zoom operation is being performed, in order to give priority to the zoom operation performed by a user in relation to the preset zoom operation, the preset flag is set to FALSE in S 305 and the processing (S 300 ) is ended.
[0059] In a case where no zoom operation is being performed in S 304 , the processing proceeds to S 306 . In S 306 , it is determined whether the present zoom position is in the digital zoom region or not by checking the digital-zoom use flag. If the present zoom position is in the digital zoom region, the processing of proceeds to S 314 . If the present zoom position is not in the digital zoom region (that is, in the optical-zoom region), the processing of proceeds to S 307 .
[0060] In S 307 , it is determined whether the preset position is located in the optical-zoom region or not. If the preset position is located within the digital zoom region, the processing proceeds to S 311 . On the other hand, if the preset position is located within the optical-zoom region, the processing proceeds to S 308 . In S 308 , the preset position and the present zoom position are compared to each other, and if the preset position is closer to the tele-photo end than the present zoom position, the optical-zoom toward the tele-photo direction is carried out by an operation of the zoom lens driving portion 115 and the focus lens driving portion 116 in conjunction with each other. In addition, if the preset position is closer to the wide-angle end than the present zoom position, the optical-zoom toward the wide-angle direction is carried out in the same way. At this time, the zoom operation is performed at a substantially constant zooming speed (that is, at a constant magnification changing ratio) which is set by the speed selection volume 203 . In addition, in a case where the speed selection volume 203 is not provided, the zoom operation may be carried out at a prescribed zooming speed.
[0061] In S 309 , the preset position and the present optical-zoom position are compared to each other. If the positions are identical to a same value, the preset flag is set to FALSE in S 310 , the zoom operation is stopped, and the processing (S 300 ) is ended.
[0062] On the other hand, in S 311 , the optical-zoom operation toward the tele-photo direction is carried out to determine in S 312 whether the optical-zoom position has reached an optical tele-photo end (a marginal position of the optical-zoom) or not. If the optical-zoom position has not reached the optical tele-photo end, the processing (S 300 ) is temporarily ended to wait until the start time of the next processing (S 300 ). If the optical-zoom position has reached the optical tele-photo end, the processing proceeds to S 313 . In S 313 , the digital-zoom use flag is changed to TRUE, and the processing proceeds to the digital-zoom operation in S 318 .
[0063] In S 314 , it is determined whether the preset position is in the digital zoom region or not. If the preset position is located in the digital zoom region, the processing proceeds to S 318 . If the preset position is not located in the digital zoom region, the processing proceeds to S 315 . In S 318 , the digital-zoom is performed at the zooming speed which is set by the speed selection volume 203 toward the preset position. Then, in S 319 , it is determined whether the preset position and the present zoom position (digital-zoom position) have become identical to each other or not. If the positions are identical to each other, the digital-zoom operation is stopped in S 320 , the preset flag is set to FALSE, and the processing (S 300 ) is ended.
[0064] On the other hand, in S 315 , the digital-zoom toward the wide-angle direction is carried out at the zooming speed which is set by the speed selection volume 203 . Then, in S 316 , it is determined whether the digital-zoom position has reached the digital wide-angle end. If the digital-zoom position has not reached the digital wide-angle end, S 316 is carried out again in the next routine and the digital-zoom toward the wide-angle direction is performed until the digital-zoom position reaches the digital wide-angle end.
[0065] In addition, if the digital-zoom position has reached the digital wide-angle end, the processing proceeds to S 317 . In S 317 , the digital-zoom use flag is set to FALSE, the digital-zoom operation is stopped, and then the processing proceeds to S 308 to carry out the optical-zoom to the wide-angle end up to the preset position.
[0066] By repeatedly carrying out the processing (S 300 ) as explained above at regular time intervals, it becomes possible to carry out the preset zoom operation across the digital-zoom and the optical-zoom, namely the preset zooming from the present zoom position in one of the optical-zoom region and the digital zoom region to the preset position in the other region.
[0067] For example, as shown in FIG. 5A , in a case where the present zooming position is located in the optical-zoom region, as indicated by rhombus symbol, and where the preset position is located in the digital zoom region, as indicated by circular symbol, when the preset execution switch 202 is operated, in FIGS. 3A and 3B , the processing proceeds in the order of S 302 →S 303 →S 304 →S 306 →S 307 →S 311 →S 312 →END. In this case, in the optical-zoom region, a series of the processings of S 301 →S 304 →S 306 →S 307 →S 311 →S 312 →END are repeated to perform the optical-zoom operation, and at the shift from the optical-zoom region to the digital zoom region, the processing proceeds in the order of S 301 →S 304 →S 306 →S 307 →S 311 →S 312 →S 313 →S 318 →S 319 →END. Upon the shift, the microcomputer 112 controls the optical-zooming speed and the digital-zooming speed so that the virtual zooming speed is maintained at the zooming speed which is set by the speed selection volume 203 . Thereby a photographer never feels uncomfortable when the zooming region is shifted. This also applies to other embodiments which are to be described later.
[0068] In addition, after the zoom position has shifted to the digital zoom region, a series of the processings of S 301 →S 304 →S 306 →S 314 →S 318 →S 319 →END are repeated, and finally, the processing proceeds in the order of S 301 →S 304 →S 306 →S 314 →S 318 →S 319 →S 320 →END, and the preset zoom operation is ended.
[0069] The change in the preset zoom operation between the optical-zoom position and the digital-zoom position is as indicated by reference numerals 502 and 503 in FIGS. 5A and 5B .
[0070] In addition, as shown in FIG. 6A , in a case where the present zooming position is within the digital zoom region, as indicated by rhombus symbol, and where the preset position is within the optical-zoom region, as indicated by circular symbol, when the preset execution switch 202 is operated, in FIGS. 3 A and 3 B, the processing proceeds in the order of S 302 →S 303 →S 304 →S 306 →S 314 →S 315 →S 316 →END. In this case, in the digital zoom region, a series of the processings of S 301 →S 303 →S 304 →S 306 →S 314 →S 315 →S 316 →END are repeated, and upon the shift from the digital zoom region to the optical-zoom region, the processing proceeds in the order of S 301 →S 303 →S 304 →S 306 →S 314 →S 315 →S 316 →S 317 →S 318 →S 309 →END. In response to the shift, the microcomputer 112 controls the digital-zooming speed and the optical-zooming speed so that the virtual zooming speed is maintained at the zooming speed which is set by the speed selection volume 203 . This also applies to other embodiments which are to be described later.
[0071] In addition, after the zoom position has shifted to the optical-zoom region, a series of the processings of S 301 →S 303 →S 304 →S 306 →S 307 →S 308 →S 309 →END are repeated, and finally, the processing proceeds in the order of S 301 →S 303 →S 304 →S 306 →S 307 →S 308 →S 309 →S 310 →END, and the preset zoom operation is ended.
[0072] The change of the optical-zoom position and the digital-zoom position in the preset zoom operation is as indicated by reference numerals 602 and 603 in FIG. 6B .
[0073] Through the control as described above, it becomes possible to carry out the preset zoom operation across the optical-zoom region and the digital zoom region.
[0074] Here, the processing (S 800 ) by the microcomputer 112 in a case where a switch (not shown) which is capable of invalidating the digital-zooming function is added will now be explained with reference to FIG. 8 .
[0075] First, in S 801 , the microcomputer 112 determines whether an operation of the switch for invalidating the digital-zoom has been performed or not. If the operation of the switch has been performed, the processing proceeds to S 802 . In S 802 , it is determined whether the preset zoom operation is currently being executed or not. If the preset zoom operation is currently being executed, the operation of invalidating the digital-zooming itself is invalidated. In addition, if the preset zoom operation is not being executed, the processing proceeds to S 803 . In S 803 , it is determined whether the present zoom position is located in the digital zoom region or not, by checking the digital-zoom use flag. If the present zoom position is located in the digital zoom region, the digital-zoom position is immediately changed to the digital wide-angle end in S 804 . Here, the zoom operation by the digital-zoom is not performed. That is, the digital-zoom is set OFF and the digital-zoom magnification is set to 1.
[0076] Then, the processing proceeds to S 805 . In S 805 , it is determined whether the preset position is located in the digital zoom region or not. If the preset position is located in the digital zoom region, the processing proceeds to S 806 to change the preset position to the optical tele-photo end. In other words, the zoom position stored in the zoom position memory 201 is rewritten into the optical tele-photo end. Thereby in a case where the digital-zoom is prohibited, when the preset position is in the digital zoom region, the zoom state is changed to the optical tele-photo end (digital wide-angle end).
[0077] For example, as indicated by reference numeral 701 in FIG. 7A , in a case where both the present zoom position (indicated by a rhombus) and the preset position are located in the digital zoom region, when the invalidation operation of the digital-zoom is performed, the processing proceeds in the order of S 801 →S 802 →S 803 →S 804 →S 805 →S 806 , and comes to a state as indicated by reference numeral 702 in FIG. 7A . The change with time in the digital-zoom position and the optical-zoom position at this time is indicated by reference numerals 703 and 704 .
[0078] Note that the digital-zooming invalidation processing can be adopted as well for other embodiments to be described later.
Second Embodiment
[0079] Next, as a second embodiment of the present invention, explanation will now be made as to a lens-incorporated video camera which is capable of performing a shuttle shot zoom operation across the optical-zoom region and the digital zoom region. The shuttle shot zoom operation (function) is one of memory zoom functions as a zoom auxiliary function. The shuttle shot zoom function is used for the zoom operation to the preset position which is stored in advance, as in the preset zoom operation. Also, the shuttle shot zoom function is used for storing the start position of the zoom operation at this time (an original zoom position), reversing a direction of the zoom operation after or in the middle of the zoom operation to the preset position mentioned above to return the position to the original zoom position.
[0080] Accordingly, one more zoom position to be stored is added, compared to the preset zoom operation as explained in the first embodiment. In addition, two operations, namely an operation for starting the zoom operation to the preset position and an operation for starting a returning operation to the original zoom position (or an operation for canceling the zoom operation to the preset position) are necessary. In this embodiment, the two operations mentioned above correspond to an ON operation and the canceling the ON operation (an OFF operation) of one operation member (a shuttle shot execution switch). The other constitutions are the same as those of the first embodiment. Accordingly, the explanation as to the same constitutions is omitted.
[0081] FIG. 10 shows a constitution of a shuttle shot zoom operation portion 117 ′ of this embodiment which includes a shuttle shot execution switch 1002 . A shuttle shot zoom position memory 1001 stores the preset position and the original zoom position (hereafter referred to as a cancellation position). The shuttle shot execution switch 1002 is constituted by a push-in type switch. The shuttle shot execution switch 1002 executes the zoom operation to the preset position (hereafter referred to as an outward preset zoom operation) while being pushed in. Then, when the pushed-in state is released, the zoom operation to the cancellation position (hereafter referred to as a cancellation zoom operation) is executed. A speed selection volume 1003 is used by a user to select the zooming speed during the shuttle shot zoom operation, just as in the first embodiment.
[0082] Next, a control of the shuttle shot zoom operation in this embodiment will be explained. FIGS. 11A and 11B are flow charts of the operation of the microcomputer 112 , which carries out the control.
[0083] First, in S 1101 , the microcomputer 112 determines whether the shuttle shot zoom operation is being executed, by checking a shuttle shot performing flag which is to be described later. If the shuttle shot zoom operation has already been executed, the processing proceeds to S 1104 . If the shuttle shot zoom operation has not been executed, the processing proceeds to S 1102 . In S 1102 , it is determined whether the shuttle shot execution switch 1003 is operated (set ON) or not. If the shuttle shot execution switch 1003 is not operated, it is determined in S 1122 whether a cancellation flag is TRUE or not. If the cancellation flag is TRUE, the processing proceeds to a subroutine of the cancellation zoom operation of S 1123 which is to be described later. If the cancellation flag is not TRUE, S 1100 , which is a shuttle shot execution routine, is ended, and the processing of S 1100 is started again after a predetermined period of time.
[0084] In a case where it is determined in S 1102 that the shuttle shot zoom operation is being executed, the processing proceeds to a subroutine S 1103 that is an initialization processing at the time when the shuttle shot zooming is started. A content of the processing is shown in FIG. 13 .
[0085] First, in S 1301 , the shuttle shot performing flag is changed to TRUE to show that the shuttle shot zoom operation is currently being executed. In addition, in order to carry out the cancellation zoom operation when the shuttle shot execution switch 1002 shifts from an ON state to an OFF state (hereafter referred to as cancelled), the cancellation flag is set TRUE.
[0086] Then, in the next step, S 1302 , it is determined whether the digital-zoom is being in execution, by means of the digital-zoom use flag, which is also explained in the first embodiment. In a case where the digital-zoom is being in execution, in S 1304 , the present digital-zoom position is stored in the shuttle shot position memory 1001 , as the cancellation position which is a target zooming position at the time of canceling. In addition, in a case where the digital-zoom is not being in execution, the present optical position is stored in the shuttle shot position memory 1001 as the cancellation position. Then, the initialization processing (S 1103 ) is ended and the processing proceeds to S 1104 in FIGS. 11A and 11B .
[0087] In S 1104 , the microcomputer 112 determines whether the zoom operation is being performed in a zoom operation portion 118 or not. If the zoom operation is being performed, in order to give priority to the zoom operation performed by a user in relation to the shuttle shot zoom operation, and the processing proceeds to S 1105 to set the shuttle shot performing flag to FALSE and set the cancellation flag to FALSE as well, thereby ending the processing (S 1100 ).
[0088] If it is determined that no zoom operation is being performed in S 1104 , the processing proceeds to S 1106 . In S 1106 , it is determined whether the present zoom position is in the digital zoom region or not by means of the digital-zoom use flag. If the present zoom position is in the digital zoom region, the processing proceeds to S 1114 . If the present zoom position is not in the digital zoom region but in the optical-zoom region, the processing proceeds to S 1107 .
[0089] In S 1107 , it is determined whether the preset position stored in the shuttle shot position memory 1001 is located in the digital zoom region or not. If the preset position is located in the digital zoom region, the processing proceeds to S 1111 . On the other hand, if the preset position is located in the optical-zooming region, the processing proceeds to S 1108 . In S 1108 , the preset position and the present zoom position are compared to each other. If the preset position is closer to the tele-photo end than the present zoom position, the zoom operation is carried out toward the tele-photo direction by an operation of the zoom lens driving portion 115 and the focus lens driving portion 116 . In addition, if the preset position is closer to the wide-angle end than the present zoom position, in the same way, the optical-zoom operation is carried out toward the wide-angle direction. At this time, the zoom operation is carried out at the zooming speed which has been set by the speed selection volume 1003 .
[0090] Next, in S 1109 , comparing the preset position and the present optical-zoom position to each other, if the positions are identical to a same value, the shuttle shot performing flag is set to FALSE in S 1110 . In addition, the zoom operation is stopped and the outward preset zoom operation is completed.
[0091] In S 1111 , the optical-zoom operation toward the tele-photo direction is performed and it is determined in S 1112 whether the optical tele-photo end (a marginal position of the optical-zoom) and the present zoom position are located at a same position. If they are located at different positions, the processing (S 1109 ) is temporarily ended. If the optical tele-photo end and the present zoom position are located at a same position, the processing proceeds to S 1113 . In S 1113 , the digital-zoom use flag is changed to TRUE, and then the processing proceeds to the digital-zoom operation.
[0092] In S 1114 , it is determined whether the preset position is in the digital zoom region or not. If the preset position is located in the digital zoom region, the processing proceeds to S 1118 . If the preset position is not located in the digital zoom region (but in the optical-zoom region), the processing proceeds to S 1115 .
[0093] In S 1118 , the digital-zoom is performed at the zooming speed which is set by the speed selection volume 1003 toward the preset position. Then, in S 1119 , it is determined whether the preset position and the present zoom position have become identical to each other or not. If the positions are identical to each other, the digital-zoom operation is stopped in S 1120 , and the shuttle shot performing flag is set to FALSE. The cancellation flag is set to TRUE, thereby completing the preset zoom operation in the shuttle shot zoom operation.
[0094] In S 1115 , the digital-zoom operation toward the wide-angle direction is carried out at a substantially constant zooming speed which has been set by the speed selection volume 1003 . Then, in S 1116 , it is determined whether the present digital-zoom position has reached the digital wide-angle end or not. If the present digital-zoom position has not reached the digital wide-angle end yet, the digital-zoom toward the wide-angle direction is carried out until it is determined in S 1116 on and after the next routine that the digital-zoom position has reached the digital wide-angle end. On the other hand, if the digital-zoom position has reached the digital wide-angle end, the processing proceeds to S 1117 . In S 1117 , the digital-zoom use flag is set to FALSE and the digital-zoom operation is stopped. Then, the processing proceeds further to S 1108 and the optical-zoom operation toward the wide-angle direction is carried out.
[0095] The cancellation zoom operation is carried out in accordance with a flow chart as shown in FIGS. 12A and 12B . First, in S 1201 , the microcomputer 112 determines whether the cancellation zoom operation has been executed or not, by a cancellation flag which is to be described later. If the cancellation zoom operation has already been executed, the processing proceeds to S 1204 . If the cancellation zoom operation has not been executed yet, the processing proceeds to S 1202 , and it is determined whether the canceling operation (cancellation execution operation) of the preset execution switch 1202 has been performed or not.
[0096] In a case where the cancellation execution operation is not operated, the processing (S 1123 ) is ended and after a predetermined period of time, the processing of S 1123 is started again.
[0097] If it is determined in S 1201 that the cancellation zoom operation is being executed, the cancellation flag is changed to TRUE to show that the cancellation zoom operation is currently being executed. Then, the processing proceeds to the next process, S 1204 .
[0098] In S 1204 , the microcomputer 112 determines whether the zoom operation is being performed in a zoom operation portion 118 or not. If the zoom operation is being performed, in order to give priority to the zoom operation performed by a user in relation to the cancellation zoom operation, the preset flag is set to FALSE in S 1205 and the processing (S 1123 ) is ended.
[0099] If no zoom operation is being performed in S 1204 , the processing proceeds to S 1206 . In S 1206 , it is determined whether the present zoom position is in the digital zoom region or not by checking the digital-zoom use flag. If the present zoom position is in the digital zoom region, the processing proceeds to S 1214 . If the present zoom position is not in the digital zoom region, the processing proceeds to S 1207 .
[0100] In S 1207 , it is determined whether the cancellation position is located in the optical-zoom region or not. If the cancellation position is located within the digital zoom region, the processing proceeds to S 1211 . On the other hand, if the preset position is located within the optical-zoom region, the processing proceeds to S 1208 . In S 1208 , the cancellation position and the present zoom position are compared to each other, and if the cancellation position is more tele-photo side than the present zoom position, the optical-zoom toward the tele-photo direction is carried out through an operation of the zoom lens driving portion 115 and the focus lens driving portion 116 in conjunction with each other. In addition, if the cancellation position is more wide-angle side than the present zoom position, the optical-zoom toward the wide-angle direction is carried out in the same way. At this time, the zoom operation is performed at a substantially constant zooming speed which is set by the speed selection volume 1003 . In addition, if the speed selection volume 1003 is not provided, the zoom operation may be carried out at a prescribed zooming speed.
[0101] In S 1209 , the cancellation position and the present optical-zoom position are compared to each other. If the positions are identical to a same value, the preset flag is set to FALSE in S 1210 , the zoom operation is stopped, and the processing (S 1123 ) is ended.
[0102] On the other hand, in S 1211 , the optical-zoom operation toward the tele-photo direction is carried out to determine in S 1212 whether the optical-zoom position has reached an optical tele-photo end (a marginal position of the optical-zoom) or not. If the optical-zoom position has not reached the optical tele-photo end, the processing (S 1123 ) is temporarily ended to wait until the start time of the next processing (S 1123 ). If the optical-zoom position has reached the optical tele-photo end, the processing proceeds to S 1213 . In S 1213 , the digital-zoom use flag is changed to TRUE, and the processing proceeds to the digital-zoom operation in S 1218 .
[0103] In S 1214 , it is determined whether the cancellation position is in the digital zoom region or not. If the cancellation position is located in the digital zoom region, the processing proceeds to S 1218 . If the preset position is not located in the digital zoom region, the processing proceeds to S 1215 . In S 1218 , the digital-zoom is performed at the zooming speed which is set by the speed selection volume 1003 toward the preset position. Then, in S 1219 , it is determined whether the cancellation position and the present zoom position (digital-zoom position) have become identical to each other or not. If the positions are identical to each other, the digital-zoom operation is stopped in S 1220 , the preset flag is set to FALSE, and the processing (S 1123 ) is ended.
[0104] On the other hand, in S 1215 , the digital-zoom toward the wide-angle direction is carried out at the zooming speed which is set by the speed selection volume 1003 . Then, in S 1216 , it is determined whether the digital-zoom position has reached the digital wide-angle end. If the digital-zoom position has not reached the digital wide-angle end, the processing of S 1216 is carried out again in the next routine and the digital-zoom toward the wide-angle direction is performed until the digital-zoom position reaches the digital wide-angle end.
[0105] In addition, if the digital-zoom position has reached the digital wide-angle end, the processing proceeds to S 1217 . In S 1217 , the digital-zoom use flag is set to FALSE, the digital-zoom operation is stopped, and then the processing proceeds to S 1208 to carry out the optical-zoom toward the wide-angle direction up to the preset position.
[0106] By repeating the processing (S 1123 ) as explained above at regular time intervals, it becomes possible to carry out the shuttle shot zoom operation across the digital-zoom region and the optical-zoom region, namely the shuttle shot zoom operation from the present zoom position (cancellation position) in either one of the optical-zoom region and the digital zoom region to the preset position in the other region.
[0107] Note that the flow chart shown in FIGS. 12A and 12B are equivalent to the flow chart shown in FIGS. 3A and 3B of the first embodiment except that the term “preset” in the flow chart as shown in FIGS. 3A and 3B is replaced by the term “cancel”. Accordingly, the specific flow of the processings in each of the zoom regions is the same as that explained in relation to FIGS. 3A and 3B .
[0108] In addition, in this embodiment, the explanation is made as to a case where the cancellation zoom operation is started by cancellation of the operation of the shuttle shot execution switch after the zoom position reaches the preset position. However, in a case where the operation of the shuttle shot execution switch is cancelled before the zoom position reaches the preset position (in other words, in the middle of the outward preset zoom operation), the cancellation zoom operation may be started from the zoom position.
[0109] In addition, in this embodiment, the optical-zoom region and the digital zoom region do not overlap each other, and the zoom position belongs only to either one of the optical-zoom region and the digital zoom region. However, the optical-zoom region and the digital zoom region may partially overlap each other as will be discussed below.
Third Embodiment
[0110] Next, as a third embodiment of the present invention, the preset zoom operation and the shuttle shot zoom operation across the optical-zoom region and the digital zoom region in an interchangeable lens type video camera will now be explained with reference to FIG. 14 .
[0111] The photography optical system of the interchangeable lens which constitutes the photographing system is a so-called rear-focus type zoom optical system. Light from an object OBJ which is incident into the optical system passes through a first lens 1401 , which is fixed; a second lens (variator lens) 1402 for zooming; an iris 1403 for adjusting light quantity; a third lens 1404 , which is fixed; and a fourth lens (focus lens) 1405 for focusing, and then passes through a mount portion of the interchangeable lens and the video camera body to form an image on an image pickup element 1407 such as a CCD sensor or CMOS sensor.
[0112] An electric signal generated through a photoelectric conversion operation by the image pickup element 1406 is sent to a camera signal processing circuit 1407 . The electric signal is converted into an analog video signal which is subjected to a signal processing of such as signal amplification and the like. Further, the analog video signal is converted into a digital video signal by means of an A/D converter 1408 . The digital video signal is sent to a memory 1409 . The memory 1409 temporarily stores the video signal.
[0113] Here, a digital-zoom circuit 1410 carries out a zoom processing of the digital video signal stored in the memory 1409 , on the basis of a zoom magnification signal by a camera microcomputer 1411 . The digital-zoom circuit 1411 , in order to obtain a zoom magnification equal to or larger than 1, things out image signals stored in the memory 1409 , and carries out the zoom processing by interpolating the image signals which are thinned out, by means of various methods. By carrying out the zoom processing like this by changing a magnification smoothly in terms of time, it becomes possible to obtain a moving image which is zoomed in or zoomed out The video signal in the memory 1409 which is processed into a video image of an appropriate magnification by the digital-zoom circuit 1410 is then subjected to processings such as a color correction processing, a white balance processing, and the like. After that, the video signal is outputted to a recording medium (such as a semiconductor memory, an optical disk, or a magnetic tape) or an external device of a personal computer, a television monitor, and the like.
[0114] The lens microcomputer 1413 reads a zoom command signal outputted from a zoom operation portion 1419 , which is operated in order to change an amount of zooming (magnification).
[0115] Here, an explanation will be made as to a case where the lens microcomputer 1413 carries out an optical-zoom control. In a rear focus type optical system as in this embodiment, the lens cannot be focused, by merely moving a zoom lens 1402 as explained in the first embodiment as well. Accordingly, the lens microcomputer 1413 detects the position of the zoom lens 1402 and the focus lens 1405 by means of a zoom lens position detection device 1414 and a focus lens position detection device 1415 . In addition, the lens microcomputer 1413 moves the zoom lens 1402 and the focus lens 1405 via a zoom lens driving portion 1416 and a focus lens driving portion 1417 so that a lens position relationship as shown in FIG. 4 can be established when a zoom command is outputted by a zoom operation portion 1419 .
[0116] In addition, provided on the lens side is a preset zoom operation portion or a shuttle shot zoom operation portion 1418 , as an exclusive operation member of the preset zoom function which is one of the memory zoom functions as a zoom auxiliary function. The shuttle shot zoom operation portion 1418 has the same structure as that in the first embodiment shown in FIG. 2 .
[0117] In the photographing system of this embodiment, it is possible to carry out the optical-zoom, which is performed by moving the variator lens 1402 and the focus lens 1405 in conjunction with each other, and the digital-zoom in which the zooming is performed through image processing of the video signal. More specifically, the zooming in a low magnification region is carried out by means of the optical-zoom, and the zooming based on the digital-zoom is carried out to move a lens toward the tele-photo side in a region more tele-photo side than the optical tele-photo end.
[0118] In addition, in this embodiment, the optical-zoom region and the digital zoom region do not overlap each other and the zoom position belongs only to either one of the optical-zoom region and the digital zoom region. However, in order to smoothly carry out shifting between the optical-zoom region and the digital zoom region (that is, so that no joint between the zoom regions is conspicuous), a region in which the optical-zoom region and the digital zoom region overlap each other may be provided as will be discussed below.
[0119] In addition, just as explained in the first and the second embodiments, it is possible in this embodiment also to carry out the preset zoom operation and the shuttle shot zoom operation across the optical-zoom region and the digital zoom region. The specific processings of the preset zoom operation and the shuttle shot zoom operation are basically the same as those explained in the first and the second embodiments. In this embodiment, the lens microcomputer 1413 functions as zoom control means and the camera microcomputer 1411 makes the digital-zooming circuit 1410 perform the digital-zoom in accordance with a digital-zoom command received from the lens microcomputer 1413 .
[0120] Here, explanation will now be made as to a communication processing between the lens microcomputer 1413 and the camera microcomputer 1411 . First, an operation flow chart of the camera microcomputer 1411 is shown in FIG. 15 .
[0121] In S 1501 , the camera microcomputer 1411 communicates with the lens microcomputer 1413 . Through this communication, the camera microcomputer 1411 receives a digital zoom command from the lens microcomputer 1413 . Then, in S 1502 , it is determined whether the digital zoom command is received or not. If the digital zoom command is received, the digital-zoom is performed in S 1503 . Then, the processing proceeds to S 1504 .
[0122] In addition, if the digital-zoom command is not received in S 1502 , the processing proceeds to S 1504 . In S 1504 , for the next communication with the lens microcomputer 1413 , present digital-zooming position information (information indicating the digital-zoom position such as the digital-zoom magnification) is set in transmission data. Then, the processing (S 1500 ) is ended. The processing (S 1500 ) is carried out at regular time intervals, and information is exchanged between the lens microcomputer 1413 and the camera microcomputer 1411 .
[0123] Next, an operation flow chart of the lens microcomputer 1413 is shown in FIG. 16 . In S 1601 , the lens microcomputer 1413 communicates with the camera microcomputer 1411 . The lens microcomputer 1413 receives the digital-zooming information and the like from the camera microcomputer 1411 and sends the digital-zoom command and digital-zooming control data (data as to the zooming speed and the direction of zooming) to the camera microcomputer 1411 . Then, the preset zoom operation subroutine S 300 is called to carry out the processing of the preset zoom operation. In addition, on the basis of the processing, in S 1602 , the digital-zoom command and the control data for digital-zoom to be transmitted to the camera microcomputer 1411 in the next communication are set in the transmission data.
[0124] In addition, the shuttle shot zoom operation can be carried out by substituting the operation flow chart shown in FIG. 16 with an operation flow chart shown in FIG. 17 . More specifically, S 300 shown in FIG. 16 is substituted with S 1100 described in the second embodiment with reference to FIGS. 11A, 11B , 12 A and 12 B.
[0125] As is described above, according to this embodiment, in an interchangeable lens type photographing system, it becomes possible to implement the preset zoom operation and the shuttle shot zoom operation across the optical-zoom region and the digital zoom region.
Fourth Embodiment
[0126] In the third embodiment, explanation has been made as to a case where the preset zoom operation portion or the shuttle shot zoom operation portion is provided on the lens side and a primary control of the preset zoom operation or the shuttle shot zoom operation is carried out by the lens microcomputer. In a fourth embodiment of the present invention, as shown in FIG. 18 , the preset zoom operation portion or the shuttle shot zoom operation portion 1818 is provided on the side of the camera body, and in addition, the primary control of the preset zoom operation or the shuttle shot zoom operation is carried out by a camera microcomputer 1811 .
[0127] Note that the constitution of the photographing system of this embodiment is the same as that of the third embodiment except that the preset zoom operation portion or the shuttle shot zoom operation portion 1818 is provided on the side of the camera body. The common constituent elements are indicated with reference numerals in the eighteen hundreds of which the last two digits are the same as those of reference numerals in the fourteen hundreds in the third embodiment.
[0128] In addition, in this embodiment as well, the optical-zoom region and the digital zoom region do not overlap each other and the zoom position belongs only to either one of the optical-zoom region and the digital zoom region. However, a region in which the optical-zoom region and the digital zoom region overlap each other may be provided as will be described below.
[0129] In addition, just as explained in the third embodiment, it is possible in this embodiment also to carry out the preset zoom operation and the shuttle shot zoom operation across the optical-zoom region and the digital zoom region. The specific processings of the preset zoom operation and the shuttle shot zoom operation are basically the same as those explained in the first and the second embodiments. In this embodiment, the camera microcomputer 1811 functions as zoom control means and the lens microcomputer 1813 performs the optical-zoom in accordance with an optical-zoom command received from the camera microcomputer 1811 via a zoom lens driving portion 1816 and a focus lens driving portion 1815 .
[0130] Here, explanation will now be made as to a communication processing between the camera microcomputer 1811 and the lens microcomputer- 1813 . First, an operation flow chart of the camera microcomputer 1811 is shown in FIG. 19 .
[0131] First, in S 1901 , the camera microcomputer 1811 communicates with the lens microcomputer 1813 and receives the optical-zooming information and the like on the lens side. The camera microcomputer 1811 sends the optical-zoom command and optical-zooming control data (data as to the zooming speed and the direction of zooming) to the lens microcomputer 1813 . Then, the preset zoom operation subroutine S 300 described in FIGS. 3A and 3B of the first embodiment is called to carry out the processing necessary for the preset zoom operation. In addition, on the basis of the processing, in S 1902 , the optical-zoom command and the control data for optical-zoom to be transmitted to the lens microcomputer 1813 in the next communication are set in the transmission data.
[0132] Next, an operation flow chart of the lens microcomputer 1813 is shown in FIG. 20 . First, in S 2001 , the lens microcomputer 1813 communicates with the camera microcomputer 1811 . Through this communication, the lens microcomputer 1813 receives an optical zoom command from the camera microcomputer 1811 . Then, in S 2002 , it is determined whether the optical zoom command is received or not. If the optical zoom command is received, the optical-zoom is performed in S 2003 in response to the command. Then, the processing proceeds to S 2004 .
[0133] On the other hand, in a case where the optical-zoom command is not received in S 2002 , the processing proceeds to S 2004 . In S 2004 , for the next communication with the camera microcomputer 1811 , present optical-zooming information is set in transmission data. Then, the processing ends. The processing in S 2000 is carried out at regular time intervals, and information is exchanged between the lens microcomputer 1813 and the camera microcomputer 1811 .
[0134] In addition, the shuttle shot zoom operation can be carried out by substituting the operation flow chart shown in FIG. 19 with an operation flow chart shown in FIG. 21 . More specifically, S 300 shown in FIG. 19 is substituted with S 1100 as described in the second embodiment with reference to FIGS. 11A, 11B , 12 A and 12 B.
[0135] As is described above, according to this embodiment, in an interchangeable lens type photographing system, it becomes possible to implement the preset zoom operation and the shuttle shot zoom operation across the optical-zoom region and the digital zoom region.
[0136] In the third and fourth embodiments which are mentioned above, explanation is made as to a case where the preset zoom operation portion or the shuttle shot zoom operation portion is integrated in one operation portion and is provided on the side of the lens or the camera body together with the zoom operation portion. However, each of these portions may be provided separately to the lens side and the camera body side. In addition, in each of the embodiments mentioned above, explanation is made as to a case where the preset zoom operation portion or the shuttle shot zoom operation portion is integrally provided to the lens-incorporated camera, interchangeable lens, or the camera body. However, the preset zoom operation portion or the shuttle shot zoom operation portion may be made connectable to the lens-incorporated camera, interchangeable lens, or the camera body as an independent control unit.
[0137] In addition, in each of the embodiments mentioned above, explanation is made as to a case where the memory zoom operation is carried out from the arbitrary zoom position in one of the optical-zoom region and the digital zoom region which do not overlap each other to the stored preset position (or the cancellation position) in the other region. However, the present invention can be applied to a case where the optical-zoom region and the digital zoom region overlap each other.
Fifth Embodiment
[0138] FIG. 22 shows a zoom range of the photographing system according to a fifth embodiment of the present invention, in which the optical-zoom region and the digital zoom region overlap each other. FIG. 22 shows a case, for example, where the present zoom position (indicated by a rhombus) is located in the optical-zoom region and the preset position (indicated by a circle) is located in an overlap region in which the optical-zoom region and the digital zoom region overlap each other, in other words, the preset position is located in the digital zoom region. The present zoom position may be located in the digital zoom region and the preset position may be located in the overlap region (in other words, the optical-zoom position), although not shown.
[0139] As described above, the preset position can be also stored in the overlap region, whereby usability of the photographing system can further be enhanced.
[0140] This application claims priority from Japanese Patent Application No. 2004-224778 filed on Jul. 30, 2004, which is hereby incorporated by reference herein. | To provide a controlling apparatus for a photographing system that enables effective use of a memory zoom function regardless of whether a zoom position is within an optical-zoom region or a digital zoom region. The present invention provides a controlling apparatus for a photographing system having an optical-zoom region and a digital zoom region, including a zoom controlling unit for making the photographing system perform a memory zoom operation which is a zoom operation to a zoomed state stored in a storage unit. In addition, the zoom controlling unit makes the photographing system perform the memory zoom operation from a first zoomed state corresponding to one of the optical-zoom region and the digital zoom region to a second zoomed state which corresponds to the other zoom region and is stored in the storage unit. | 7 |
RELATED APPLICATION
This application is a divisional of U.S. application Ser. No. 10/934,748, filed Sep. 7, 2004 abandoned.
FIELD OF THE INVENTION
The present invention relates to novel N-Poly (alkenyl) acryl amides and process for preparation thereof. More particularly, the present invention relates to a process of preparation of N-poly(alkenyl) acryl amides of formula (1) where in m=1-8, n=2-100
BACKGROUND OF THE INVENTION
N-alkylacrylamides, such as N-isopropyl, N-tert-butylacrylamide and N-n-octylacrylamide, are of important classes of monomers for the synthesis of polymers, which are useful in applications such as sizing agents, rheology modifiers and water soluble polymers. Amongst these, N-isopropylacrylamide has assumed significant importance owing to the commercial importance of its polymer. Poly(N-isopropylacrylamide) has been widely studied for its novel thermal behaviour in aqueous media [Schild H G. Progress in Polymer Science. 17, 163 (1992)] and possesses inverse solubility upon heating, a property contrary to the behaviour of most polymers in organic solvents under atmospheric pressure near ambient temperature. Its macromolecular transition from a hydrophilic to hydrophobic structure occurs at what is known as lower critical solution temperature (LCST). Experimentally, this temperature lies between 30-35° C., the exact temperature being a characteristic of the microstructure of the polymer. At molecular level, poly(N-isopropylacrylamide) has been used in many forms including single chain, macroscopic gel, microgels, latex, thin film, membrane, coating, and fibres.
N-alkylacrylamides (alkyl=C 6 to C 18 ) are also widely used as comonomers for the preparation of hydrophobically modified polyelectrolytes [Glass J E, Polymers in aqueous media:performance through association . ACS symposium series, 223. Washington: American Chemical Society, 1989 and Shalaby S W, McCormick C L, Glass J E. In: Shalaby S W, McCormick C L, Glass J E, editors. Water soluble polymers: synthesis, solution properties and applications . ACS symposium series 467. Washington: American Chemical Society, 1991]. These polymers consist of a water-soluble backbone containing a small proportion of hydrophobic groups (<3 mol %) usually in the form of pendant side chains or terminal groups. In aqueous solution the hydrophobic groups aggregate to minimize their exposure to water and, thereby, form hydrophobic microdomains in a fashion analogous to that of surfactants above their critical micelle concentration. Above a certain concentration (C ag ), intermolecular hydrophobic interactions lead to the formation of a three dimensional network of polymer chains resulting in an increase in the apparent molecular weight and, consequently, a substantial viscosity enhancement.
Copolymers of N-alkylacrylamides with various other monomers are also finding diverse applications. For example, poly(N-dodecylacrylamide-co-N-methyl-4-vinyl pyridinium Na) is reported to be a useful as salt resistant viscosity builder [D. Christine, B. Alain and L. Pierre, Macromol. Symp. 102,233 (1995), D. Christine, B. Alain, B. Fransis and V. M. Laure, Polymer 36, 2095 (1995)], poly (N-stearoyl acrylamide-co-2-(3-acrylamidopropyl) dimethyl aminoethyl isoproply phosphate) is used as phosphatidylcholine analogous material [W Yenfeng, C. Tianming, K. Masaya and N. Taiao, J. Polym. Sci. Chem. Edn. 34, 449 (1996)], poly (N-tert-octylacrylamide-co-N-alkylacrylamide) has been employed as a thickener in cosmetics [J. Mondet and B. Lion Eur. Pat. Appl. EP 494,022] and poly (N-octylacrylamide-co-3-acrylamido-3-methyl butanoate Na) has been used for for oil recovery applications [A. Kitagawa and T Koichi, Jpn. Kokai Tokkyo Koho JP 07,188,347].
N-alkylacrylamides are, thus, a useful class of monomers. In order to meet the growing demand and new applications of N-alkylacrylamides, various methods have been developed for their synthesis.
Some of these methods for the synthesis of N-alkylacrylamides include (1) reaction of acryloyl chloride with alkyl amine; (2) pyrolysis or thermal decomposition of carboxylic acid amides, and (3) reaction of iso-olefins with nitriles.
In the first method N-alkylacrylamides are prepared by reacting acryloyl chloride with the corresponding alkyl amines in the presence of an acid quencher i.e. triethyl amine at 0° C. [C. G. Overberger, C. Frazier and J. Mandehman, J. Am. Chem. Soc. 75, 3326 (1953), J. Lal and G. S. Trick, J. Polym. Sci. A 2, 4559 (1964), E. F. Jr. Jordan, G. R. Riser and B. Artymyshyn, J. Appl. Polym. Sci. 13, 1777 (1969), K. J. Shea, G. J. Stoddard, D. M Shavelle, F. Wakui and R. M. Chaote, Macromolecules 23, 4497 (1990)].
In the second method N-alkylacrylamides are prepared by amidation of bicyclic carboxylic acids followed by the thermal decomposition of the carboxamide. For example, the reaction of dimethylamine with bicyclo [2.2.1]hept-2-ene-2-carboxylic acid in an autoclave gave N,N-dimethyl bicyclo [2.2.1]hept-2ene-2-carboxylic acid which was subjected to thermal decomposition at 200° C./vacuum to give N,N-dimethyl bicyclo [2.2.1]hept-2-ene-2-carboxamide [A. Ohshima and K. Tsubashima Jpn. Tokkyo Koho 7909 170, A. Oshima, K. Tsubashima and N. Takahashi Ger. Offen. 2,217,623].
In method (3) N-alkylacrylamides are prepared by reacting acrylonitrile with various iso-olefins. It is also known to synthesise N-tert-octylacrylamide by reacting acrylonitrile with 2,4,4-trimethyl-1-pentene at 40° C. for 3 hours using 65% H 2 SO 4 as solvent [T Takada, Y Kawakatsu, T Mihamisawa and K Hara, Japan Kokai-7391011].
A method for the preparation of N-alkylamides using 60% H 2 SO 4 and cation exchange resin as catalysts have been disclosed [S. Sivaram, N. Kalyanam, Ind. pat. 158395 A and S. Sivaram, N. Kalyanam Ind. Pat. 158038].
The above methods are beset with many disadvantages. Method (1) cannot be used for preparation of higher N-alkyl acrylamides (where alkyl chain length>C18) as alkylamines with>18 carbon atoms are not readily available. Besides, the method uses acryloyl chloride, which is an expensive and hazardous reagent and requires disposal of large quantities of chloride as waste.
Methods of type (2) suffer from the drawbacks of high temperatures, high vacuum and tedious work up procedures. This method is also applicable generally to only alkyl amides with small alkyl chain lengths. The reaction of olefins with nitriles is the most suitable general method for the synthesis of N-alkyl acrylamides and has been widely practiced. However, this method is restricted by the availability of suitable iso-olefins (isobutylene, 2,4,4-trimethyl-1-pentene etc) with carbon numbers less than eight or twelve.
It is therefore important to devise methods for the synthesis of N-alkylacrylamides which overcome the disadvantages of the prior art discussed above as well as create new N-alkylacrylamides in view of their growing importance in various fields of technology.
OBJECTS OF THE INVENTION
The main object of the invention is to provide a method for the preparation of N-poly(alkenyl) acrylamides which overcomes the disadvantages of prior art discussed above.
It is another object of the invention to provide novel N-poly(alkenyl) acrylamides with a wide range of applications.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides novel N-poly(alkenyl) acrylamides having formula (I)
wherein m=1-8, n=2-100.
The compounds of formula (1) are obtained by the reaction of an unsaturated poly(olefin) of the formula C n H 2m where n=2-200 and m=1-8, with acrylonitrile in presence of an acid catalyst.
The present invention also provides a process for the preparation of N-poly(alkenyl) acrylamides of formula (1)
wherein m=1-8, n=2-100, which comprises reacting a vinylidene terminated poly(α-olefin) with acrylonitrile in presence of an acid catalyst at 50-75° C., in a solvent if Mn<1000, and for a period ranging between 1-12 hours to obtain the desired product and separating the product from the reaction mixture.
In one of the embodiments of the present invention, vinylidene terminated poly(α-olefin) has a general formula C n H 2m wherein m=1-8, n=2-100 and are prepared by the polymerization of α-olefins using an organometallic catalyst system.
In another embodiment of the present invention, the acid catalyst includes but not limited to dilute sulfuric acid, dilute phosphoric acid, dilute hydrochloric acid and mixtures of concentrated sulfuric acid (98%) and acetic acid.
In yet another embodiment a solvent may be needed if Mn<1000.
In a feature of the present invention, the convention method used for separating the product is filtration.
Yet another embodiment of the invention involves preparation of N-poly(alkenyl) rylamides a polymerizable macromonomer, containing a hydrophobic alkyl group and a drophilic amide group in the same molecule.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides novel N-poly(alkenyl) acrylamides having formula (I)
wherein m=1-8, n=2-100. In accordance with the process of the invention, the compounds of formula (1) are obtained by the reaction of an unsaturated poly(olefin) of the formula C n H 2m where n=2-200 and m=1-8, with acrylonitrile in presence of an acid catalyst. The process of the invention comprises reacting a vinylidene terminated poly(α-olefin) with acrylonitrile in presence of an acid catalyst at 50-75° C., in a solvent if the Mn of the polyolefin is <1000, and for a period ranging between 1-12 hours to obtain the desired product and separating the product from the reaction mixture. The preferred method of separation is by filtration.
The vinylidene terminated poly(α-olefin) has a general formula C n H 2m where m=1-8 and n=2-100 and are prepared by the polymerization of α-olefins using an organometallic catalyst system.
The acid catalyst used in the process of the invention includes but is not limited to dilute sulfuric acid, dilute phosphoric acid, dilute hydrochloric acid and mixtures of concentrated sulfuric acid (98%) and acetic acid. As explained above if the Mn of the polyolefin is <1000, a solvent such as chlorobenzene is used.
The N-poly(alkenyl) acrylamides contains a hydrophobic alkyl group and a hydrophilic amide group in the same molecule.
The process for the present invention is described herein below with examples which are illustrative and should not be construed to limit the scope of the invention in any manner.
All manipulations with the metallocene catalysts were carried out in a glove box under nitrogen, and high vacuum techniques were used where appropriate. Oligomerization of hexene-1 used in the examples was carried out using Cp 2 ZrCl 2 /MAO catalyst at different temperatures according to prior art methods (carbon numbers 20-500). Oligomers of poly(hexene-1) with Mn varying from 500-10000 were obtained with variation in polymerization temperature from 50 to −20° C. The number average molecular weight of poly(1-olefin) was measured by VPO as well as from NMR. The number average degree of Functionality (Fn) of terminally unsaturated poly(1-olefin) was measured by the ratio of the number average molecular weight of poly(1-olefin) from VPO by the number average molecular weight of poly(1-olefin) from NMR.
The reaction of vinylidene terminated poly(hexene-1) with acrylonitrile was carried out by a solvent free method for low molecular weight oligomers (Mn<1000). However, for higher molecular weight polymers, the reaction was carried out in chlorobenzene.
The number average degree of Functionality (Fn) of N-poly(alkenyl) acrylamide was measured by the ratio of the number average molecular weight (Mn) of N-poly(alkenyl) acrylamide from VPO by the number average molecular weight of N-poly(alkenyl) acrylamide measured by 1 H NMR. Structural analysis was carried out by both 1 H and 13 C NMR. The peaks due acrylamide group were observed at 6.2, 5.5 and 5.2 ppm for the corresponding protons of CH 2 , CH and NH respectively in 1 H NMR.
EXAMPLE-1
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 5.2 g (0.1 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature. After the addition, temperature was increased to 75° C., followed by addition of 3.8 g (0.01 mol) of liquid oligomer of poly(hexene-1) (Mn=380) from dropping funnel. The addition was continued for a period of 1 hour. After the addition, the reaction was continued for a period of 12 hours. The reaction was worked up by addition of 10-15 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 4.2 g of a viscous liquid. The number average molecular weight analysis of the product by VPO showed a value of 440. The number average degree of functionality (Fn) was found to be 90 mol %.
EXAMPLE-2
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 5.2 g (0.1 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature. After the addition, temperature was increased to 75° C., followed by addition of 5.5 g (0.01 mol) of liquid oligomer of poly(hexene-1) (Mn=550) from dropping funnel. The addition was continued for a period of 1 hour. After the addition, the reaction was continued for a period of 12 hours. The reaction was worked up by addition of 10-15 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 6.0 g of a viscous liquid. The number average molecular weight analysis of the product by VPO showed a value of 630. The number average degree of functionality was calculated as 85 mol %.
EXAMPLE-3
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 2.6 g (0.05 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature. After the addition, temperature was increased to 75° C., followed by addition of 5.0 g (0.005 mol) of liquid oligomer of poly(hexene-1) (Mn=1000) from dropping funnel. The addition was continued for a period of 1 hour. After the addition, the reaction was continued for a period of 12 hours. The reaction was worked up by addition of 10-15 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 5.4 g of a viscous liquid. The number average molecular weight analysis of the product by VPO showed a value of 1080. The number average degree of functionality (Fn) was found to be 80 mol %.
EXAMPLE-4
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 2.6 g (0.05 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature and temperature was increased to 75° C. Approximately 9.9 g (0.0055 mol) of liquid oligomer of poly(hexene-1) (Mn=1800) dissolved in 50 mL of chlorobenzene (as it was not free flowing liquid) was added drop wisely to the 250 mL round bottom flask. The addition was continued for a period of 1 hour. After the addition, the reaction was continued further for a period of 12 hours. The reaction was worked up by addition of 40-50 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 9.2 g of a viscous liquid. The number average molecular weight analysis of the product by VPO showed a value of 1860. The number average degree of functionality was calculated as 62 mol %.
EXAMPLE-5
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 1.3 g (0.025 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature and temperature was increased to 75° C. Approximately 7.0 g (0.0025 mol) of liquid oligomer of poly(hexene-1) (Mn=2800) dissolved in 50 mL of chlorobenzene (as it was not free flowing liquid) was added drop wisely to the 250 mL round bottom flask. The addition was continued for a period of 1 hour. After the addition, the reaction was continued further for a period of 12 hours. The reaction was worked up by addition of 40-50 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 7.1 g of a viscous liquid. The number average molecular weight analysis of the product by VPO showed a value of 2860. The number average degree of functionality was calculated as 50 mol %.
EXAMPLE-6
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 0.65 g (0.0125 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature and temperature was increased to 75° C. Approximately 4.3 g.(0.001 mol) of liquid oligomer of poly(hexene-1) (Mn=4300) dissolved in 25 mL of chlorobenzene (as it was not free flowing liquid) was added drop wisely to the 250 mL round bottom flask. The addition was continued for a period of 1 hour. After the addition, the reaction was continued further for a period of 12 hours. The reaction was worked up by addition of 40-50 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 4.0 g. The number average molecular weight analysis of the product by VPO showed a value of 4340. The number average degree of functionality was calculated as 36 mol %.
EXAMPLE-7
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 0.65 g (0.0125 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature and temperature was increased to 75° C. Approximately 7.0 g (0.001 mol) of liquid oligomer of poly(hexene-1) (Mn=6900) dissolved in 50 mL of chlorobenzene (as it was not free flowing liquid) was added drop wisely to the 250 mL round bottom flask. The addition was continued for a period of 1 hour. After the addition, the reaction was continued further for a period of 12 hours. The reaction was worked up by addition of 40-50 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 6.9 g. The number average molecular weight analysis of the product by VPO showed a value of 6980. The number average degree of functionality was calculated as 33 mol %.
EXAMPLE-8
A two necked round bottom flask, fitted with a dropping funnel and reflux condenser was charged with 0.65 g (0.0125 mol) of acrylonitrile and 70% H 2 SO 4 (2 mL) at room temperature and temperature was increased to 75° C. Approximately 10.0 g (0.001 mol) of liquid oligomer of poly(hexene-1) (Mn=10080) dissolved in 50 mL of chlorobenzene (as it was not free flowing liquid) was added drop wisely to the 250 mL round bottom flask. The addition was continued for a period of 1 hour. After the addition, the reaction was continued further for a period of 12 hours. The reaction was worked up by addition of 40-50 mL of distilled water and both organic and aqueous layers were transferred into a separating funnel. The product was extracted with diethyl ether to obtain a yield of 9.8 g. The number average molecular weight analysis of the product by VPO showed a value of 12280. The number average degree of functionality was calculated as 29 mol %. | The present invention relates to novel N-Poly (alkenyl) acryl amides of formula (1) where in m=1-8, n=2-100
and to a process for preparation thereof and process for preparation thereof by reacting an unsaturated poly(olefin) of the formula C n H 2m where n and m are as given above with acrylonitrile in presence of an acid catalyst. | 2 |
FIELD OF THE INVENTION
The present invention relates to diaphragm-type flush valves for use in a toilet room on either a commode or a urinal, and particularly to the bypass orifice and filter used to control the flow of water from the flush valve inlet to the chamber above the diaphragm. Specifically, the present invention relates to a filter which may be attached to the orifice member and which has a plurality of openings, each of which is smaller in its minor dimension than the metering restriction in the orifice member so that any particle that passes through the filter will also pass through the metering orifice.
THE RELATED PRIOR ART
U.S. Pat. No. 3,656,499, owned by Sloan Valve Company of Franklin Park, Ill., the assignee of the present application, shows a diaphragm-type flush valve having a bypass orifice in the flush valve diaphragm. This product is sold by Sloan Valve Company under the trademark ROYAL.
U.S. Pat. No. 4,261,545, also owned by Sloan Valve Company, shows a piston-type flush valve and a bypass orifice and filter for such a flush valve. This product is sold by Sloan Valve Company under the trademark CROWN.
SUMMARY OF THE INVENTION
The present invention relates to flush valves of the type found in a toilet room on either a commode or urinal and more specifically to a bypass orifice filter for use in a diaphragm-type flush valve.
A primary purpose of the invention is to provide a bypass orifice and filter in which the openings in the filter are individually smaller than the restriction in the bypass orifice to prevent the orifice from clogging due to particles within the water.
Another purpose is to provide a bypass orifice of the type described in which the metering restriction in the orifice member may be of varying size depending upon the desired amount of water flow through the flush valve during each operation thereof.
Another purpose is a bypass orifice filter for the use described in which the filter prevents clogging of the bypass orifice metering restriction.
Other purposes will appear in the ensuing specification, drawings and claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is illustrated diagrammatically in the following drawings wherein:
FIG. 1 is a side view, in part section, of a diaphragm-type flush valve;
FIG. 2 is a top view of the filter element;
FIG. 3 is a side view of the filter element;
FIG. 4 is a side view, in part section, showing the filter element connected to the orifice member;
FIG. 5 is an axial section through the orifice member;
FIG. 6 is a bottom view of the orifice member of FIG. 5;
FIG. 7 is a side view, in part section, showing a second embodiment of the invention;
FIG. 8 is a top section of the filter element and orifice member of FIG. 7;
FIG. 9 is a side view of a third embodiment of the invention;
FIG. 10 is a top section of the filter element and orifice member of FIG. 9;
FIG. 11 is side view, in part section, of a fourth embodiment of the invention; and
FIG. 12 is a top section of the filter element and orifice member of FIG. 11;
DESCRIPTION OF THE PREFERRED EMBODIMENT
Sloan Valve Company of Franklin Park, Ill., assignee of the present application, manufactures and sells a diaphragm-type flush valve under the trademark ROYAL. This is the most widely used flush valve for commercial toilet rooms in the United States. A diaphragm-type flush valve requires a bypass to connect the water inlet with the chamber above the flush valve diaphragm, as pressure in this chamber is what causes the diaphragm to move to its valve closing position. The present invention provides a combination bypass orifice and filter, with the filter having openings therein sized to prevent clogging of the metering restriction in the bypass orifice.
In the drawings, the flush valve body is indicated generally at 10 and has a water inlet 12 and a water outlet 14. The flush valve has a diaphragm assembly 16 which includes a flexible diaphragm 18 clamped about its periphery between an internal cover 20 and a shoulder 22 formed in the flush valve body 10. A guide member 24 is attached to the diaphragm and extends within a barrel 26 of the flush valve, the barrel forming a passage between the inlet and the outlet. At the top of the barrel there is a seat 28 upon which the diaphragm assembly closes.
The diaphragm is provided with a central opening 30 within which is positioned a relief valve 32, the lower end of which, indicated at 34, is positioned for contact by plunger 36. As is well known in the art, plunger 36 is operated by movement of handle 38. The description and function of the flush valve are more fully described in the above-identified United States patent.
A bypass orifice and filter element is indicated generally at 40 in FIG. 1 and is formed of two separate parts. There is an orifice member 42 and a filter element 44. Orifice member 42 has a central passage 46 terminating in a metering orifice 48 at its upstream end. The exterior of orifice member 42 has a shoulder 50 which is positioned on top of diaphragm 18 when the orifice member is mounted therein. Note particularly FIG. 4. A cylindrical outer portion 52 of the orifice member fits within an opening 54 in the diaphragm and the orifice member has a tapered end section 56 which cooperates with mating portions of the filter element for attachment of the two parts. There is an annular tapered recess 58 on the orifice member which is just above a slanted or tapered outer surface 60.
The filter element includes a solid bottom 62 and a plurality of upstanding arms 64, each of which terminates in an inwardly-directed hook portion 66. As particularly shown in FIG. 4, to attach the filter element to the orifice member, the flexible arms 64 of the filter element will bend outwardly until the hooks 66 can be positioned within annular recess 58 on the exterior of the orifice member. The two elements are then joined together. Normally, the orifice member will first be positioned within the diaphragm and then the filter element will be attached to the upstream end of the orifice member such that the upper surface 68 of each arm 64 is positioned against the lower surface of diaphragm 18.
In between each of the axially-extending arms 64 of the filter element there is a gap 70 which extends from the solid bottom 62 of the filter element and terminates at slanted surface 60 of the orifice member. The width of each of the gaps 70, as particularly shown in FIG. 2, is less than the smallest diameter or smallest dimension of the metering restriction 48. Thus, any particles which will pass through the gaps 70 will pass through the metering restriction. The filter, therefore, prevents any clogging of the bypass orifice.
The metering restriction 48 may be of several different sizes, depending upon the desired volume of water used to flush a particular toilet device. The bypass orifice determines the rate at which water flows into the chamber 72 above diaphragm 18 and it is water pressure within this chamber which causes the diaphragm to close on seat 28, thus terminating operation of the flush valve. The faster water flows through this orifice, the quicker the diaphragm will close and the less water will pass through for a particular flushing operation. However, regardless of the size of the metering restriction 48, the smallest dimension of gap 70 will always be less than the metering restriction 48 so that the filter will stop any particle which might otherwise tend to clog the metering restriction.
The gaps 70 provide a substantial passage for the flow of water and thus will not in any sense restrict the flow of water through the bypass orifice. Even if there is a slight clogging of one portion of one of the gaps 70, the total area for water flow is substantially greater than that of the metering restriction 48.
In the embodiment of FIGS. 7 and 8, the bypass orifice and filter are combined into a single element 80 which has an upper flange 82 which overlies the flush valve diaphragm 18. There is an opening 84 in the flange which functions as the bypass orifice. Member 80 has a lower cylindrical section 86 with a plurality of outwardly-extending radial projections 88. The cylindrical portion 86 is centered within the opening in the diaphragm by a retainer 90 having a lower flange 92 which lies against the underside of the diaphragm and an upwardly, inwardly directed group of spaced projections 94 which retain the element 80 in the position shown in FIG. 7. The projections 88 which bear against the inside of retainer 90 maintain concentricity of the cylindrical portion 86 and the space between the cylindrical portion 86 of element 80 and the inside surface 96 of retainer 90, through which water will pass, is smaller in radial dimension than the diameter of bypass orifice 84. Thus, any particle which will pass through the filter comprised of the circumferential spaces between the exterior of cylindrical portion 86 and the inner surface 96 of the retainer will also pass through bypass orifice 84.
In the embodiment of FIGS. 9 and 10, the bypass orifice and filter element 100 has an upper flange 102 which again overlies the flexible diaphragm 18. The orifice is indicated at 104 and the member 100 has a cylindrical portion 106 which will be concentrically spaced within the opening in the diaphragm by a retainer 108. Retainer 108 has a plurality of inwardly-directed projections 110 which will bear against a smaller cylindrical portion 112 of the member 100, thereby retaining member 100 in a concentric position such that the exterior gap between cylindrical portion 106 and the inside surface of retainer 108 is uniform. This space, indicated at 114, will have a smaller radial dimension than the diameter of bypass orifice 104, again so that any particle which will pass through the filter, which is space 114, will also pass through the bypass orifice.
In the embodiment of FIGS. 11 and 12, the combined bypass orifice and filter element is indicated at 120 and includes a flange 122 and a bypass opening 124. There is a cylindrical portion 126 of the member 120 which has an exterior grooved surface, as illustrated particularly in FIG. 12. The grooves 128 may be uniformly arranged about the periphery of the cylindrical portion 126. A retainer 130 having inwardly-directed arms 132 will be used to center the member 120. However, it should be noted that the exterior of cylindrical portion 126 will be in spaced contact with the interior of retainer 30 between each of the spaced grooves 128. Again, the size of the grooves 128 will be such that any particle which would pass through the grooves would also pass through the bypass orifice 124.
Whereas the preferred form of the invention has been shown and described herein, it should be realized that there may be many modifications, substitutions and alterations thereto. | A bypass orifice and filter for use in the diaphragm of a toilet room flush valve includes an orifice member adapted to be mounted in the flush valve diaphragm, and a filter element attached to the upstream side of the orifice member. The orifice member has a metering restriction to limit the flow of water therethrough and the filter element has a plurality of openings therein in communication with the orifice member metering restriction. The smallest dimension of the openings in the filter element are less than the smallest dimension of the metering restriction so that any particle in the water passing through the filter element will pass through the metering orifice. In some embodiments the orifice member and filter element are an integral unit. | 4 |
This invention relates to a new rapid method of production for cured thermosetting resinous fibers.
The term cured thermosetting resinous fibers is meant to include fibers formed of such thermosetting resinous or polymeric materials as represented by phenol formaldehyde and other phenol-aldehyde resins, melamine and urea formaldehyde resins, epoxy resins and the like. It is understood that these resins form the principal constituent of the fiber but that other important constituents may be present such as polyamides (nylon 6,6) in the case of the phenol formaldehyde resin fiber.
Procedures for conversion of phenolic novolac resins into cured fibers are well-known. U.S. Pat. No. 3,650,102 describes such a fiber forming process. It is most desirable to manufacture phenolic resin fibers beginning with novolac phenolic resins, i.e., those phenolic resins manufactured from phenol and formaldehyde wherein excess phenol is used. The novolac resins are preferred due to their ease of manufacture and control and in addition, it is somewhat easier to cure novolac resins in the fiber form. In the fiber forming process described by U.S. Pat. No. 3,650,102, a phenolic novolac resin in a thermoplastic state (A or B stage) is reduced to a molten or plastic stage and formed into fibers by a conventional fiberizing technique, e.g., melt spinning. The novolac fibers are then converted to the cured, infusible, stage by heating the fibers, preferably in the presence of formaldehyde and an acid catalyst. These constituents diffuse into the fiber, and with proper temperatures and times, advance the molecular weight of the novolac and crosslink the molecules to obtain infusible, cured phenolic fibers.
This method of manufacture of phenolic resin fibers takes considerable time, generally running from 6 to 16 hours, from the time the process begins until the cured phenolic resin fiber is obtained.
A more rapid method of manufacture of phenolic resin fibers has been described in U.S. Pat. No. 4,076,792. In this invention, uncured novolac resin is blended with 3 to 12 percent by weight of a novolac crosslinking agent from the group consisting of hexamethylenetetramine and/or paraformaldehyde. This blending is accomplished in a commercial blending apparatus, such as a ball mill. The resin which is to be fiberized is melted just prior to the fiberizing process, that is, the time between melting and fiberizing is generally from about 1 to 15 seconds. The quick fiberizing is required in order to avoid premature curing. In a particular method of fiber forming the resin particles blended with crosslinking agent is centrifugally forced through orifices in a cylinder which is heated sufficiently rapidly to melt the resin. The cylinder is rotated at sufficient speed to cause fibers to be pulled through the orifices by centrifugal force. As an example of such a process described in U.S. Pat. No. 4,076,692, utilization is made of a cotton candy machine to provide for the fiberizing by centrifugal force. All other examples, including that of the application of centrifugal force are suited only for the production of blown or short, discontinuous fibers.
Upon forming the fibers, they are rapidly cured by heating in an acidic vapor at from about 20° C. to above 300° C. and at from about 1 to about 10 atmospheres of pressure. The curing time for complete cure of the fibers is less than 10 minutes and usually less than 5 minutes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram for the formation of continuous fibers.
FIG. 2 is a flow diagram for the formation of discontinuous fibers.
BRIEF DESCRIPTION OF THE INVENTION
This invention described here is a process for continuous rapid production of continuous or blown (short, discontinuous) cured thermosetting resinous fibers, such as phenol formaldehyde resinous fibers. An uncured novolac resin preblended with from about 3 to 15 weight percent of a novolac crosslinking agent desirably selected from the group consisting of hexamethylenetetramine and paraformaldehyde, is continuously melted in an extruder (single or twin screw). The blend is fed through the extruder at a temperature of from about 95° to 150° C. Other additives (e.g., additional curing agent or solvent) may be added between the feed section and extruder output end or die section. The blended phenolic resin is discharged into a gear pump to which the spinnerette is attached and the temperature of the metal is maintained from about 95° to 150° C. while the blended resin is fiberized by melt spinning or solution spinning if solvent is added during the mixing and extrusion. The uncured fibers emerging from the die are cured by contacting them with acidic vapor and/or formaldehyde at from about 20° to about 300° C. and from 1 to about 10 atmospheres of pressure until desired degree of curing is obtained.
DETAILED DESCRIPTION OF INVENTION
In order to continuously form a phenolic resin novolac containing curing agent into a thermosetting fiber, it must be able to be extruded through a die or spinnerette before significant crosslinking or curing results. This requires control of the novolac characteristics as well as the temperature and time history of the novolac from the time it enters the extruder or other suitable mixing device until it is extruded through the orifices of the die or spinnerette.
Novolac resins which may be used in the practice of this invention are well known to the skilled in the art and are readily available commercially. In general, such novolac resins are thermoplastic soluble phenol-aldehyde resins in which the phenol and aldyhyde are polymerized in the presence of an acid catalyst and/or with an excess phenol.
The most desirable type of phenolic resin for fiber formation from a commercial standpoint, due to its ease of formation and availability, is a novolac formed from phenol and formaldehyde wherein excess phenol is used. Crosslinking agents which may be used in conjunction with the uncured novolac to form a novoloid are hexamethylenetetramine (hexa), paraformaldehyde and cyclic formals, such as dioxolanes and dioxanes. The preferred crosslinking agents are hexa and paraformaldehyde.
Those novolac resins which are particularly suitable for use in accordance with this invention provide maximum curing times at necessary extrusion temperatures and provide reasonable viscosities for fiberizing at the lowest temperatures possible so as to lengthen curing times. Thus, novolac resins having number average molecular weights ranging from 300 to 800, preferably 300 to 500 gm/gm. mole, and melting points between 90° and 110° C. are preferred. In addition, moisture contents should be controlled so as to increase curing times and control viscosity and should be less than 1 percent, preferably less than 0.3 percent.
The blending of the uncured novolac resin with the crosslinking agent can be done in any commercial blending apparatus, such as a ball mill. This blended resin is fed into the hopper or feed section of an extruder, preferably a twin screw extruder. Alternately, the novolac by itself can be fed into the feed section of an extruder and the curing agent by itself or in a high concentration in the novolac can be fed downstream through an opening in the extruder. This latter technique reduces the residence time in the extruder for the blended material at elevated temperature and extends the total working time available for fiber forming without curing of the resin. When hexa is used, as representative of such crosslinking agents, the amount employed is generally in the range of 3 to 15 percent by weight of the resin. When the crosslinking agent is paraformaldehyde, it is preferred to make use of between 3 and 10 percent by weight.
The blended resin is maintained at constant temperature in the extrusion device through fluid temperature control of the barrel and screw, or screws, in the case of a twin screw extruder. The temperature of the molten phenolic resin is preferably maintained at a temperature between 110° C. and 130° C. as it is conveyed towards the exit end of the extruder. A filter can be provided at the exit end of the extruder from which the molten resin is fed directly into a gear pump in order to control the flow and pressure of the polymer as it enters the spinnerette. The molten phenolic resin which is conveyed by the gear pump to the spinnerette is maintained at a temperature between 110° and 130° C., dependent somewhat on the novolac molecular weight and hexa content, to prevent curing of the resin as it flows through the orifice.
In addition to controlling the resin viscosity by temperature, moisture content, resin molecular weight and hexa content, a compatible solvent or plasticizer can be blended into the molten phenolic resin as it is conveyed through the extruder. For example, solvents such as cyclohexanone, p-xylene or acetone can be pumped into the extruder, or plasticizers such as glycerol monostearate or various phthalate esters can be pumped into the extruder for admixture with the molten resin. The addition of solvents or plasticizers reduces the viscosity and allow the extrusion and fiberizing to be conducted at lower temperatures, with corresponding increase in the curing times or to delay cure. The addition of solvents, blended through the extruder, enables the fiber to be formed by a solution spinning rather than melt spinning, although the gear pump and spinnerette are still utilized.
After the fibers are formed, they are cured by contacting them with an acidic gas or vapor at from about 20° to about 300° C. and at from about 1 to about 10 atmospheres of pressure. The acidic gas may either be the gas of a conventional hydrogen containing acid such as HCl, HBr or a Lewis acid such as BF 3 . Cure should be carried out at a temperature above about 100° C. but below decomposition temperature of the organic resinous component. The most desirable curing temperature is between about 100° and 250° C. so that a rapid complete cure is obtained in minimal time while decomposition and undesirable melting of the resin is avoided. The curing time for complete cure of the fibers will be less than 10 minutes.
In addition to heating the fibers in an atmosphere of acidic gas or vapor to cause cure without fiber fusion, the fibers may be heated in the presence of formaldehyde or paraformaldehyde vapors with an acid catalyst to also cause rapid curing of the surface and stabilization of the fiber prior to complete curing of the fiber cross-section. In this manner, the fiber surface chemistry is also altered by increasing the concentration of methylol groups due to reaction with excess formaldehyde. Without the formaldehyde cure, crosslinking occurs by methylene bridges in the case of the hexa cured material. Thus, the fiber surface chemistry can be altered by the final method of cure. This is significant with respect to the ability of the fiber to serve as a reinforcement for various other materials, such as plastics, rubber, cement, etc.
In accordance with the practice of this invention, either continuous fibers or blown short fibers can be equally produced. In the case of continuous fibers, the emerging fiberized novolac is taken up on textile winding equipment and strands are formed with the number of filaments per strand depending on the number of orifices in the spinnerette. Blown fibers can be prepared by blasting the molten resinous material with a high velocity heated air or gas stream as it issues from the spinnerette whereby the resinous material is drawn into filaments and broken into short fibers.
When a plasticizer or particularly a solvent is added to the phenolic novolac, the solvent is primarily evaporated from the fiber prior to complete cure. The curing of the fiber is accomplished as described above and it is desirable to remove the solvent prior to complete cure when the diffusion rates are still acceptable. This can be accomplished by slightly reducing the cure temperatures and extending the cure times.
When the novolac is preblended with a curing agent, curing will proceed unless temperatures and times are accurately controlled during the extrusion and spinning process. It is desirable though not essential in such case to minimize the contact of the molten polymer stream with the walls of the orifices in the spinnerette. This can be accomplished by the use of ultrasonic vibration of the spinnerette in a frequency range of 10,000 Hz to 30,000 Hz. Small amplitude vibrations at high frequencies will minimize the coefficient of friction, thus heat build up as well, and will also minimize the contact between the polymer and orifice wall. Another design change is to use a sintered metal to form the orifice wall and to force an inert gas (e.g., nitrogen or argon) through the orifice wall so as to create a pressure inside the orifice. Thus, the molten novolac will flow through each orifice but will be compressed so as to reduce its tendency to contact the orifice wall. This technique can also include the use of acidic gases rather than inert gases so as to stabilize or cure the fiber surface as it passes through the spinnerette. Furthermore, formaldehyde solutions can be pumped through the spinnerette for the same purpose.
EXAMPLES
EXAMPLE 1
A novolac resin (Monsanto Resinox 754) having an average particle size smaller than 200 mesh is blended with about 8 percent of hexamethylenetetramine in an extruder 10. This resin is first dried in a drier 12 to a moisture content of less than 0.3 wt. percent and fed into a twin screw extruder 10 (Werner-Pfleiderer, ZSK-53) having a filter at the exit and whereby the resin is melted and conveyed to a gear pump 14 at a temperature of 120° C. The resin is metered to the gear pump and then extruded through the spinnerette 16 at a temperature not exceeding 125° C. The resulting fibers 18 are exposed to a cure chamber 20 to 100 percent BF 3 gas at a maximum temperature of 180° C. at a pressure of 1 atmosphere until cured. The resulting fibers which are completely cured in 10 minutes are wound upon a reel 22.
EXAMPLE 2
The novolac resin from Example 1 is fed into the extruder without having been preblended with hexa. Upon melting of the novolac at a temperature of 125° C. in the extruder, the hexa is metered into the extruder to be mixed with the melted novolac. The metering is adjusted to provide a hexa content of 10 wt. percent. The resin is filtered and metered to the gear pump at a temperature not exceeding 125° C. Fibers are formed and cured as in Example 1.
EXAMPLE 3
An oxalic acid catalyzed novolac resin (Durez 31044) having an average particle size smaller than 200 mesh is dried to a moisture content less than 0.3 wt. percent. This resin is fed into the extruder and heated to a temperature of 120° C. Cyclohexanone solvent (10 wt. percent) is pumped into the extruder and mixed with the molten polymer to reduce its viscosity. This polymer is fed to the spinnerette as in Example 1. The fibers are maintained at 100° C. for from 5 to 10 minutes to aid in the solvent evaporation and then fully cured according to Example 1 in less than 10 minutes.
EXAMPLE 4
An oxalic acid catalyzed novolac resin as in Example 1, is delivered to the spinnerette. Upon emerging from the spinnerette, the molten resin is blasted by a stream of air issuing from nozzles 30 at a temperature of about 100° C. whereby the molten resin is attenuated into fine discontinuous fibers 32 which are collected as a felt 36 on a moving belt 35 at the bottom of a curing chamber 20. The fibers have an average length of less than 1/2 inch. The fibers are cured in the presence of 100 percent BF 3 gas or HCl gas at a pressure of 1 atmosphere and at a maximum temperature of 180° C. Complete cure occurs in less than 10 minutes. | The preparation of cured thermosetting resinous fibers for extruding a dried novoloc resin in admixture with a crosslinking agent to a gear pump having a spinnerette connected thereto for issuance of the molten resin from the spinnerette into an atomsphere of an acid gas for cure of the resinous fibers issuing from the spinnerette. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor memory device in which the selective operation of a memory cell block selected from a plurality of memory cell blocks can be carried out. The device according to the present invention is applicable to, for example, a dynamic random access memory.
2. Description of the Related Arts
In the prior art semiconductor memory device, a memory cell array is sometimes constituted by a plurality of memory cell blocks.
In such device, it is possible to keep the memory cell blocks which do not include the selected word line in the inactive state so that the consumption of electric power of the device is reduced.
However, in the above-described prior art device, only some of the memory cell blocks are kept in the inactive state due to a non-selection thereof, and the clock generator which is provided in common for the plurality of memory cell blocks is always in operation to supply clock signals such as word line activation clock signal to all of the plurality of memory cell blocks. Hence, the reduction of the electric power consumption is not satisfactorily attained in such a prior art device.
Particularly, in a large capacity semiconductor memory device having a chip size of the order of 10 mm 2 or more, the length of the wiring for transmitting clock signals becomes large, and accordingly, the parasitic capacitance of the wiring becomes large, so that a high speed operation of the device is difficult to attain. Also, the consumption of electric power becomes large, and an IR drop caused by the resistance of the wiring becomes significant.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved semiconductor memory device in which the capacitance of the wirings is reduced so that the charge/discharge current of the wirings is reduced, the CR value of the wirings is reduced so that the operation speed of the device is enhanced, and only one clock generator and the corresponding memory cell block is required to be operated, so that the consumption of electric power is reduced.
According to the present invention, there is provided a semiconductor memory device including a memory cell array constituted by a plurality of memory cell blocks, each of the memory cell blocks being operatively connected with a row decoder and a column decoder; a clock generator unit constituted by a plurality of clock generator sections, each of the clock generator sections corresponding to each of the memory cell blocks; and a block selector unit for selecting one of the clock generator sections in correspondence with the row address of a designated address. Accordingly, only a clock generator section corresponding to the selected memory cell block is operated by the designated address.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIGS. 1a and b show a prior art semiconductor memory device;
FIG. 2 shows the structure of the clock generator in the device of FIG. 1;
FIGS. 3a and b show a semiconductor memory device according to an embodiment of the present invention;
FIG. 4 shows the structure of the clock generator in the device of FIG. 3;
FIG. 5 shows the structure of the block selector in the device of FIG. 3;
FIG. 6 shows the structures of the row decoder and word driver in the device of FIG. 3;
FIGS. 7a and b show a modified embodiment of the present invention; and
FIGS. 8a and b show another modified embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before describing a typical embodiment of the present invention, a prior art semiconductor memory device is explained with reference to FIGS. 1 and 2. The structure of the clock generator in the device of FIG. 1 is shown in FIG. 2.
The device of FIG. 1 is constructed by a No. 1 memory cell block 11. No. 2 memory cell block 12, word drivers 411, 412, row decoders 421, 422, sense amplifier and input/output circuits 21, 22, column decoders 31, 32, clock generation portion 6 having an address drive generator 6A, block selector 6B, clock generator 6C, write clock generator 7, data input buffer 81, and data output buffer 82.
The clock generation portion 6 receives a chip activation signal S(CE), and a clock signal S(AD) from the clock generation portion 6 is supplied to the address buffer 52. The external address bits A 0 , A 1 , A 2 ,. . . A n are latched in the address buffer 52. In the address buffer 52, the MOS level address bits a 0 , a 1 , a 2 , . . . a n and the inverted MOS level address bits a 0 , a 1 , a 2 , . . . a n are produced from the external address bits A 0 , A 1 , A 2 . . . A n , and the produced signals are supplied to the column decoders 31, 32 and the row decoders 421, 422.
The clock signal S(WD) for activating word lines from the clock generation portion 6 is supplied to the word drivers 411 and 412. The clock signal S(LE) for resetting bit lines from the clock generation portion 6 is supplied to the sense amplifier and input/output circuits 21 and 22, to precharge the bit lines.
The clock signal S(CD) for activating bit lines from the clock generation portion 6 is supplied to the column decoders 31 and 32. The write clock generator 7 supplies the write clock signal S(7) to the data input buffer 81 in response to the write enable signal S(WE). The input data D(IN) in the data input buffer 81 is supplied to the sense amplifier and input/output circuits 21 and 22 in accordance with the write clock signal S(7).
The clock generator 6C includes a sequence of buffers: BUFFER-1, BUFFER-2, BUFFER-3, . . . BUFFER-X. Each of the buffers produces a predetermined clock signal such as S(AD), S(WD), S(LE), S(OB) or the like with a predetermined delay time.
A semiconductor memory device according to an embodiment of the present invention is shown in FIG. 3. The structures of the clock selector and the block selector in the device of FIG. 3 are shown in FIGS. 4 and 5, respectively.
The semiconductor memory device of FIG. 3 is constructed from a No. 1 memory cell block 11, No. 2 memory cell block 12, word drivers 411, 412, row decoders 421, 422, sense amplifier and input/output circuits 21, 22, column decoders 31, 32, address drive generator 51, address buffer 52, block selector 53, No. 1 clock generator 61, No. 2 clock generator 62, write clock generator 7, data input buffer 81, and data output buffer 82.
The address drive generator 51 receives the chip activation signal S(CE), and the clock signal S(AD) from the address generator 51 is supplied to the address buffer 52. The external addresses bits A 0 , A 1 , A 2 . . . A n are latched in the address buffer 52. In the address buffer 52, the MOS level address bits a 0 , a 1 , a 2 , . . . a n and the inverted MOS level address bits a 0 , a 1 , a 2 , . . . a n are produced from the external address bits A 0 , A 1 , A 2 , . . . A n , and the produced signals are supplied to the column decoders 31, 32, and the row decoders 421, 422.
The clock signals S(WD) for activating word lines from the No. 1 clock generator 61 and the No. 2 clock generator 62 are supplied to the word drivers 411 and 412.
The clock signals S(LE) for resetting bit lines from the clock generators 61 and 62 are supplied to the sense amplifier and input/output circuits 21 and 22 to precharge the bit lines.
The clock signals S(CD) for activating bit lines from the clock generators 61 and 62 are supplied to the column decoders 31 and 32.
The write clock generator 7 supplies the write clock signal S(7) to the data input buffer 81 in response to the write enable signal S(WE). The input data D(IN) in the data input buffer 81 is supplied to the sense amplifier and input/output circuits 21 and 22 in accordance with the write clock signal S(7).
The block selector 53 receives the signal representing a portion of the row address, for example, the uppermost bit of the row address, delivered from the address buffer 52, and selects either the No. 1 clock generator 61 by signal S(φ 1 ) or the No. 2 clock generator 62 by signal S(φ 2 ) in correspondence with the information of the portion of the row address.
The No. 1 clock generator 61 produces the word line activation clock signal S(WD), the bit line resetting clock signal S(LE), and the bit line activation clock signal S(CD) for the No. 1 cell block 11. The No. 2 clock generator 62 produces the same signals as in the case of the No. 1 clock generator 61 for the No. 2 cell block 12.
The address drive generator 51 receives the chip activation signal S(CE) and delivers the clock signal S(AD).
In the operation of the device of FIG. 3, both the row decoders 412 and 422 are activated. However, only one of the word drivers 411 and 412 is activated in accordance with the selection between the No. 1 clock generator 61 and the No. 2 clock generator 62.
The structure of the No. 1 and No. 2 clock generators is shown in FIG. 4, and the structure of the block selector 53 is shown in FIG. 5.
As shown in FIG. 4, the No. 1 clock generator 61 includes the series connected buffers: BUFFER-2, BUFFER-3, BUFFER-4, and so on. Each of these buffers operates with a predetermined delay time. The No. 2 clock generator 62 includes similar series connected buffers.
As shown in FIG. 5, the block selector 53 is constructed from a series connection of a NAND gate and an inverter. One input terminal of the NAND gate receives the signal S(φ) from the address drive generator, while the other input terminal receives address bits a n and a n from the address buffer 52. The address bits a n and a n are the MOS level address bits converted from the external address A n . When A n is at a HIGH level, a n is at a HIGH level, and a n is at a LOW level. The selection signal S(φ 1 ) or S(φ 2 ) is delivered from one of the inverters of the block selector 53.
The characteristic of the capacitance distribution in the word driver 411 in the device of FIG. 3 will be explained with reference to FIG. 6, which shows the structures of the row decoder 421 and the word driver 411 in the device of FIG. 3. The word driver 411 is constructed from flip-flop circuits.
The signal S(WD1) and the signal S(WD2) are supplied as a power source voltage to one branch of the flip-flop circuits. The outputs of the row decoder 421 are supplied to the gates of the transistors in the one branch of the flip-flop circuits. The reset clock signals S(R1) and S(R2) are supplied to the gates of the transistors in the other branch of the flip-flop circuits.
In the word driver 411 of the device of FIG. 3, the portions l(1a) and l(2a) of the wirings l(1) and l(2) do not exist. Since there are no wirings of the portions l(1a) and l(2a), the parasitic capacitance of the entire wiring is reduced accordingly. Therefore, the entire parasitic capacitance of the wirings is reduced in the device of FIG. 3. Accordingly, the operation speed of the device is enhanced and the consumption of electric power is reduced in the device of FIG. 3.
Contrary to this, if the portions l(1a) and l(2a) exist as in the case of the prior art device, a considerably large parasitic capacitance of the wiring is formed, and this formed parasitic capacitance is added to the drain capacitances of the transistors of the flip-flop circuits in the word driver. This large capacitance requires a considerably large capacity of the power source, and constitutes a disadvantage of the prior art.
In the device of FIG. 3, the parasitic capacitances of the wirings for transmitting the signals S(WD), S(LE), and the like from the clock generators 61 and 62 (FIG. 4) are reduced, and thus the charge/discharge current is reduced, and the time of charge/discharge is reduced. Also, the capacity requirement for the buffers: BUFFER-2, BUFFER-3, etc., is reduced. Only one of the clock generators is required to operate so that the consumption of electric power is reduced.
Although a typical embodiment of the present invention is explained with reference to FIGS. 3 to 6 in which the division by 2 of the cell blocks is realized, other embodiments of the present invention are possible in which the division by 4, 8, 16, or the like of the cell blocks is realized.
Also, although the device of FIG. 3, the division is realized only in the row decoder side, it is also possible to realize the division not only in the row decoder side but also in the column decoder and input-output side. The clock generator should be divided in correspondence with such division in the column decoder and input-output circuit side.
A semiconductor memory device according to a modified embodiment of the present invention is shown in FIG. 7. The column decoder 30 is provided commonly for the No. 1 cell block 11 and the No. 2 cell block 12.
In the address buffer 52, the sequence of the non-inverted bit and the inverted bit a 0 , a 0 ; a 1 , a 1 ; . . . a n , a n is produced from the external address EA 0 , EA 1 , . . . EA n , and the uppermost bit a i , a i among the above-mentioned sequence is supplied to the block selector 53.
The clock signal S(φ 1 ) from the block selector 53 is supplied to the No. 1 clock generator 61, the clock signal S(φ 2 ) from the block selector 53 is supplied to the No. 2 clock generator 62, and the clock signal S(WD1) from the No. 1 clock generator 61 is supplied to the word driver 411. The clock signal S(WD2) from the No. 2 clock generator 62 is supplied to the word driver 412.
A semiconductor memory device according to another modified embodiment of the present invention is shown in FIG. 8. In the device of FIG. 8, the memory cell block is divided into m divisions along the row direction and n divisions along the column direction, to consequently attain mxn divisions.
The block selector 53 delivers the clock signals S(φ 11 ), S(φ 21 ), . . . S(φ m1 ); S(φ 12 ), S(φ 22 ), . . . S(φ m2 ); . . . S(φ 1n ), S(φ 2n ), . . . S(φ mn ) which are supplied to the clock generators No. 11, No. 21, . . . No. m1; No. 12, No. 22, . . . No. m2; . . . ; No. 1n, No. 2n, . . . No. mn. For example, the No. 11 clock generator delivers the signals for the No. 11 cell block, and the No. mn clock generator delivers the signal for the No. mn cell block. | A semiconductor memory device having a memory cell array constituted by a plurality of memory cell blocks includes a clock generator unit constituted by a plurality of clock generator sections, each of the clock generator sections corresponding to each of the memory cell blocks, and a block selector unit for selecting one of the clock generator sections in correspondence with the row address of a designated address. Accordingly, only a clock generator section corresponding to the selected memory cell block is operated by the designated address. | 6 |
FIELD OF THE INVENTION
This invention generally relates to continuous ink jet print heads, and is specifically concerned with the use of an interposer member between the manifold and the die of a continuous ink jet print head module that results in a more durable print head and facilitates both assembly and recycling of the print head components.
BACKGROUND OF THE INVENTION
Ink jet printing has become recognized as a prominent contender in the digitally controlled, electronic printing arena because, e.g., of its non-impact, low-noise characteristics, its use of plain paper and its avoidance of toner transfer and fixing, as well as its very fast printing speed. Ink jet printing mechanisms can be categorized by technology as either drop on demand ink jet or continuous ink jet.
The first technology, “drop-on-demand” ink jet printing, provides ink droplets that impact upon a recording surface by using a pressurization actuator (thermal, piezoelectric, etc.). Many commonly practiced drop-on-demand technologies use thermal actuation to eject ink droplets from a nozzle. A heater, located at or near the nozzle, heats the ink sufficiently close to its boiling point to form a vapor bubble that creates enough internal pressure to eject an ink droplet. This form of ink jet is commonly termed “thermal ink jet (TIJ).” Other known drop-on-demand droplet ejection mechanisms include piezoelectric actuators, thermo-mechanical actuators, and electrostatic actuators.
The second technology, commonly referred to as “continuous” ink jet printing, uses a pressurized ink source that produces a continuous stream of ink droplets from a nozzle. The stream is perturbed in some fashion causing it to break up into droplets at a nominally constant distance known as the break-off length from the nozzle. Control of these droplets can be either thermally-based or electrostatically-based. In thermally-based control, pulsed currents are applied to small, ring-shaped heating elements surrounding the nozzles to heat the ink passing through the nozzle region, and form ink droplets of different sizes. A pneumatic deflector generates a current of air which deflects the trajectory of the droplets so that the smaller droplets strike a printing medium, while the larger droplets strike a recycling gutter for collection and recirculation. In electrostatically-based control, a charging electrode structure is positioned at the nominally constant break-off point so as to induce a data-dependent amount of electrical charge on the drop at the moment of break-off. The charged droplets are directed through a fixed electrostatic field region causing each droplet to deflect proportionately to its charge such that some strike a recording medium while others strike a gutter for collection and recirculation.
The print heads of continuous ink jet printers generally comprise one or more printing modules, each of which includes a manifold having a slot-like opening for supplying a pressurized flow of ink, and a die mounted over the slot-like opening of the manifold. The manifold is precision-machined from a corrosion resistant metal, such as stainless steel, to tolerances better than 1/1,000 of an inch. The manifold has an elongated, generally rectangular face that includes the slot for conducting pressurized ink. The die is an elongated, rectangular plate of silicon which overlies the rectangular face of the manifold. It is precision fabricated to form a row of many small ink jet nozzles uniformly spaced apart at close intervals to achieve high resolution printing. Below each nozzle, a high aspect-ratio cavity is etched thru the thickness of the die so that pressurized ink can pass from the manifold through the cavity and out of each nozzle. In addition to the fabricated nozzles, the die can also include integrated micro-electronic circuitry. In the case of thermally-based control, such circuitry includes a circular micro heater around each nozzle, and an electrically conductive lead connected to each micro-heater that terminates in a metal pad on the other side of the die. Microwires are provided between each of the metal pads of the die to a corresponding metal pad on a flexible interconnect, which in turn is connected to the output of a control circuit of the printer.
For printing at 600 dots per inch (dpi), the nozzle-to-neighboring nozzle separation needs to be less than 43 micrometers. To print on a standard 8.5×11 inch media, the immobile ink ejecting print head can contain a single die that is 8.5″ long. Alternatively, printing may be from two dies each about 4.3″ long, or several shorter dies. Multiple dies need to be assembled end-to-end, usually in an offset manner, to form an 8.5″ long printing engine. It is difficult to fabricate 8.5″ silicon-based print head dies due to silicon wafer size limitations. On the other hand, in order to minimize the number of end-to-end assemblies, and to maintain quality control of individual dies, the use of a multitude of short dies is not preferred. One optimum compromise is to assemble two print head modules, each of which contains a 4.3″ long die. Two such modules can then be butted together to print onto 8.5″ wide media, or multiples of such modules can be lined up for printing even wider media. For 600 dpi printing applications, about 2600 nozzles are present in a 4.3″ long die. Full-size page printing needs two such modules for each color. Consequently, for full, four color printing (using black, magenta, yellow, and cyan inks), a minimum of eight modules are needed in a continuous ink jet printer.
During assembly of the die into a print head module, it is critical that the die containing the printing jets be precisely positioned on its respective manifold so that when the manifolds of two or more modules are mounted in end-to-end relationship in the print head housing, the spacing between the last ink jet on the die of one module is spaced about 43 microns from the first jet on the die of the abutting module. If the spacing between these two ink jets of the abutting modules varies substantially from 43 microns, either a light or dark streak artifact may occur in the printed product produced by the print head, depending upon whether these two ink jets are too far or too close to one another. The tolerance for such alignment has been examined by the applicant, and it has been found that if the nozzle misalignment is less than half the nozzle to nozzle separation, i.e. less than 21 micrometers, the resulting printing quality is acceptable, especially if some printing compensation procedure is used. For example, in a nozzle misalignment situation where the first and last nozzles are closer than 43 microns, a 25-50% decrease in ejected drop volume from these nozzles can be programmed in. Conversely, if the first to last nozzle misalignment is further than 43 micrometers, then a 25-50% increase in ejected drop volume is effective in masking printing artifacts. Hence the criteria for nozzle alignment tolerances are less than one half of the nozzle to nozzle separation distance.
It is, of course, highly desirable that the print head be durable and capable of as many hours of reliable operation as possible without servicing or replacement. Continuous ink jet print heads are almost exclusively used for long runs of high volume, commercial printing where the time and costs associated with print head replacement have a substantial impact on the expenses associated with such printing. At the same time, it is also highly desirable that the module be assembled in such a way as to allow the manifold to be recycled at the end of the service life of the print head, which may be several hundreds of hours. The manifold, being precision-machined out of stainless steel, is a relatively expensive component of the print head and has a potentially long service life. By contrast, the silicon die costs less than a tenth as much as the manifold, yet has a far shorter service life. While it is important that the die be mounted on to the surface of the manifold in such a way as to achieve a precise, secure and leak-proof bond during the service life of the die, it is equally important that the die be removable from the manifold at the end of the print head service life without damage to the manifold so that it can be re-used.
Finally, it is critical that the microwiring connecting the electrodes in the die to the pads of the integrated flexible interconnect be insulated from exposure to ink and mechanical shock which could interfere with the transmission of electrical control signals to the micro-heaters surrounding the dies.
To achieve all of the aforementioned assembly objectives of precise positioning, durability, die removability, and insulation of the microwiring between the die and the integrated control circuit, the silicon dies are usually bonded over the slot-like opening of the stainless steel manifold with ultra-violet or other room temperature curable epoxy adhesives. The curing of such epoxies does not significantly change the precise positioning between the die and the manifold, and can provide a reasonably secure and leak-proof bond. Such cured epoxies further allow the die to be easily removed from the manifold without damage by the application of localized heat to the die for a relatively short time. Finally, such epoxies can be easily be applied to form a “glop top” over the microwiring during assembly of the printing module that protectively encapsulates the microwiring connecting the die contact pads to the flexible interconnect contact pads.
While the use of room-temperature or ultra-violet cured epoxies results in a durable continuous ink jet print head that fulfills all of the aforementioned criteria, the bonds created by such curable epoxy materials ultimately fail over time, largely as a result of continuous exposure to the corrosive inks used in printing. In particular, the applicant has observed that the first occurrence of bond failure is usually in the area between the glop top and the microwiring that interconnects the die with the flexible interconnect. Bond failure caused by de-lamination in the glop top area can expose the microwiring to the conductive ink, resulting in a short circuit. Alternatively, bond failure caused by swelling of the glop top can lift up the microwires above the conductive pads on the die, creating an electrical open circuit between one or more of the circular micro heaters and the flexible interconnect. Both situations will cause undesirable image artifacts. The epoxy between the die and the manifold can also be gradually corroded by the ink, eventually resulting in leakage of ink into the printer. Consequently, a longer-lived and more reliable form of die/manifold bonding and encapsulation of the microwiring is needed which maintains all of the aforementioned assembly objectives of precise die/manifold positioning and die removability.
SUMMARY OF THE INVENTION
The invention is a recyclable continuous ink jet print head which uses an interposer member formed from a material having a coefficient of thermal conductivity that is equal to or greater than the material forming the die and a coefficient of thermal expansion (CTE) that is between the CTE of the manifold and the CTE of the die. Such an interposer member would allow more durable heat curable epoxy adhesives to be used to bond the die and the manifold and to encapsulate the microwiring between the die and the control circuit while still allowing the die to be easily removed from the manifold so that the manifold may be recycled.
Heat curable epoxy adhesives generally have superior strength, wetability and durability characteristics over ultraviolet curable epoxy adhesives, and hence would provide longer-lasting encapsulation of the microwiring. However, the applicant has observed that the heat curing step frequently causes misalignment between the die and the manifold due to the difference in the coefficient of thermal expansion (CTE) between the silicon forming the die and the stainless steel forming the manifold. Specifically, the CTE of silicon is 3×10 −6 /° K. at 20° C., whereas the CTE of stainless steel can range from 12-20×10 −6 /° K. at 20° C., depending upon the specific alloy constituents. The resulting misalignment often causes the spacing between the last ink jet on one die to be spaced too far away or too close to the first jet on the other die when the manifolds of the two modules are positioned end-to-end, thus potentially degrading the quality of the printing at the joint between the two dies. While some compensation is possible using software, it is preferred that this artifact be minimized at the time when the print head modules are first assembled.
To solve the misalignment problem, the invention provides an interposing member between the die and the manifold having a CTE about halfway between the CTE of the die and manifold. Such an interposing member reduces the amount of thermally-induced shifting of the die on the manifold caused by the heat curing of an epoxy adhesive by a factor of about one-half.
There are a number of relatively common and inexpensive ceramic materials (such as SiO 2 and AlO 3 ) that have a CTE close to halfway between that of the die and the manifold. However, applicant has observed that the low thermal conductivity associated with such ceramic materials substantially interferes with the transfer of heat between the die and the epoxy material bonding the die to the manifold. Specifically, while the thermal conductivity of the silicon forming the die is 130 W/m° K., the thermal conductivity of ceramic materials such as SiO 2 and AlO 3 is only 1.38 and 18.0 W/m° K., respectively. Such low thermal conductivity necessitates exposure of the entire manifold to high temperatures before the die can be removed, and this can corrode and warp the manifold to the extent that it becomes unusable.
To solve the die removal problem, the invention further provides that the interposing member have a coefficient of thermal conductivity that is at least as high as that of the silicon forming the die, and preferably higher. Such a preferred material is a metal/non-metal composite, such as Al—SiC (obtained from Thermal Composite, Inc.). Such a material can have a CTE of 7.4×10 −6 /° K. at 20° C., which is close to halfway between the CTE of silicon (3×10 −6 /° K. at 20° C.) and the CTE of stainless steel (12×10 6 /° K. at 20° C.). Moreover, such a material has a thermal conductivity of 165 W/m° K., which is 27% greater than the 130 W/m° K. thermal conductivity of the silicon forming the die.
The interposer is preferably dimensioned so that its outer edges extend beyond the outer edges of the die to better conduct localized heat directed at the region surrounding the die to the epoxy bonds securing the interposer member to the surface of the manifold. In the preferred embodiment, the outer edge of the interposer extends beyond the outer edges of the die between about 0 and 5.0 mm.
Finally, the invention encompasses an assembly and recycling method for a continuous ink jet print heat. The method generally includes the steps of applying a thermally curable epoxy material between an interposing member and the manifold and the interposing member and the die and over the microwiring connecting the electrodes in the die to the integrated control circuit. The epoxy material is then heat cured to a temperature of between about 50° C. and 130° C. The intermediate CTE of the interposing member reduces nozzle misalignment caused by such heat curing to within acceptable tolerances. At the end of the service life of the resulting print head, localized heat is applied to the interposing member to loosen the epoxy material bonding the interposing member to the manifold. The relatively high thermal conductivity of the interposing member efficiently directs the localized heat to the epoxy bond, effectively softening it. The die is then removed along with the interposer, and residual epoxy material is abraded off of the surface of the manifold, resulting in the recycling of the most expensive component of the print head module.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a continuous ink jet print head utilizing two print head modules, arranged end-to-end in an offset geometry.
FIG. 2 is a side, partial cross sectional view of the print head of FIG. 1 along the line 2 - 2 ;
FIG. 3 is an enlargement of the area encircled in phantom and represented using the reference numeral 3 in FIG. 1 , illustrating the critical spacing between the last ink jet nozzles of the first printing module and the first ink jet nozzles of the second printing module;
FIG. 4 is an exploded, perspective view of one of the printing modules used in the print head;
FIG. 5 is front view of the printing module illustrated in FIG. 4 in partially assembled form, illustrating the front face of the die in cut-away form to show the network of conductors connected to the micro heaters surrounding around each nozzle;
FIG. 6 is an enlarged cross sectional view of the printing module illustrated in FIG. 5 in completely assembled form along the line 6 - 6 ;
FIGS. 7A-7C illustrate the assembly steps of the method of the invention, and
FIG. 8 illustrates the die removal step of the method of the invention that facilitates the recycling of the manifold.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1 and 2 , the continuous ink jet print head 1 of the invention comprises, in this example, a pair of front support plates 5 a , 5 b supported by a frame 6 (indicated in phantom). Each of the support plates 5 a , 5 b includes a rectangular opening 7 . A pair of printing modules 9 a , 9 b is precision mounted on the backs of the front support plates 5 a , 5 b such that the die 10 of each is framed in the rectangular opening 7 . Each of the printing modules 9 a , 9 b includes a manifold 12 that is machined out of a corrosion-resistant metal, such as stainless steel, to tolerances of better than 1/1,000 of an inch. As is best seen in FIGS. 2 and 4 , the manifold 12 is generally in the shape of a rectangular prism. A port 14 is provided on one side for admitting pressurized ink to a hollow interior. The manifold 12 further includes a rectangular front face 16 over which the die 10 is mounted. An ink-distributing slot 18 (also shown in FIG. 4 ) extends along the length of the front face 16 . A recessed, rectangular surface 20 is disposed above and directly adjacent to front face 16 . As will be described in more detail hereinafter, a rectangular interposer member 22 overlies the front face 16 of the manifold 12 , and the plate-like rectangular die 10 overlies the interposer member 22 . The die 10 of each printing module 9 a , 9 b has a row of ink jet nozzles 28 as shown. An integrated control circuit 36 is mounted over the rectangular recessed surface 20 .
FIG. 3 , an enlargement of the area encircled in phantom and represented using the reference numeral 3 in FIG. 1 , illustrates the criticality of mounting the die 10 in a precise position with respect to the manifold 12 . A mounting system (not shown) precisely attaches the manifold 12 of each of the printing modules 9 a , 9 b in a predetermined position with respect to its front support plate 5 a , 5 b such that not only are the rectangular dies 10 aligned with the rectangular openings 7 a , 7 b , but that the distance “x” between the last nozzle 29 a of the left die 10 and the first nozzle 29 b of the right die 10 is the same distance “x” as between adjacent nozzles 28 on the same die 10 . Since the distance “x” between the nozzles 28 is in fact 43 microns in commercially-operable print heads, such precise positioning is challenging, and requires precise alignment between the die 10 and the front face 16 of the manifold 12 as the mounting system cannot directly mount the dies 10 to the front support plates 5 a , 5 b . The failure to achieve such distance spacing “x” will result in the nozzles 29 a , 29 b being too far or too close to one another, which in turn will create streaking or other undesirable artifacts in the resulting printed images. As will be described in more detail hereinafter, the 43 micron distance is small enough to be adversely affected by any process that requires the heating of a printing module 9 a , 9 b due to the difference in the coefficient of thermal expansion (CTE) between the stainless steel forming the manifold 12 and the silicon forming the die 10 .
With reference to FIGS. 4 and 5 , the interposer member 22 is formed from a rectangular plate 23 of a metal/non-metal composite material that is preferably dimensioned to completely cover the rectangular front face 16 of the manifold 12 . Plate 23 includes a slot 24 which is the same size or slightly larger than the ink-distributing slot 18 in the front face 16 so as not to interfere with the flow of ink to the die 10 . The outer edge 25 of the plate 23 can extend beyond the outer edge of the die 10 for a purpose that will become evident hereinafter. The material that forms the interposer member 22 has a CTE that is between the CTE of the manifold 12 and the CTE of the die 10 , and a thermal conductivity that is at least as high as the material forming the die 10 . Preferably, the material forming the interposer member 22 has a CTE that is within about ±30% of the average value of the CTE between the manifold 12 and the die 10 . More preferably, the material forming the interposer member 22 has a CTE that is within about ±20% of the average value of the CTE between the manifold 12 and the die 10 , and a thermal conductivity that is greater than that of the die 10 . In this example of the invention, manifold 12 is formed from stainless steel, die 10 is mostly formed from silicon, and the interposer member 22 is formed from an Al/SiC composite. The Al/SiC composite has a CTE of 8.0×10 −6 /° K. at 20° C. which is within about 20% of the average between the CTE of silicon (3.0×10 −6 /° K. at 20° C.) and the CTE of the stainless steel used to form the manifold (12×10 −6 /° K. at 20° C.). Moreover, such an Al/SiC composite has a thermal conductivity of 165 W/m° K., which is 27% greater than the 130 W/m° K. thermal conductivity of the silicon forming the die 10 . Advantageously, the proportions of the amount of metal and non-metal in such composites can be adjusted to accommodate manifolds fabricated from different steel alloys and dies fabricated from non-silicon ceramic materials having a broad range of CTEs and different thermal conductivities.
With reference in particular to FIG. 5 , the die 10 is formed from a rectangular plate 27 of silicon to accommodate microcircuitry in the form of micro heaters 30 which surround each of the nozzles 28 , and terminal leads 31 that extend from the micro heaters 30 to the connector pads 32 spaced along the upper lengthwise edge of the plate 27 . In the preferred embodiment, the row of nozzles in the die 10 is about 12 centimeters in length and includes about 2600 uniformly-spaced nozzles 28 . A print head 1 having two such modules 9 a , 9 b arranged in the offset, end-to-end configuration shown in FIG. 1 is capable of printing text or other images on standard-width 8 and ½×11 inch paper. Preferably, the rectangular die plate 27 is dimensioned to be somewhat smaller than the rectangular interposer member plate 23 such that the outer edge 25 of the interposer member 22 uniformly extends beyond the outer edge 34 of the die 10 when the die 10 is bonded over the interposer member 22 . The integrated control circuit 36 includes a rectangular flexible interconnect 38 that is dimensioned to fit over the recessed rectangular surface 20 of the manifold 14 . This interconnect 38 includes one or more processor components 40 , and a network of current-transmitting conductors 42 , each of which is connected to a connection pad 44 . Microwires 46 connect each pad 44 with one of the terminal pads 32 associated with thermally actuating one of the nozzle-surrounding micro heaters 30 .
With reference now to FIGS. 4 and 6 , a first layer 48 of heat curable epoxy adhesive bonds the interposer member 22 to the rectangular front face 16 of the manifold 12 . A second layer 50 of heat curable epoxy adhesive bonds the die 10 over the front face of the interposer member 22 . Finally, an encapsulating layer 52 of heat curable epoxy material encapsulates and bonds both the microwires 46 and the integrated control circuit 36 to the manifold 12 . The lower edge 53 of the encapsulating layer 52 overlies the top portion of the die 10 as shown. While the epoxy adhesives used to form the layers 48 , 50 and 52 may be any number of epoxy adhesives that are heat curable in a range of between about 50° C. and 130° C., epoxy adhesives that are heat curable up to about 80° C. for a two hour time are preferred. The interposer member 22 is able to effectively counteract any nozzle misalignment caused by the exposure of the stainless steel manifold 12 and silicon die 10 to the two hour, 80° C. heat curing process. The resulting encapsulating layer 52 is substantially more resistant to degradation from ink exposure than an encapsulating layer formed from an ultraviolet-curable epoxy, and less likely to fail in its function to protect the microwiring 46 by either de-lamination along the edge 53 or swelling. Additionally, the resulting bonding layers 48 , 50 between the manifold 12 , interposer member 22 and die 10 are stronger and more durable. While epoxy materials curable at higher temperatures may be used, the resulting larger displacements between the manifold 12 and the die 10 due to the differences in their CTEs begins to compromise the ability of the interposer member 22 to accommodate the displacements. Subjecting the printing modules 7 a , 7 b to higher temperatures much above 80° C. for one or more hours also increases the possibility of unwanted corrosion or warpage of the manifold 12 . While epoxy materials curable at lower temperatures may also be used, the strength of the resulting adhesive bonds is not as great as those achieved by epoxies curable at higher temperatures. Moreover, the storage of epoxies curable at lower temperatures is more difficult as they require substantial refrigeration, and the shelf life is shorter. In the preferred embodiment, bonding layers 48 and 50 are formed from Hysol® 536 1A2 epoxy adhesive available from the Henkel Corporation located in Rocky Hill, Conn. This adhesive is preferably filled with sufficient silica microbeads to lower its CTE by about 50%. The encapsulating layer 52 or glop top is formed from Epo-Tek OG 116-31 available from Epoxy Technology located in Billerica, Mass.
FIGS. 7A-7C and 8 A- 8 B illustrate a preferred embodiment of the method of the invention. In particular, FIGS. 7A-7C illustrate the printer module assembly steps of the method, while FIGS. 8A-8B illustrate the manifold recycling steps of the method.
In the assembly steps of the method, the first layer of epoxy material 48 is applied to the front face 16 of the manifold 12 around the ink-conducting slot 18 , and the interposer member 22 is precisely positioned over the front face 16 via an unillustrated alignment jig as indicated in FIG. 7A . Tacking beads 55 formed from an ultra-violet curable epoxy material are next applied via a syringe between the front face 16 and the outer ends of the interposer member 22 . The beads 55 are then cured via ultra-violet light to secure the interposer member 22 in its precise position over front face 16 . This step ensures the interposer member 22 does not accidentally shift on the manifold 12 before the die bond is thermally cured. Once the tack epoxy is cured, the die-manifold assembly is released from its alignment jig.
Next, as shown in FIG. 7B , the die 10 is precisely positioned over the interposer member 22 via another unillustrated alignment jig. Tacking beads 57 formed from an ultra-violet curable epoxy material are next applied via a syringe between the outer ends of the die 10 and the interposer member 22 . The beads 57 are then cured via ultra-violet light to secure the die 10 in its precise position over interposer member 22 . Next, as indicated in FIG. 7B , the flexible interconnect 38 is precisely positioned and epoxy bonded over the rectangular recessed surface 20 of the manifold 12 via another alignment jig, so that complementary sets of metal pads 44 on the flexible interconnect 38 are lined up across the connector pads 32 of the die 10 . Microwires 46 are then wire bonded between each set of pads 32 , 44 .
In the last assembly steps of the method, as shown in FIG. 7C , the epoxy forming the encapsulating layer 52 is applied over the integrated control circuit 36 and the microwires 46 and over the adjacent edges of the interposer member 22 and die 10 up to the outer edge 53 . The resulting printing module assembly 9 a is then heated to 80° C. for two hours to cure the epoxy materials forming the layers 48 , 50 and 52 . In the preferred embodiment, the epoxy material forming the tacking beads 55 , 57 is Ablestik AA50T UV curable epoxy available from the Henkel Corporation located in Rocky Hill, Conn. The applicant has found that such epoxy material does not soften when subjected to the 80° C. curing temperature and hence continues to hold the interposer member 22 and die 10 in their properly aligned positions with respect to the front face 16 of the manifold 12 through the heat curing step. After the completion of the curing step, the resulting printing modules 9 a , 9 b are precision mounted on the back side of the support plates 5 a , 5 b to complete the assembly of the print head 1 .
At the end of the life of the print head 1 , the printing modules 9 a , 9 b are removed from the support plates 5 a , 5 b of the print head 1 . As illustrated in FIG. 8A , localized radiant heat H from a masked, high-intensity infra-red lamp is focused over the front of the manifold 12 in order to apply localized heat of about 300° C. to the epoxy layers 48 , 50 bonding the die 10 and interposer member 22 to the manifold 12 , and to the encapsulating layer 52 . The localized heat H is conducted to the bonding layers 48 , 50 through the thickness of the die 10 and the interposer member 22 . The localized heat H is conducted particularly efficiently to the epoxy layers 48 , 50 and to the top edge of the encapsulating layer 52 through the outer edge 25 of the interposer member 22 that extends beyond the outer edge 34 of the die 10 , which in turn softens these layers after only about 1 minute of exposure. Such a short exposure to the localized heat produced by the infra-red lamp causes no significant corrosion or thermal warpage of the manifold 12 . After the die 10 , interposer member 22 and integrated control circuit 36 are removed from the manifold 12 , some residual bonding material 60 still remains on the front face 16 . This residual material 60 is removed by sandblasting with a mild abrasive (as indicated) such as sodium bicarbonate, and the resulting cleaned manifold 12 is recycled and assembled into another print head module.
Example 1 (Control)
A 4.3 inch long Si die containing nozzles and microelectronics circuitries was bonded to a stainless steel manifold using Hysol QMI 550EC adhesive (from Henkel Corporation, San Diego, Calif.), Before curing the die bond, the distance between the center of the first to the center of the last, or 2560 th , nozzle was measured by a Smartscope Quest 650, made by Optical Gauging Products, Rochester, N.Y.), and found to be 108.324 (+−0.0005) mm. After curing to 120 C for 1 hr, and cooling to room temperature, the same measurement was found to be 108.262 mm. The array of nozzles had shrunk by 62 microns. The high curing temperature produced a relatively large dimensional change in the die that is outside of acceptable tolerances.
Example 2 (Control)
A 4.3 inch long Si die containing nozzles and microelectronics circuitries was bonded to a stainless steel manifold using QMI 536 1A2 adhesive (from Henkel Corporation, San Diego, Calif.). Before curing, the distance between the center of the first to the center of the last, or 2560 th nozzle was measured to be 108.323 millimeters. After thermal curing to 80 C for 2 hr, and then cooling to room temperature, the distance between the first to the last or 2560 th nozzle was measured to be 108.290 millimeters. The nozzle array had shrunk by 33 microns. By going to a lower curing temperature, the CTE mismatch between the die and the manifold manifested relatively less dimensional change. However, the dimensional change of 33 microns is still outside the range of acceptable tolerances.
Example 3 (Invention)
An Al/SiC interposer (made of MCX-724, from Thermal Transfer Composite LLC, Newark, Del.) cut to the same outer dimension as the 4.3 inch long Si die, was bonded to the stainless steel manifold using QMI 536 1A2 adhesive. This was then treated at 80 C, for 2 hr. Then a 4.3 inch long Si die containing nozzles and microelectronics circuitries was bonded to the Al/SiC interposer using QMI 536 1A2 adhesive. Before curing, the distance between the center of the first to the center of the last, or 2560 th , nozzles was measured to be 108.323 millimeters. After thermal curing to 80 C, for 2 hr, and then cooling to room temperature, the distance between the first to the last, or 2560 th nozzle was measured to be 108.307 millimeters. The nozzle array had shrunk by 16 microns. By going to a lower curing temperature, and using an interposer with a CTE approximately half way between those of the manifold and the die, the dimensional change is reduced to within acceptable tolerances.
For manifold recycling, focused infrared light from a thermal heat lamp was positioned on top of the die and flexible interconnect for 2 minute, so that its surface temperature reached about 300 C. Afterwards, the interposer was easily pushed off the manifold, with the die still attached to the interposer. The surface of the manifold where some epoxy residue was present was then soda-blasted, and the manifold re-used.
Example 4 (Invention)
An Al/SiC interposer (made of MCX-724, from Thermal Transfer Composite LLC, Newark, Del.) was cut to a length two mm longer than the 4.3 inch long Si die. This was bonded to the stainless steel manifold using QMI 536 1A2 adhesive, such that 1 millimeter of the interposer protruded from below and along the edges of the Si die. Before curing, the distance between the center of the first to the center of the last, or 2560 th , nozzles was measured to be 108.323 millimeters. After thermal curing to 80 C, for 2 hr, and then cooling to room temperature, the distance between the first to the last, or 2560 th nozzle was measured to be 108.307 millimeters. The nozzle array had shrunk by 16 microns. By going to a lower curing temperature, and using a longer interposer with a CTE approximately half way between those of the manifold and the die, the dimensional change is relatively low and well within tolerances.
For manifold recycling, focused light from a thermal heat lamp was positioned on top of the die and flexible interconnect for 2 minute, so that its surface temperature reached about 300 C. Afterwards, the interposer was easily pushed off the manifold, with the die still attached to the interposer. The surface of the manifold where epoxy residue was present was then soda-blasted, and re-used.
Hence the presence of the interposer member 22 cuts the error in the distance “x” caused by the heat treatment approximately in half, and to a distance which can be can be compensated for by the software used to control the control circuit 36 .
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
1 ) continuous ink jet print head
5 ) support plates a, b
6 ) frame
7 ) rectangular opening
9 ) printing modules a, b
10 ) die
12 ) manifold
14 ) port
16 ) front face
18 ) slot
20 ) recessed surface
22 ) interposer member
23 ) rectangular plate
24 ) slot
25 ) outer edge
27 ) rectangular plate
28 ) ink jet nozzles
29 ) first and last nozzles a, b
30 ) circular micro heaters
31 ) conductor leads
32 ) terminal pads
34 ) outer edge
36 ) integrated control circuit
38 ) flexible interconnect
40 ) processor components
42 ) conductors
44 ) connection pads
46 ) microwires
48 ) first layer of epoxy
50 ) second layer of epoxy
52 ) encapsulating layer
53 ) outer edge of encapsulating layer
55 ) tacking beads
57 ) tacking beads
60 ) residual epoxy material | A recyclable continuous ink jet print head is provided that includes a manifold formed from a metal such as stainless steel, a die having ink jet nozzles formed from a ceramic material such as silicon, a control circuit connected to the die via microwiring, and an interposing member disposed between the manifold and the die. The interposing member is formed from a composite material such as Al—SiC having a coefficient of thermal conductivity that is higher than that of the silicon die, and a coefficient of thermal expansion (CTE) that is between that of the die and the manifold. During manufacture, the CTE value of the interposing member allows long-lasting, heat-cured epoxy compositions to be used to bond the die to the manifold and to encapsulate the microwiring between the die and a control circuit with while maintaining proper alignment of the die ink jet nozzles on the manifold. When the die wears out, the high thermal conductivity of the interposing member allows the die to be easily removed from the manifold, thereby facilitating re-cycling of the manifold. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a roll for use in casting metal products and an associated method, and more specifically to a roll defining an enclosed space which contains a working fluid which is converted from liquid to vapor phase and back again respectively to remove heat from the roll outer surface.
Roll casting, such as single roll casting, twin roll casting or melt spinning for example, is a well known method of producing metal products such as metal foil and strip. Roll casting is used to cast steel, aluminum, copper and other metals.
In most roll casting operations, molten metal is introduced onto the surface of the rotating roll. The rotating roll removes heat from the molten metal, causing the molten metal to solidify into a cast metal product such as foil or strip. There are numerous examples of roll casting machines in the prior art, such as those disclosed in U.S. Pat. Nos. 4,489,773; 4,502,528; 4,794,977 and 4,842,040.
In all of the above-cited patents, and in roll casting in general, heat is removed by providing a coolant that circulates in the hollow roll. For example, U.S. Pat. No. 4,794,977 teaches that the coolant is supplied to the core of the roll from an outside source and is guided to the outer surface by guide means. After performing its transfer function at the inner surface of the outer shell, the coolant is directed into the core and is exhausted therefrom.
There are several limitations inherent in these so-called "open systems". First, a strict design for sealing and mechanical couplings is required for safety and maintenance reasons. Second, the coolant, because it does not change phase from liquid to vapor, must be kept at a low temperature in order to perform its heat exchanging role. This, however, causes a large thermal gradient (metal to coolant) through the roll which induces thermal stresses that accelerate roll damage and shorten roll life. Third, because the heat extraction rate is limited, thinner roll walls are used which weaken the strength of the roll and which may result in roll deformation. Finally, it is difficult to maintain uniform circumferential temperature near the roll surface.
Thus, what is needed is a roll design that avoids the limitations of the prior art but which provides excellent heat extraction to produce quality cast metal products.
SUMMARY OF THE INVENTION
The roll of the invention has met the above need. The roll comprises a heat exchanger core and an outer generally cylindrical shell surrounding the core, the core and the shell defining an enclosed space. A working fluid is contained in the enclosed space. When molten metal is cast onto the shell, the working fluid in proximity to the outer shell changes from a liquid to a vapor. Due to the rotation of the roll, the liquid phase of the working fluid forces the vapor in proximity with the outer cylindrical shell to return to the area adjacent to the core. At this area, the vapor is condensed into a liquid which is then subsequently delivered radially to the outer cylindrical shell. In this way, the working fluid constantly changes from vapor to liquid and back to vapor again and acts to continuously remove heat from the molten metal cast onto the outer cylindrical shell.
A single roll caster, a twin roll caster, and a melt spinning apparatus are also disclosed using the roll of the invention.
The method of the invention comprises providing a supply of molten metal and introducing the molten metal onto the surface of a rotatable roll as set forth above.
It is an object of the invention to provide a "closed system"in which a working fluid is enclosed in the space defined by the outer cylindrical shell and the inner core.
It is a further object of the invention to use a working fluid which changes to the vapor phase when near the outer cylindrical shell and which changes back to the liquid phase when in proximity with the core.
It is still a further object of the invention to provide heat exchanger means in the core to enhance the phase change in the working fluid from vapor to liquid.
It is yet another object of the invention to provide a thicker roll wall thickness so as to minimize thermal stresses and increase the working life of the roll.
It is another object of the invention to reduce the thermal gradient in the outer cylindrical shell thus prolonging roll life.
It is a further object of the invention to provide a roll that is easy to manufacture and safe to operate and maintain.
These and other objects of the invention will become more readily apparent as the following detailed description of the preferred embodiments proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded perspective view showing the roll of the invention.
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a view similar to FIG. 2 only showing the action of the working fluid when molten metal is introduced onto the rotating roll.
FIG. 4 is a schematic view showing the coolant pumping system.
FIG. 5 is a vertical section of one embodiment of a heat exchanger means.
FIG. 6 is a vertical section of another embodiment of a heat exchanger means.
FIG. 7 is a longitudinal section of the roll showing enhancements to the core and the roughening of the inner surface of the shell.
FIG. 8 is an elevational view of a single roll caster using the roll of the invention.
FIG. 9 is an elevational view of a twin roll caster using two rolls of the invention.
FIG. 10 is an elevational view of a melt spinning apparatus using the roll of the invention.
DETAILED DESCRIPTION
As used herein, whenever the name of a metal is used, such as steel, aluminum or copper, that name is deemed to include alloys of that particular metal. Also as used herein the term "metal products"means castings made of metal.
Referring now to FIG. 1, a roll 20 for use in casting metal products in accordance with the invention is shown. The roll 20 is generally cylindrical and is made of a suitable material, such as steel. The roll 20 includes an outer cylindrical shell 22 consisting of a pair of flanges 23, 24 which form end walls and which define openings 25, 26 and a central cylindrical shell portion 27. The central cylindrical shell portion 27 consists of an inner cylindrical surface 28 and an outer cylindrical surface 29.
A sleeve member 34 made of copper, preferably, is disposed on a portion of the outer cylindrical surface 29 of the central cylindrical shell portion 27. As is known to those skilled in the art, the copper sleeve member 34 is shrink-fit onto the central cylindrical shell portion 27. This involves heating the sleeve so that it will expand, and when expanded, slipping the central cylindrical shell into the sleeve 34. When the sleeve 34 cools it will contract and intimately engage the shell 27. It is well known that the copper sleeve member 34 is employed in lieu of casting molten metal directly onto a roll surface, in that the copper sleeve member 34 only, and not the entire roll, can be replaced after prolonged casting of the molten metal. It will be appreciated, however, that the invention herein also contemplates casting the molten metal directly onto the central cylindrical shell portion 27 without the need for the sleeve 34, however, this is less preferred.
Disposed inside and surrounded by the central cylindrical shell portion 27 is a cylindrical core member 40 which is shown in phantom line drawing in FIG. 1 and in cross-section in FIG. 2. The core member 40 has an inner cylindrical surface 42 and an outer cylindrical surface 44 and defines a passageway 46. The core member 40 has a longitudinal axis that is generally the same as the longitudinal axis of the central cylindrical shell portion 27. The core member 40 is supported inside the central cylindrical shell portion 27 by the end walls 23, 24 and, optionally, by a series of ribs 48, four of which are shown in FIG. 2.
The ribs 48 can be secured to the core member 40 as by welding or the ribs 48 may be formed integrally with the core member 40. The number of ribs 48, their arrangement and the size of the ribs 48 will vary according to the size of the roll 20, but it is desired to keep the number at a minimum and in fact, to not use ribs 48 at all. Most of the support for the core member 40 is provided by the end walls 23, 24. It will be appreciated that the core member 40 protrudes beyond the end walls 23, 24 thus providing extra support for the core member 40.
Referring to FIG. 2, it can be seen that the outer cylindrical shell 22 and the core member 40 define a completely enclosed space 50. Disposed in this enclosed space 50 is a working fluid 52. This working fluid 52 is chosen so that its boiling point is approximately equal to the temperature at the inner cylindrical surface 28 when molten metal is cast onto the roll 20. This is because, as will be explained below, the working fluid 52 undergoes a phase change from liquid to vapor when it is adjacent to the outer cylindrical surface. Furthermore, the working fluid 52 preferably has a melting point below room temperature (i.e., 20° C.), because it is desired to keep the working fluid 52 in a liquid phase when the roll is not being used. A working fluid 52 that is contemplated by the invention is water.
The amount of working fluid 52 is chosen such that the enclosed space 50 is not too solidly packed with working fluid 52 so the working fluid 52 is unable to change from a liquid to vapor phase, however, on the other extreme, the amount of working fluid must be adequate to cause effective heat transfer in the roll.
The roll 20 is constructed in the following manner. The central cylindrical shell portion 27 is first provided, and the end walls 23, 24 are kept off to the side. The core member 40, having ribs 48 are placed into position inside the outer cylindrical shell 27 and can be fastened by screws (not shown) which are placed in the shell 27 and through the rib 48. The flanges 23 and 24 are then secured to the outer cylindrical shell 27. The working fluid 52 is introduced into the enclosed space 50 through a port 54 disposed on flange 23 (See FIG. 1).
FIG. 3 is a partially schematic diagram which shows the operation of the roll 20 when metal is cast thereon.
The roll 20 is rotatably mounted and is driven by drive means (not shown) in the direction of arrow A. Molten metal 56 from a molten metal source (not shown), is introduced onto the copper sleeve 34 of the roll 20. Due to the properties of the working fluid 52, once the molten metal 56 is introduced onto the copper sleeve 34, the working fluid 52 will take heat away from the molten metal 56 through the surface of the sleeve 34 and the shell 27.
The solidifying molten metal 58 releases heat and this heat causes the working fluid 52 in the enclosed space 50 of the roll 20 to change from a liquid to a vapor, due to the above mentioned properties of the working fluid. Once the working fluid 52 changes to vapor, the rotation of the roll 22 causes the vapor phase to move towards the central core member 40. This movement will also be facilitated by the force of the liquid being delivered radially, due to centrifugal force, towards the outer cylindrical shell, as is shown by the arrow B in FIG. 3. Once the vapor is in proximity with the central core member 40, it is condensed into a liquid, because, as will be shown in FIG. 4, the central core member 40 is a heat exchanger which takes heat away from the working fluid vapor. As will be appreciated, this process of continuous phase changes from liquid to vapor and back to liquid continues as long as the roll 20 is rotating and as long as the core member 40 acts as a heat exchanger.
The rotational speed of the roll 20 is related to the efficiency of the heat removal process. The greater the rotational speed (measured in rpm's) the higher the H value (H being defined as BTU/hr-ft 2 ) and the more efficient the process. Higher rotational speeds also translate into greater peripheral speed of the metal product that comes off of the roll. The roll can be rotated at speeds from 0.5 rpm to 300 rpm. The wall thickness of the cylindrical shell of the invention can be greater than the thickness of prior art rolls because of the enhanced thermal transfer of the roll of the invention. This results in longer roll life. Also, because of the increased efficiency of the thermal transfer of the roll of the invention, thermal gradients in the roll are reduced thus reducing thermal stresses in the roll. This, too, will prolong roll life.
Referring now to FIG. 4, the heat exchanging core member 40 will be discussed in detail. As was described in FIG. 2 above, the core member 40 defines a passageway 46. In one embodiment, the heat exchange mechanism simply is to introduce a coolant, such as water, for example, into the passageway 46. This is accomplished by the system shown in FIG. 4 which includes a pump 60, a heat exchanger 62 to cool the heated water and inlet tubing 64 to introduce the cooled water into the passageway and outlet tubing 66 to take the heated water away from the core member 40 and deliver it back to the heat exchanger 62 and pump 60.
Other embodiments of the heat exchanging core member are shown in FIGS. 5 and 6. FIG. 5 shows a heat exchanging means 70 which consists of a series of tubes 72 that are disposed along the core members longitudinal axis. The tubes 72 are held in place by a plurality of spacer plates, one of which, spacer plate 74, is shown in FIG. 5. A coolant, such as water, is introduced into the tubes 72 by a closed system similar to that shown in FIG. 4. FIG. 6 shows another embodiment whereby longitudinal aluminum fins 78 can be used to enhance the heat exchange in the core member 40.
FIG. 7 illustrates another embodiment of the roll. This roll 80 has a core member 81 which includes arcuate vanes 82 which will act to enhance the radial "throwing"of the working fluid to the outer cylindrical shell 83 described above. This roll 80 also shows a roughened inner surface 84 for the central cylindrical shell member 83. The roughened inner surface 84 also improves heat transfer from the outer surface of the cylindrical shell 83 to the inner surface thereof. Instead of roughening or even in addition to roughening, the inner surface of the shell can also have fins or vanes (not shown) which also enhance heat transfer.
It will be appreciated by those skilled in the art that a roll made in accordance with the invention can be used in single roll casting processes as well as twin roll casting processes. Referring to FIG. 8, a single roll casting process is shown using a roll 88 made in accordance with the invention. As is known to those skilled in the art, molten metal 90 from a tundish 91 overflows the tundish 91 and is introduced onto the rotating roll 20. The molten metal 90 is solidified as it contacts the roll 20 and the solidified metal product 92 moves off of the roll 20 in the direction of arrow F. The sheet 92 can then be coiled (not shown).
FIG. 9 shows a twin roll casting process wherein an upper roll 95 and a lower roll 96 form a casting mold 97. One or both of the rolls 95 and 96 can be made in accordance with the invention. Molten metal 98 from a tundish 99 is introduced into the casting mold 97 and is solidified therein and a cast metal product 100 is produced. Although a horizontal casting arrangement is shown, it will be appreciated that the rolls of the invention are suitable for vertical twin roll casting processes or casting machines which are angularly disposed.
FIG. 10 shows a melt spinning apparatus 120 which includes a roll 122 made in accordance with the invention. As is known to those skilled in the art, the melt spinning apparatus 120 consists of a tundish 130 which holds molten metal 132, the molten metal 132 being delivered to the roll 122 by a nozzle 136. The molten metal 132 solidifies upon contact with the roll 122 and a cast metal product 138 is produced.
It will be appreciated that the rolls can be used for casting several types of molten metal including but not limited to steel and aluminum. Aluminum alloys such as Aluminum Association designations 1100, 1145, 3003, 5052, 7072 and 8XXX can be cast into aluminum foils and sheet having thicknesses from about 1 to 10 mm.
It will be appreciated that a roll for use in casting molten metal has been disclosed that can be used in single or twin roll casting processes. The roll effectively and efficiently removes heat from the solidifying molten metal while avoiding the several limitations of prior art rolls and processes set forth in the Background section above.
While specific embodiments of the invention have been disclosed, it will be appreciated by those skilled in the art that various modifications and alterations to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof. | A roll for use in a roll caster. The roll has a heat exchanger core and an outer generally cylindrical shell surrounding the core, the core and the shell defining an enclosed space. A working fluid is contained in the enclosed space. When molten metal is cast onto the shell, the working fluid in proximity to the outer shell changes from a liquid to a vapor. Due to the rotation of the roll, the liquid phase of the working fluid forces the vapor in proximity with the outer cylindrical shell to return to the area adjacent to the core. At this area, the vapor phase is condensed into a liquid which is then subsequently delivered radially to the outer cylindrical shell. In this way, the working fluid constantly changes from vapor to liquid and back to vapor again and acts to continuously remove heat from the molten metal cast onto the outer cylindrical shell. A single roll caster, a twin roll caster, and a melt spinning apparatus as well as an associated method are also disclosed. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is related to U.S. patent application Ser. No. 11/081,870, filed Mar. 15, 2005.
FIELD OF THE INVENTION
The present invention relates to reduced power cells.
BACKGROUND OF THE INVENTION
Volatile memory circuits are quite common today. Such memory circuits can be contained in an individual integrated circuit (IC) chip or can be part of other IC's. These IC's include a configurable IC that uses a memory circuit to store configuration data. The configurable IC can be configured to perform a set of operations based on the stored configuration data.
The use of configurable IC's has dramatically increased in recent years. One example of a configurable IC is a field programmable gate array (FPGA). An FPGA is a field programmable IC that has an internal array of logic circuits (also called logic blocks) that are connected together through numerous interconnect circuits (also called interconnects) and that are surrounded by input/output blocks. Like some other configurable IC's, the logic circuits and the interconnect circuits of an FPGA are configurable. In other words, each of these circuits receives configuration data that configures the circuit to perform an operation in a set of operations that it can perform. One benefit of configurable IC's is that they can be uniformly mass produced and then subsequently configured to perform different operations.
As mentioned above, configurable IC's typically store their configuration data in memory cells. FIG. 1 illustrates a memory circuit 100 of a configurable IC. As shown in this figure, the memory circuit 100 includes: (1) a storage cell 128 for storing a configuration data value; (2) a VDDcell line 106 for supplying power to the storage cell 128 ; (3) true and complement bit lines 110 and 115 for reading and/or writing the contents of the storage cell 128 ; (4) pass gates 120 and 125 for connecting the bit lines 110 and 115 to the storage cell 128 ; and (5) output lines 160 and 165 for outputting, through configuration buffers 140 and 145 , the contents of the storage cell 128 without the need for a read operation.
The typical storage cell 128 in the art requires that the voltage within the cell 128 and through the buffers 140 and 145 be driven to the rails in order for the cell 128 to retain stable values and output a useable configuration value (i.e., VDDcell 106 is typically VDD). If the voltage within the storage cell 128 is less than the voltage on a word line used to read the cell, then a read operation could cause instability in the value stored by the storage cell 128 by undesirably altering the value stored in the storage cell 128 . This condition is also known as “read upset.”
However, requiring the voltage within the cell 128 and through the buffers 140 and 145 to be driven to the rails exasperates current leakage from the cell, since current leakage from the memory cell is non linearly (e.g., exponentially) proportional to the voltages that are used to store data in the memory cell. Specifically, in the memory cell 100 there are two kinds of leakage that are problematic: sub threshold leakage and gate leakage.
FIG. 2 illustrates an example of sub threshold leakage through an NMOS transistor 200 that is commonly used in memory circuits. In FIG. 2 , the gate and source leads of the NMOS transistor 200 are short circuited to represent that their voltage difference is zero (i.e., Vg−s=0). Even though the transistor is “off” in this sub threshold condition, there is still undesirable leakage current through the transistor 200 , as shown in FIG. 2 .
FIG. 3 illustrates an example of gate leakage through an NMOS transistor 305 . Electron tunneling through the gate oxide of a transistor causes gate leakage current. For a 90 nm electronic component (e.g., a transistor), gate oxide can be about fourteen angstroms or approximately seven silicon dioxide atoms thick. This distance is sufficiently short to allow tunneling current to flow through the gate oxide even at voltage levels as low as one volt. Gate leakage in N-channel devices is significantly worse than in P-channel devices.
With the size of electronic components continually becoming smaller due to improvements in semiconductor technology, leakage current is a continually growing problem. Leakage current in a standard (six transistor) memory cell is exponentially proportionate to voltage. So if the voltage in the cell can be reduced, then the amount of leakage (i.e., both gate and sub threshold leakage) in the cell can be exponentially reduced. However, a typical memory cell has particular voltage requirements in order for the cell to function properly. Thus, if the voltage within the cell is reduced too much, then the cell becomes unstable and unable to store and output data reliably, as seen in the case of the read upset condition. Thus, there is a need in the art for a useable reduced power configuration storage cell, such that the leakage from electronic components within the cell is reduced, while retaining useable output configuration signals.
SUMMARY OF THE INVENTION
The invention relates to reduced power cells. Some embodiments of the invention provide a memory circuit that has a storage cell. The storage cell contains several electronic components and an input. The electronic components receive a reduced voltage from the input to the cell. The reduced voltage reduces the current leakage of the electronic components within the cell. Some embodiments provide a memory circuit that has a level converter. The level converter receives a reduced voltage and converts the reduced voltage into values that can be used to store and retrieve data with stability in the cell. Some embodiments provide a method for storing data in a memory circuit that has a storage cell. The method applies a reduced voltage to the input of the cell. The method level converts the reduced voltage. The reduced voltage is converted to a value that can be used to store and retrieve data with stability in the cell. The reduced voltage reduces a current leakage of electronic components within the cell.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features, and advantages of the invention will be apparent to one skilled in the art, in view of the following detailed description in which:
FIG. 1 illustrates a diagram of a typical memory circuit as is known in the art.
FIG. 2 illustrates sub threshold leakage through an NMOS transistor.
FIG. 3 illustrates gate leakage through an NMOS transistor and sub threshold leakage through a PMOS transistor.
FIG. 4 illustrates a diagram of a memory circuit comprising a reduced power storage cell according to some embodiments of the invention.
FIG. 5 illustrates a control circuit for a memory circuit comprising a reduced power storage cell according to some embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention is directed towards reduced power static random access memory (SRAM) cells. In the following description, numerous details are set forth for purpose of explanation. However, one of ordinary skill in the art will realize that the invention may be practiced without the use of these specific details. For instance, the invention has primarily been described with reference to the storage cells for volatile memory (e.g., SRAM) in a configurable IC. However, the same techniques can easily be applied for other types of memory and electronic circuits. In other instances, well-known structures and devices are shown in block diagram form in order not to obscure the description of the invention with unnecessary detail.
I. Reduced Power Memory Cell
To address the problems of current leakage present in memory cells, some embodiments provide a memory circuit 400 illustrated in FIG. 4 that includes a reduced power storage cell 428 . During normal operation, the reduced power storage cell 428 is supplied with a lower voltage so that it will leak less current, and therefore consume less power than the storage cells known in the art. Moreover, the reduced power storage cell 428 outputs through an amplifier circuit 438 , which also leaks less current than the buffers in the art.
As shown in FIG. 4 , the memory circuit 400 includes a word line 405 , a VDDcell line 406 , a bit line 410 , a complement bit line 415 , pass gates 420 and 425 , a reduced power storage cell 428 , and an amplifier stage 438 . In some embodiments, the pass gates 420 and 425 are NMOS transistors that connect the bit line 410 and the complement bit line 415 to the storage cell 428 when the signal on the word line 405 is high.
The pass gates 420 and 425 enable writes to, and reads from, the storage cell 428 . During a read operation, the value in the storage cell 428 is “read” out onto the bit line 410 and the complement bit line 415 (hereinafter also referred to as the bit lines). Specifically, for the read operation of some embodiments, the voltages stored at the nodes 426 and 427 pass through the pass gates 420 and 425 to affect the voltages on the bit lines 410 and 415 . In some embodiments, the bit lines 410 and 415 are precharged and then allowed to float high in anticipation of a read operation. Also during a read operation, a sense amplifier (not shown in FIG. 4 ) monitors the bit lines 410 and 415 to sense or “read” the value stored in the storage cell 428 through the bit lines 410 and 415 .
During a write operation, the values on the bit lines 410 and 415 are “written” into the storage cell 428 . Specifically, for the write operation of some embodiments, voltages on the bit lines 410 and 415 pass through the pass gates 420 and 425 to alter the voltages stored at the nodes 426 and 427 . As shown in FIG. 4 , some memory cells require a true configuration signal and its complement signal (provided by the bit lines 410 and 415 ) for the memory circuit 400 to execute reliable read and write operations. In these embodiments, the bit lines 410 and 415 are precharged, then one is pulled low to effect differential signals for the write operation.
FIG. 4 illustrates that the reduced power storage cell 428 of some embodiments is formed by cross coupling a pair of standard complementary metal oxide semiconductor (CMOS) inverters. These CMOS inverters are cross-coupled in that the output of the first inverter is coupled to the input of the second inverter and the output of the second inverter is coupled to the input of the first inverter.
The cut-out in FIG. 4 illustrates the cross coupled transistors of two standard CMOS inverters. This cut-out includes PMOS transistors 431 and 436 and NMOS transistors 432 and 437 . To form a first inverter, the drains of the transistors 431 and 432 are connected, and the gates of these transistors are also connected. To form a second inverter, the drains of the transistors 436 and 437 are connected, and the gates of these transistors are also connected. Cross-coupling of the two inverters is achieved by connecting the drains of the first inverter's transistors to the gates of the second inverter's transistors, and by connecting the drains of the second inverter's transistors to the gates of the first inverter's transistors. The sources of the transistors 432 and 437 are connected to ground.
The source leads of the PMOS transistors 431 and 436 are connected to the VDDcell line 406 . When the VDDcell line 406 supplies power to the storage cell 428 , a value that represents a bit can be stored at the output (the transistor drains) of the first inverter (i.e., at node 426 ) and a value that represents the complement of the bit can be stored at the output (the transistor drains) of the second inverter (i.e., at node 427 ). In certain conditions (i.e., during the normal operation of the cell 428 ), the VDDcell line 406 supplies reduced power by using a reduced voltage. Thus, the storage cell 428 stores reduced voltages at the nodes 426 and 427 to represent the stored bit and its complement.
When operating based on a reduced voltage (e.g., VDDcell less than VDD), the storage cell 428 consumes less power, since the power consumed by a circuit is non linearly proportional to the voltage within the circuit. In some embodiments, the voltage supplied by the VDDcell line 406 is less than the voltage provided by the VDD line 407 by one NMOS threshold. In other embodiments, the voltage from the VDDcell line 406 is less than the voltage from the VDD line 407 by more than one NMOS threshold. At the reduced voltage, the current leakage from the electronic components of the storage cell 428 is exponentially lower at the lower voltage.
As mentioned above, the storage cell 428 normally provides continuous output of its stored value. While the storage cell 428 stores values at a voltage less than VDD, a typical useable configuration output has a voltage approximately equal to the full supply voltage VDD. Some embodiments compensate for the reduced voltage within the cell 428 by replacing the pair of configuration buffers 140 and 145 shown in FIG. 1 , with the amplifier stage 438 of FIG. 4 . In these embodiments, though reduced voltage is supplied to the storage cell 428 , the storage cell 428 outputs the value representing the stored bit through the amplifier stage 438 at the full supply voltage (VDD). Moreover, the amplifier stage 438 buffers the storage cell 428 from the configuration outputs 460 and 465 , to prevent an undesirable change in the stored data when these outputs 460 and 465 are accessed by external circuitry (not shown).
As shown in FIG. 4 , the amplifier stage 438 can be implemented by using the PMOS transistors 441 and 446 , and the NMOS transistors 442 and 447 . In these embodiments, the sources of the PMOS transistors 441 and 446 are coupled to the VDD line 407 (VDD≧VDDcell). The PMOS transistors 441 and 446 are cross-coupled, meaning that the gate of the PMOS 441 is coupled to the drain of the PMOS 446 , and the gate of the PMOS 446 is coupled to the drain of the PMOS 441 . As further shown in FIG. 4 , the drain of the PMOS 441 is coupled to the drain of the NMOS 442 and the drain of the PMOS 446 is coupled to the drain of the NMOS 447 . The sources of the NMOS transistors 442 and 447 are grounded.
Also shown in FIG. 4 , the gate of the NMOS transistor 442 is coupled to the storage cell 428 and the pass gate 420 at the node 426 . Similarly, the gate of the NMOS transistor 447 is coupled to the storage cell 428 and the pass gate 425 at the node 427 .
In some embodiments, the four transistors 441 , 442 , 446 and 447 described above form the amplifier stage 438 by implementing a static level converter. In these embodiments, the level converter does not directly drive the PMOS transistors 441 and 446 . Rather, the cross-coupled PMOS transistors 441 and 446 provide differential level conversion. Thus, the voltage VDD supplied by the VDD line 407 from the level converter (the four transistors) of the amplifier stage 438 drives the configuration outputs 460 and 465 , instead of the reduced voltage from the VDDcell line 406 .
The advantage of the level converter is that the voltage swing on the NMOS transistors 442 and 447 from the storage cell 428 is not required to go all the way to the rails (all the way to the full supply voltage VDD) for the value in the storage cell 428 to be correctly outputted. This allows the storage cell 428 to operate at reduced voltages. The reduced operating voltage reduces both the sub threshold leakage and the gate leakage of the cell 428 . The storage cell 428 in the memory circuit 400 consumes less power at the reduced voltage (supplied by the VDDcell line 406 ). Despite operating at the reduced voltage, the cell 428 properly outputs its configuration value.
Moreover, since the supply voltage VDD (from VDD line 407 ) passes only through the PMOS transistors 441 and 446 before reaching the outputs 460 and 465 , the amplifier stage 438 leaks significantly less current than the configuration buffers 140 and 145 of the prior art memory cell 100 illustrated in FIG. 1 . This is partly because the configuration buffers 140 and 145 are typically implemented with a greater number of transistors, each of which leaks current, and partly because these transistors include NMOS transistors, each of which leaks more current than PMOS transistors.
II. Operation and Control of the Reduced Power Cell
The operation of the reduced power storage cell 428 will now be described in relation to FIGS. 4 and 5 . As previously described, FIG. 4 illustrates a memory circuit 400 that includes the reduced power cell 428 . FIG. 5 illustrates a control circuit 501 that provides control signals for the memory circuit 400 . The memory circuit 400 is represented in FIG. 5 as the simplified memory circuit 500 .
More specifically, FIG. 5 illustrates the control circuit 501 having two control inputs, Not_Enable (EN-bar 520 ) and Word_Line_Enable (WL_EN 530 ), that provide three states: 1) Disabled; 2) Read/Write; and 3) Normal states for the memory circuit 500 . The input Not_Enable 520 is coupled to the input of the inverter 525 . The output of the inverter 525 is coupled to the NMOS transistor 540 . The NMOS transistor 540 connects the VDD line 507 to the VDDcell line 506 . The input Word_Line_Enable 530 is coupled to the input of the inverter 535 . An output of the inverter 535 is coupled to the transistors 545 , 550 , and 555 .
As further shown in FIG. 5 , the PMOS transistor 545 connects the VDD line 507 to the VDDcell line 506 . The PMOS transistor 555 connects the VDDcell line 506 to the word line 505 . The PMOS transistor 545 is “stacked” above the PMOS transistor 555 such that the voltage on the word line 505 may never exceed the voltage on the VDDcell line 506 . Likewise, the voltage on the VDDcell line 506 may never exceed the voltage on the VDD line 507 . Since these voltages are tiered or “stacked” above and below the PMOS transistors 545 and 555 (i.e., the voltage on the VDD line 507 ≧VDDcell line 506 ≧word line 505 ), a read operation will not upset a value stored in the storage cell 528 . In other words, because the voltage on the word line 505 may equal, but may never exceed, the voltage on the VDDcell line 506 , a “read upset” condition is avoided by the control circuit 501 .
The three states for the memory circuit 500 will now be described by reference to the control circuit 501 . As previously discussed, the three states for the memory circuit 500 include a Disabled State, a Read/Write State, and a Normal State.
1. Disabled State (EN-bar=1, WL_EN=0)
When the input signal at the input Not_Enable 520 has a logical “1” and the signal at the input Word_Line_Enable 530 has a logical “0,” both the NMOS 540 and the PMOS 545 transistors are turned off and no power is supplied to the VDDcell line 506 . Thus, no power is supplied to the storage cell 528 that is coupled to the VDDcell line 506 . In this Disabled State, the memory circuit 500 that is controlled by the control circuit 501 is not used at all in the current arrangement.
As is more specifically shown by reference to FIG. 4 , during the Disabled State, the word line 405 and the VDDcell line 406 have a logical “0.” When the VDDcell line 406 has a logical “0,” no power is provided to the storage cell 428 . Further, since the storage cell 428 outputs no value to the NMOS transistors 442 and 447 , the output of the amplifier stage 438 floats (e.g., at one P-channel threshold below the rail). Thus, the memory circuit 400 stores and outputs no value in the Disabled State.
The Disabled State is useful, for example, in the case of a configurable circuit where it is desirable to power off parts of the circuit (e.g., an array or parts of an array of memory cells). Powering off cells in this manner can additionally conserve power.
2. Read/Write State (EN-bar=0, WL_EN=1)
For the Read/Write State, the control circuit 501 : (1) provides the full supply voltage VDD to the storage cell 528 , so that it can store and output a value, and so that the memory circuit 500 can access the cell 528 through a read/write operation; (2) enables the word line 505 to select the cell 528 for the read/write operation; and (3) prevents the voltage on the word line 505 from exceeding the voltage on the VDDcell line 506 , such that a read upset condition is avoided.
More specifically, when an input signal at the input Not_Enable 520 has a logical “0” and the input Word_Line_Enable 530 has a logical “1,” then current flows from the VDD line 507 through the VDDcell line 506 (via the PMOS transistor 545 ), and from the VDDcell line 506 through the word line 505 (via the PMOS transistor 555 ). In other words, the PMOS transistors 545 and 555 switch to low impedance which pulls the voltages on these lines (VDD cell line 506 and word line 505 ) up to the level of approximately VDD. In this state, the memory circuit 500 performs a read and/or write operation by using the full supply voltage VDD, in the manner of a typical memory cell in the art.
As more specifically shown in FIG. 4 , during a read or a write operation, both the VDDcell line 406 and the word line 405 are activated (have a logical “1”). As previously described, the VDDcell line 406 provides a voltage at approximately VDD to the storage cell 428 to allow for a typical read or write operation by using the full supply voltage VDD. Since the word line 405 is activated, the pass gates 420 and 425 are turned on, and voltage signals are allowed to pass between the bit lines 410 and 415 , and the storage cell 428 . During a write operation, the voltage signals on the bit lines 410 and 415 modify the voltages (which represent the stored value) at the nodes 426 and 427 . For instance, the value on the bit line 410 passes through the pass gate 420 and is stored in the storage cell 428 at node 426 during a write operation. Conversely, the value stored in the storage cell 428 at node 426 passes through the pass gate 420 to modify the voltage on the bit line 410 , during a read operation. Write and read operations occur in the same manner through the pass gate 425 between the node 427 and the complement bit line 415 in the Read/Write State. Moreover, the nodes 426 and 427 (representing the stored bit and its complement) each may have a value approximately equal to VDD that is applied to the amplifier stage 438 . As previously mentioned, the amplifier stage 438 produces an output with a voltage of approximately VDD.
Specifically, as shown in FIG. 4 , the storage cell 428 is coupled to the amplifier stage 438 at the gate-inputs of the NMOS transistors 442 and 447 . Thus, if a logical “1” is at the node 426 , then the NMOS transistor 442 will be activated and the PMOS transistor 446 will also be activated. Accordingly, current will flow from the VDD line 407 through the PMOS transistor 446 to the configuration output 465 . Conversely, the cross-coupled PMOS transistor 441 will ensure that the output 460 will be pulled low (i.e., grounded through the NMOS transistor 442 .
As previously mentioned, the amplifier stage 438 leaks less current than its counterpart in the prior art (buffers 140 and 145 ) because the output voltage only passes through a low impedance PMOS transistor. However, the Normal State has even lower current leakage.
3. Normal State (EN-bar=0, WL_EN=0)
As shown in FIG. 5 , when the input signal at the input Not_Enable 520 has a logical “0” and the signal at the input Word_Line_Enable 530 has a logical “0,” the NMOS transistor 540 is turned on and current flows from the VDD line 507 through the VDDcell line 506 . Because the signal at the output of the inverter 535 is a logical “1,” both the PMOS transistors 545 and 555 are turned off and the word line 505 has a logical “0.” When the PMOS transistors 545 and 555 are off, the word line 505 is not enabled for reading or writing the contents of the storage cell 528 in the memory circuit 500 . Moreover, because the NMOS transistor 540 connects the VDDcell line 506 to the VDD line 507 , the VDDcell line 506 has a reduced voltage of approximately one NMOS threshold below the full supply voltage VDD.
Therefore, the memory circuit 500 is used in the current arrangement (of a configurable IC, for instance) but the memory circuit 500 is not currently being accessed by a read or write operation through the word line 505 . However, the memory circuit 500 is outputting a value stored in the storage cell 528 to the configuration outputs 560 and 565 . This is the normal active state of the memory circuit 500 .
As more specifically shown in FIG. 4 , during the Normal State, the VDDcell line 406 is activated but the word line 405 is de-activated. Since the word line 405 is de-activated, the pass gates 420 and 425 are turned off. When the pass gates 420 and 425 are turned off, the bit lines 410 and 415 are not used to write to, and are not used to read from, the storage cell 428 . However, since the VDDcell line 406 is activated, (a reduced) power is supplied to the storage cell 428 to maintain a value stored in the storage cell 428 . Since the cell operates at the reduced voltage (which in some embodiments is less than VDD by an NMOS threshold), the electronic components of the cell 428 leak exponentially less current than the prior art cell. Further, the value stored in the storage cell 428 is applied to the amplifier stage 438 through the NMOS transistors 442 and 447 .
Accordingly, the amplifier stage 438 outputs the value stored in the storage cell 428 at a voltage approximately equal to VDD (from the VDD line 407 ). As mentioned above, the voltage signal from the VDD line 407 through the PMOS transistors 441 and 446 to the configuration outputs 460 and 465 is roughly equal to the full supply voltage VDD. In this manner, the voltage signal from the storage cell 428 that is approximately equal to VDDcell is amplified (level-converted) for output at the amplifier stage 438 to a value that is approximately equal to VDD. As previously mentioned, the voltage on the VDDcell line 406 can be less than the voltage on the VDD line 407 by one or more NMOS thresholds because the NMOS transistors 442 and 447 of the amplifier stage 438 do not require full swing. Thus, the amplifier stage 438 converts (amplifies) the voltage level from the storage cell 428 before outputting the voltage signal at the configuration outputs 460 and 465 . Therefore, in the Normal State, the storage cell 428 can operate at a reduced voltage to minimize leakage while maintaining and outputting a stable configuration output value at approximately the full supply voltage VDD.
4. Table Showing Inputs, Outputs, and States
Table 1 summarizes the three states for the memory circuit 500 in relation to the input values for the control circuit 501 . Table 1 also shows the values of the VDDcell line 506 and the word line 505 for the three states according to one embodiment of the present invention. For instance, the VDDcell line 506 is approximately equal to VDD (the full supply voltage) which allows typical reading and/or writing operations during the Read/Write State. During the Read/Write State the word line 505 is also approximately equal to VDD. During the Normal State, however, the word line 505 is de-activated and the VDDcell line 506 is about one NMOS threshold below VDD. As described above, reducing the VDDcell voltage by only one NMOS threshold is sufficient to result in a significant reduction in current leakage.
III. Performance and Advantages
As mentioned in relation to FIG. 4 , the voltage within the cell (VDDcell) can be reduced from about 1.0V to about 0.8V or approximately one NMOS threshold, in some embodiments. In other embodiments VDDcell may be reduced by a plurality of NMOS thresholds to further reduce current leakage through the electronic components (e.g., the MOS transistors) of the memory circuit storage cell.
Some embodiments use 90 nm electronic components. At 90 nm the sub threshold leakage and the gate leakage are roughly equal. Since gate leakage is more sensitive to voltage reductions, some embodiments provide greater reduction in the gate leakage for 90 nm components. For 65 nm components, gate leakage is often worse than sub threshold leakage. Thus, a greater improvement in overall leakage reduction may occur for electronic components using 65 nm technologies.
Some embodiments allow the reduced voltage to be used for a set of cells that are similar to the cell 428 in FIG. 4 , to reduce the power consumed and leaked by the entire set of memory cells. For instance, the invention also allows an entire row of cells to be powered down at a time. This feature can be useful, for instance, in an FPGA where the whole array may not be needed for some arrangements of the FPGA. Thus, the present invention allows for additional power savings by allowing unused parts of the array to be powered off. The invention has been described in relation to FPGA's and configuration cells. However, one of ordinary skill in the art will recognize that the invention would be useful in a variety of memory and other applications where reduced power consumption and lower leakage are desirable.
The foregoing has described a reduced power cell. One of ordinary skill will also recognize that the invention can be embodied in other specific forms without departing from the spirit of the invention, even though the invention has been described with reference to numerous specific details. In view of the foregoing, one of ordinary skill in the art would understand that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
TABLE 1
State
EN-bar 520
WL EN 530
VDDcell 406
Word Line 405
Disabled
1
0
0
0
Read/Write
0
1
(VDD)
(VDD)
Normal
0
0
(VDD-1Vth)
0 | The invention relates to reduced power cells. Some embodiments of the invention provide a memory circuit that has a storage cell. The storage cell contains several electronic components and an input. The electronic components receive a reduced voltage from the input to the cell. The reduced voltage reduces the current leakage of the electronic components within the cell. Some embodiments provide a memory circuit that has a level converter. The level converter receives a reduced voltage and converts the reduced voltage into values that can be used to store and retrieve data with stability in the cell. Some embodiments provide a method for storing data in a memory circuit that has a storage cell. The method applies a reduced voltage to the input of the cell. The method level converts the reduced voltage. The reduced voltage is converted to a value that can be used to store and retrieve data with stability in the cell. The reduced voltage reduces a current leakage of electronic components within the cell. | 6 |
The invention was made with Government support under Contract DE-AC0676RLO 1830, awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
TECHNICAL FIELD
This invention relates to methods and techniques for monitoring the flow of information in a computer network.
BACKGROUND OF THE INVENTION
The widespread use of interconnected computers has greatly enhanced the free flow of information worldwide. The commonly used TCP/IP standard has become particularly widespread, and is utilized by computers operated by academia, industry, government and consumers to share information.
In certain instances, however, the owners and/or users of these computer systems do not wish to have certain information stored on these computers shared with the outside world, and/or they do not wish for the users of these computers to access certain types of information available on other computers also connected to the network. This presents a problem. If a computer is disconnected from a network that allows the user to share information with other computers, it is more difficult for the user of that information to communicate information with the outside world. However, it is also more difficult to access acceptable information that is available by were that computer connected to the network.
Typically, a user's need to have access to the outside world is sufficient that the user's computer remains connected to the network, even though this presents a risk that an undesirable transfer of digital data may take place between that user's computer and the outside world. As a result of this risk, there is a need for methods by which computers that are connected to a network may be monitored, to detect undesirable transfers of digital data either to or from those computers.
One problem associated with the need to monitor these computer systems is associated with the large amounts of digital data that may flow through these systems. For example, and not meant to be limiting, an organization might have hundreds of different computers all connected to the internet, all of which are operated by users who are constantly uploading and downloading digital files from computers outside of the organization. Since any system set up to monitor large data flows is inherently limited by considerations including, but not limited to processor speed, memory, and memory access, there exists a need for better systems and methods that can monitor large data flows with limited system resources.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a system and method for monitoring large data flows. It is a further object of the present invention to provide a system for monitoring large data flows that organizes the data flows in a manner that allows a user to easily review the data flows to determine if data is flowing to or from undesirable sources and/or recipients. These and other objects of the present invention are accomplished by providing a method for converting packet streams into session summaries. Session summaries are defined as a group of packets each having a common source and destination internet protocol (IP) address, and, if present in the packets, common ports, including but not limited to transmission control protocol (TCP) and user datagram protocol (UDP).
The present invention first captures packets from a transport layer of a network of computer systems. Accordingly, the present invention may generally be incorporated into any computer system in communication with the transport layer of a network of computer system as a software program. The present invention thus includes any multipurpose computer system capable of operating a variety of different software programs and configured to perform the steps described herein. These multipurpose computers may also be configured to run other software, either simultaneously or in series, but such is not required. Further, the present invention would include the steps described herein in any tangible, machine readable form that would allow a multipurpose computer system to be configured to perform these steps, including but not limited to electromagnetic forms, such as a floppy disk or a magnetic tape, and optical forms, such as compact disc or a DVD.
As will be recognized by those having skill in the art, any series of steps programmed into a computer as software, including the present invention, can be reproduced by configuring the hardware of the computer to perform the identical steps. Further, a computer capable of multiple configurations can be designated as a single purpose computer, dedicated to performing only one task. Accordingly, the present invention should be understood to include any computer, system, whether multipurpose or single purpose, configured to perform the steps described herein, whether as a series of steps provided to the computer as software, or by configuring the computer's hardware to perform the series of steps.
Once a computer system configured to operate according to the present invention captures packets from a transport layer of a network of computer systems, the present invention then decodes the packets captured to determine the destination IP address and the source IP address. The present invention then identifies packets having common destination IP addresses and source IP addresses. The present invention then writes the decoded packets to an allocated memory structure as session summaries in a queue. Within the queue, each session summary contains only packets having common destination and source IP addresses. In this manner, a large data flow across the transport layer of a network of computer systems is efficiently organized according to the specific source and destination. In this manner, an analyst can efficiently review the data flow to and from a wide variety of sources to determine if any portion of the data flow contains undesirable communications.
In some embodiments of the present invention, the step of decoding the packets further comprises determining TCP port source and destination numbers, flag fields, option fields, sequence number, length parameter, and combinations thereof. By comparing these parameters among the packets being analyzed by the present invention in addition to common destination and source IP addresses, packets having common destination and source IP addresses can be more reliably grouped as being between specific users.
In some embodiments of the present invention, the step of decoding the packets further comprises determining UDP port source and destination numbers and the length parameter. By comparing these parameters among the packets being analyzed by the present invention in addition to common destination and source IP addresses, packets having common destination and source IP addresses can be more reliably grouped as being between specific users.
In a further embodiment of the present invention, packets having common destination and source IP addresses are organized in an allocated memory structure by creating a series of time buckets within the allocated memory structure. Each of the time buckets has a predefined beginning time and a predefined end time. The time buckets are sequential in time. New session summaries are associated with the time bucket covering the time period corresponding to the time the packet was captured from the transport layer. A session summary may then be moved to the time bucket at the front of the queue in response to an incoming packet having a destination IP addresses and source IP addresses matching the session summary. In this manner, the session summaries are organized in an allocated memory structure.
As used herein, an “allocated memory structure” means that the data is written to a fixed location in primary memory. Generally, primary memory (sometimes referred to as “general memory” by those having ordinary skill in the art) is memory that is not used as cache by the processor, but is randomly accessible by the processor. The use of an allocated memory structure thus allows the method of the present invention to assemble the session summaries without copying the data to other locations. This aspect of the present invention, coupled with the aging the sessions, allows the present invention to successfully convert packet streams into session summaries in environments with high levels of packet flow.
As new packets are processed, the session summaries associated with those packets are continually linked and put at the head of the queue. Thus, older session summaries migrate to the end of the queue as a passive result of the processing of new packets, as opposed to any active measures to identify them as older session summaries, such as a mark and sweep function. The use of the packet accumulation step to produce correctly aged session summaries in this manner is a key aspect of the present invention because it allows the overall system to process high volumes of packet flow efficiently. The allocated memory structure thus contains not only the hash and chaining links used in the master session cache, but also includes links used by the aging mechanism. The session either is moved to the head of the aging queue as a result of a new packet being added, or it will be removed from the end as a result of the summary falling outside of the user defined age parameter.
“Aging” sessions is accomplished by defining a “time out value” and deleting session summaries associated with time buckets older than the time out value. In this manner, allocated memory structure remains available for session summaries generated by high levels of data flow.
Transport layers for which the present invention can monitor large data flows include, but are not limited to, fast Ethernet, Ethernet, gig-E, FDDI, and wireless.
In a preferred embodiment of the present invention, separate threads and/or processes are used for the different tasks performed. For example, the step of capturing packets from a transport layer might be performed as a separate thread, and/or on a separate processor as the step of decoding the packets to determine the destination IP address and the source IP address. The steps of identifying packets having common destination IP addresses and source IP addresses and writing the decoded packets to an allocated memory structure as session summaries in a queue, might be performed as a separate thread, and/or on a separate processor. In this manner, each step is allowed to operate semi-independently, and incoming packets are not lost as a result of insufficient processing capability.
FIG. 1 is a graphical representation of the present invention.
The method of the present invention may be illustrated with reference to FIG. 1 which shows the method for converting packet streams into session summaries comprising the steps of 1 capturing packets from a transport layer, 2 decoding the packets to determine the destination IP address and the source IP address, 3 identifying packets having common destination IP addresses and source IP addresses, 4 writing the decoded packets to an allocated memory structure as session summaries in a queue wherein said session summaries contain only packets having common destination and source IP addresses, 5 creating a series of time buckets, each of the time buckets having a predefined beginning time and a predefined end time, wherein the time buckets are sequential in time, 6 associating new session summaries with the time bucket covering the time period corresponding to the time the packet was captured from the transport layer, and 7 moving a session summary to the time bucket at the front of the queue in response to an incoming packet having a destination IP addresses and source IP addresses matching the session summary, and 8 defining a time out value and deleting session summaries associated with time buckets older than the time out value.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference a project was completed which demonstrated a preferred embodiment of the present invention. The project is described below, where the following terms are defined as follows:
“Flow” and “IP flow” means any IP packet stream between the same set of IP addresses and ports with the same IP protocol type. “CF” means Continuing Fragments. The CF flag is set to indicate that it is not the first record in the flow. “MF” means more fragments. In the first record of a long flow, the MF flag is set to indicate that there are more records related to this record. The MF flag is also set unless the session is timing out due to the Session Inactivity Timeout (SIT) value.
The project which demonstrated the present invention can generally be described as sensor software. The specific program was written as a narrow focus, single purpose tool used to monitor IP packet flows, and was named “Flo” by the inventors. This embodiment of the present invention was written to read either tcpdump format files or to attach itself to an Ethernet interface. Design and testing was performed on common PCs running the Linux operating system. Those having ordinary skill in the art will readily recognize that the steps of the present invention could readily be applied in different operating environments. Thus, while the detailed description below utilizes commands common to UNIX/LINUX, equivalent commands exist in different operating systems, including but not limited to Microsoft Windows and Apple OSX, and the present invention should be understood to encompass the method as described herein written for these operating systems using these equivalent commands.
The software was written to load IP address tables which are then used to annotate the output records. A country code file, such as from GeoIP, allows each IP in a flow to be identified. Similarly, a file of address spaces in use by each site can be used to further tag the output records. Finally, a file of address spaces known to be external to all monitored sites was used to generate a list of address spaces belonging to the monitored sites.
The Flo software was constructed to handle standard Ethernet and 802.1Q (VLAN) traffic. In this demonstration, no other layer 2 protocols were supported. Those having ordinary skill in the art will readily recognize that such protocols can be supported with appropriate modifications. The payload portions of the packet are not examined in any way by Flo, however, those having ordinary skill in the art will readily recognize that the software can be readily be modified to examine those payload portions in any manner desired by a user.
A channel to the syslog daemon using LOCALO is created early in program startup. If the ‘--foreground’ switch is not given on the command line, the process is detached from the terminal. Signals create a heartbeat that allows the software to monitor the passage of time, create reports, and perform other functions on a periodic basis. These signals also monitor program shutdown.
The normal mode of operation is to run the software in daemon mode. In this mode, the software connects to an Ethernet interface to monitor packet flows in real time. The other mode is to specify an input file using the “--read” option switch. The special name “-” specifies standard input.
Packets may be decoded according to any of the various RFC specifications, such as 802.1Q (VLAN), ATM, or FDDI, for example, as determined by the needs of a particular user. While it is anticipated that IP, TCP, and UDP will be the protocols that will be preferred by most users, it should be understood that the present invention is equally capable of decoding packets and forming session summaries using any protocol that might be defined by a particular user. The actual length of the packet is compared with the length specified in the IP layer header to prevent decoding of either an illegal input or a garbage packet. The same checks are performed for UDP and TCP headers. These lengths are recorded in an intermediate structure along with the source and destination IP addresses and IP protocol type. If the protocol is one of UDP or TCP, the port numbers and the size of the data portion of the packet are recorded. If the protocol is TCP, then the flags fields along with the sequence number, if available, are also recorded.
The master cache is indexed by a hash key generated from the source and destination addresses and ports. The addresses and ports are folded together so that the packet direction does not affect the resulting key. This hash key is also used in the ring buffer indexing.
The key is used to index into the master cache using a hash table. Chaining resolves collisions. If the packet is part of an existing flow, the information from the decoded packet is merged into the previously saved information.
The passage of time represented by the timestamps in the incoming packets is managed by the ring buffer. Each flow is time stamped by the time of the last packet in the flow. This time is used to select the appropriate slot in the ring buffer. New packets for a flow carry a new timestamp and therefore change the ending timestamp for a flow. The position of a flow in ring buffer is modified based on the change in the timestamp.
Completed flows are reported by removing the last element of the ring buffer when it is about to be overwritten by new data. This embodiment of the program thus will not emit any flow records until the ring buffer has filled. Each node in the ring buffer represents flows that terminate within the same second. Other node sizes are possible but probably not necessary. The flows within each node are ordered by a hash of the source and destination addresses and ports. The records may not be in time order when appearing in the output file.
Partial flows are produced by early termination of the program. Partial flows are also produced by long duration flows which cause force out. These forced out flows will have timestamps that would appear to be in the future compared with other flow records adjacent to it in the output file. This situation is normal and is due to the forced out record being at the head of the queue and the normal complete flow records written from the end of the queue.
Two output modes were provided. The normal mode generates files in the specified output directory. The file names are derived from the termination time of the first flow written. The other mode allows the user to specify a name in which case, the file will be written in the specified directory or it can be “-” in which case it will be written to standard output.
The program will shutdown cleanly via two signals. The SIGHUP signal will flush any pending flows to the output file. These records will be marked as incomplete by use of a non-zero value in the force field. A value of zero or an empty field indicates a flow record that was written due to either the inactivity timeout or force out condition.
The TERM signal will terminate the program cleanly but will not write pending records to the output file.
The project which demonstrated the present invention is organized around a simple loop. A packet is read from either a file or a socket interface. The packet is decoded and information about the packet at the IP layer is saved in a flow buffer. Protocol specific information for UDP and TCP are also saved. The packet is assigned to an existing or new flow via the master flow cache. Information contained within the flow buffer indicates the location within the flow queue. The flow buffer is moved to the head of the flow queue if it is not already at the head.
Long duration flows are identified by producing intermediate results. At the time that a new packet for a flow is processed, the duration of the flow is compared with the “session force out” (sfo) command line parameter. If the duration exceeds this value, the session is written to the data store, and the packet data accumulators are cleared. In this way, a long running flow will consist of a series of records. The summation of the data from the individual records will reproduce the totals for the flow.
The flow queue is constructed of a sequence of individual caches identical in structure to the master cache. Each cache contains flows that currently terminate within a period of time determined by the “window” command line parameter. The length of the queue is determined by the “session inactivity timeout” (sit) command line parameter.
Flow duration and ending times are measured to the limit of the accuracy of the time stamps recorded by the system's network device driver. The resolutions of the time stamps are microseconds though the accuracy of the values may be much less. Observation of two different systems recording the same data stream and having their clocks in sync by the use of NTP shows that the time stamps may differ by at least 0.2 seconds.
The tail of the queue is examined for flows that should be flushed to disk. When no additional packets are seen for a session for a specified period of time, a record is created and recorded in the output file.
Flows for the purpose of this sensor are sequences of packets that have the same signature (source/destination address/port and protocol). Flows are not restricted to TCP but are applicable to all captured IP protocols.
There are two parameters that were used by the project which demonstrated the present invention to control the assembly of packets into flows. These are SIT (Session Inactivity Timeout) and SFO (Session Force Out). The value of SIT was nominally set to 4 minutes, however, as those having ordinary skill in the art will recognize, this value was chosen for the user's convenience, and other values could readily be utilized. Sessions, which have been idle for this length of time, are written to the capture file with the MF flag cleared indicating that there will be no subsequent records related to this flow.
Long running sessions will have more than one record relating to that session. Long running sessions are defined as a flow whose packet arrival times exceed the span of time specified by the value of SFO. Again, for the project which demonstrated the present invention this was set at 4 hours, but those having ordinary skill in the art will recognize, this value was chosen for the user's convenience, and other values could readily be utilized. The first such record in a long flow will have the MF flag set to indicate that there will be more records related to this record. Subsequent records will have the CF flag set to indicate that it is not the first record in the flow. The MF flag will also be set unless the session is timing out due to the SIT value as above.
The program logs startup, shutdown, configuration, file, and performance information to syslog using the local0 facility. If this facility is not configured, the default messages file will be used.
Several approaches to automatically obtaining a site address space have been suggested and analyzed. The first approach was to completely scan the IPv4 address space at the class C boundary (CIDR=24). This approach is not considered as the preferred approach. A modified approach to this that is more preferred would be to monitor the generated data and identify candidate address pairs where neither address had been identified as originating from the monitored site. Mapping probes sent to both addresses will be seen in the resulting data collection from only one of the addresses.
In reality, there are scans in progress across the internet at all times. In a preferred embodiment of the present invention, the only requirement for this mapping function is that the scan must originate externally from the monitored address space. Search engines, such as Google, and other internet mapping algorithms, can provide the requisite independent scanning.
A list of addresses, which are known to be external to the monitored site, were provided to the software. As sessions are identified and prepared for recording, the source and destination addresses are compared with the scanner list. Matching sessions have the other address in the session added to the list of address spaces associated with the monitored site. Addresses were initially trimmed to a CIDR value of 24. Adjacent address blocks were coalesced into larger blocks. Data is reported via syslog as a separate record for each address space.
Command line options may also be used to specify maps that provide an address to string id mapping. Two forms may be used as specified below. The first uses a CIDR block notation followed by the site tag. The tag value corresponds to the site tag used in the file name and in the site field (field 3 ) of the session/alert record, for example:
Tag aaa.bbb.ccc.ddd/cidr
Ipaddr1,ipaddr2,tag
The output from the software project which demonstrated the present invention can be quite voluminous. During conditions of a rapid scan, the number of records can more than double, which can overwhelm the processing, handling, and database loading functions. In a preferred embodiment, a limiting function is provided to prevent such an occurrence that can also be perceived as a DOS attack on the monitor software itself.
While the invention has been described in connection with specific embodiments utilized for the project undertaken to demonstrate a preferred embodiment of the present invention, those having ordinary skill in the art will readily that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A system and method for converting packet streams into session summaries. Session summaries are a group of packets each having a common source and destination internet protocol (IP) address, and, if present in the packets, common ports. The system first captures packets from a transport layer of a network of computer systems, then decodes the packets captured to determine the destination IP address and the source IP address. The system then identifies packets having common destination IP addresses and source IP addresses, then writes the decoded packets to an allocated memory structure as session summaries in a queue. | 7 |
FIELD OF THE INVENTION
This invention relates to alarm systems and more particularly to a multi-zone alarm system for the detection and indication of an alarm condition in respectively identified zones.
BACKGROUND OF THE INVENTION
In alarm systems employed to sense intrusion, fire or other condition, techniques are known for the determination at a central location of the remote zone in which an alarm has occurred. In such systems, a communications path is established between each remote alarm sensor and a central location, the communication path being provided by means of a separate communications line from the central location to each remote station, or by use of a common communications line and multiplexed signaling techniques, such as time division multiplexing or frequency division multiplexing.
It is advantageous to employ a two-wire communications path forming a single alarm loop in which all alarm sensors are connected. Such a single loop can minimize the amount of wiring necessary to interconnect the central location with the remote sensors and can provide relatively simple and efficient connection of the remote sensors with the central location. It is usually required in an alarm system to provide the capability of identifying each sensor or each zone in which an alarm has occurred. Thus, a communication technique must be employed which is capable of identifying each sensor or each zone that senses an alarm condition.
SUMMARY OF THE INVENTION
In brief, the present invention provides a multi-zone alarm system operative with a two-wire alarm loop and having a simple network at each alarm sensor for providing a coded signal indicative of sensor identity and relatively uncomplicated circuitry at a central location for interrogation or polling of the remote sensors and determination of those sensors providing an alarm signal.
A current source is provided at the central location for providing a predetermined current in the alarm loop. The networks associated with respective alarm sensors are each operative in response to its sensor actuation to provide a signal for transmission along the loop to the central location, the signal having a characteristic which denotes the identity of the actuated sensor and its zone. These signals are received at the central location by circuitry operative to provide a signal indicative of the zone in which an alarm is sensed.
DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagrammatic representation of a multi-zone alarm system embodying the invention;
FIG. 2 is a schematic representation of the alarm networks of FIG. 1;
FIG. 3 is a diagrammatic representation of the processor of FIG. 1;
FIG. 4 is a schematic representation of an alternative alarm network for use with the embodiment of FIG. 5;
FIG. 5 is a diagrammatic representation of a further embodiment of the invention employing the network of FIG. 4; and
FIG. 6 is a diagrammatic representation of an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown a programmed current source 10 connected to an alarm loop which is composed of an outgoing conductor 12 and a return conductor 16 terminating in an end of line network 14. A plurality of normally closed alarm switches 18 are connected in series in conductor 12. A plurality of networks 20 are provided each connected in parallel with respective alarm switches 18. Thus, in the illustrated embodiment, network 20a is connected across switch 18a, network 20b is connected across switch 18b and network 20c is connected across switch 18c. While three alarm switches and associated networks are illustrated in the embodiment of FIG. 1, it will be appreciated that in practice any number of switches can be employed.
The current source 10 is also coupled to a processor 22 which provides an output signal to a multi-zone display 24 which provides an output indication of the zone or zones in which an alarm has occurred. The current source provides typically a rising exponential current which is repetitive at a selected rate.
The networks 20 are identical and are implemented by the circuit shown in FIG. 2. An electronic switch 30 is connected in parallel with the associated switch 18, and a series connected capacitor C1 and resistor R1 are connected in shunt with switch 30. The switch 30 can be, for example, a silicon unilateral switch (SUS), a silicon bilateral switch (SBS), a diac, a unijunction transistor or other device or network providing the intended switching characteristic wherein switching between conductive and non-conductive states occurs at a predetermined voltage or current level. The SBS is preferable for installation convenience, since it cannot be connected in wrong polarity; thus, the network containing the SBS can be installed across the switch in either polarity. When switch 18 is open, the loop current is applied to capacitor C1, since the switch 30 is essentially an open circuit below its initial firing voltage. When the capacitor C1 has charged to the firing voltage, typically 8 volts DC, switch 30 is triggered and provides a low impedance through which capacitor C1 discharges and causing a resultant negative voltage step to appear at the input of the loop. This pulse will occur at a time dependent on the capacitance of capacitor C1, and by providing different values of capacitance for respective zones, the different zones will be sensible at different times. The time sequenced outputs from the several zones can be processed to provide both alarm and zone indications.
The switches 18 can be normally closed or normally open. When normally closed, there will be no response or report from a normal (non-alarm) zone. Upon an alarm condition, the corresponding switch 18 is opened, causing triggering of electronic switch 30 as described above, to provide a pulse which denotes the alarm zone. When switches 18 are normally open, the associated electronic switches 30 will be triggered during each polling interval and each zone will therefore issue a report during each polling interval. A missing report signifies an alarm in that zone which did not respond during a polling interval.
The end of line network 14 is the same type of circuit as networks 20 and can be employed across a switch or without an associated switch. This network 14 reports during each polling interval and an associated switch is normally open. The absence of a report from network 14, caused by closure of its switch or by an opened loop, denotes an alarm condition.
The processor is shown in greater detail in FIG. 3. A clock 32 is coupled via a gate circuit 34 to a decade counter 36, one output of which is applied to a reset multivibrator 38, the output signal of which disables gate 34. The parallel outputs of counter 36 are applied to a function generator 40 the serial output of which is applied to a current source 42 which provides the repetitive exponential current signal to the alarm loop. The decade counter 36 has a plurality of outputs, one for each zone, each enabling a respective sample and hold circuit 44. The sample and hold circuits are coupled to respective integrators 46 which, in turn, are connected to respective threshold and latch circuits 48. Respective light emitting diodes 50 or other suitable indicators are connected to respective circuits 48. The current source output is also coupled via capacitor C2 and shunt resistor R2 to each of the sample and hold circuits 44.
An alternative embodiment of the invention is shown in FIGS. 4 and 5 wherein a current ramp is provided in the alarm loop for polling of the networks associated with the respective alarm switches. The network 60 is shown in FIG. 4 and includes in parallel with the alarm switch 62 a resistor R p and an electronic switch 64 which can be an SBS or other device described above in connection with switch 30. A bypass capacitor C b is provided in shunt with the switch 64 to prevent radio frequency interference and switching transients from triggering the switch 64. A small resistance is provided by resistor R s to limit the capacitor discharge current to prevent damage to the switch contacts. The resistor R p is of a different resistance value for each associated sensor to provide triggering of switch 64 at a time denoting the identity of the associated zone.
Referring to FIG. 5, an oscillator 66 provides clock signals to a divider circuit 68 which provides timing signals to a current source 70 which provides a ramp current to the alarm loop composed of conductors 72 and 74. An end of line network 76, of the same type as network 60, is provided as a termination for the loop. The oscillator 66 provides a clock signal of convenient frequency, typically 26.3 kHz, while the divider 68 provides signals of convenient lower frequency, typically 51.4 Hz. The divider output signals are converted by current source 70 into a staircase current signal for application to the alarm loop.
Conductor 72 is AC coupled via a capacitor C 5 to a pulse detector 78 which in turn provides pulses to a demultiplexer 80. An address code is provided by divider 68 to the demultiplexer to identify the position along the staircase signal and therefore the time at which pulses are received. The demultiplexer is coupled to a plurality of integrators 82 each associated with a respective one of the alarm switches 62. Each integrator 82 is coupled to a control circuit 84, which is adjustable to accommodate normally open or normally closed alarm switch contacts, and then to an exclusive OR circuit 86. Each exclusive OR circuit 86 is coupled to a latch circuit 88, the output of which is coupled to an LED driver 90 coupled to respective LED or other output indicators 92. The outputs from each of the exclusive OR circuits 86 are also coupled to respective inputs of an OR gate 94, the output of which is applied to a control circuit 96 which provides output signals to a night relay and a day relay 100 which comprise the alarm relay circuits of the overall system.
When the current provided by current source 70 in the alarm loop exceeds the trigger current of a network 60, a negative going voltage pulse is sent back to the annunciator circuitry at a time corresponding to the point on the current ramp at which the particular network is triggered. The received pulse coupled via capacitor C 5 to pulse detector 78 which is operative to discriminate between spurious signals and to provide, in response to a received pulse of predetermined amplitude and length, an output signal to demultiplexer 80. The demultiplexer is operative in response to the timing of the received pulse, as determined by the address code from divider 68, to provide a signal to the integrator 82 associated with the alarm switch, the activation of which has been sensed by the corresponding network 60. An open alarm switch contact causes pulses to discharge the integrator for that zone to provide a logic zero output. A closed contact causes its integrator to charge up to a logic one state. The integrator output is applied to an exclusive OR gate 86 which can be programmed via control circuit 84 to allow for either normally open or normally closed switch contacts. The output of the exclusive OR gate goes low upon an alarm condition and the output signal is coupled via OR gate 94 to control circuit 96 for actuation of one or both of the alarm relays 98 and 100. The output of the energized exclusive OR gate 86 is also coupled to associated latch circuit 88 which energizes driver 90 for illuminating the associated LED 92 to indicate the zone in which an alarm has occurred. The LED's may be continuously illuminated or can be operated in a blinking mode.
An embodiment of the invention is shown in FIG. 6 and comprises a constant current source 52 connected to the alarm loop, which includes an end of line terminating resistor R T . The alarm loop includes a plurality of alarm switches 54, across each of which is connected a respective resistor of a predetermined resistance value to represent a particular zone. A resistor 1R is connected across switch 54a, a resistor 2R is connected across switch 54b and a resistor 3R is connected across switch 54c. The constant current source is also connected by way of a capacitor C3 to a read circuit 54, the output of which is applied to a multi-level comparator 56 which provides a signal indication of which zone has an alarm condition. The comparator 56 is connected to an electronic switch 58 which is also connected to capacitor C3 and, by means of a resistor R3, to ground.
The voltage V a is the product of a constant current I and the sum of all resistors across open alarm contacts. When an alarm contact opens, the voltage V a will step by an amount equal to IΔR, where ΔR is the resistance change occassioned by presence of the particular alarm resistors. This voltage step is coupled via capacitor C3 to resistor R3, the voltage across resistor R3 being sensed by a read circuit 54 which provides a signal to a multi-level comparator 56 which is operative to compare the received signal level with its internal threshold levels and provide an output signal representative of the associated zone represented by the sensed signal level. After providing a zone output, the voltage across resistor R3 is dumped by closure of switch 58 thereby grounding the junction between resistor R3 and capacitor C3. The switch 58 is then returned to its open state to enable the sensing of another alarm condition.
When an alarm switch 54 recloses, there will be a negative voltage step which is clamped by a diode D1 to prevent a false reading of the negative step. The system can also operate with normally open switches to detect switch closure as an alarm condition.
The invention is not to be limited except as indicated in the appended claims. | A multi-zone alarm system operative with a two-wire alarm loop and having a simple network at each alarm sensor for providing a coded signal indicative of sensor identity and relatively simple circuitry at a central location for interrogation of the remote sensors and determination of those sensors providing an alarm signal. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an air blowgun, and more particularly to an innovated blowpipe mechanism of the air blowgun.
2. Description of Prior Art
In accordance with the conventional air blowgun 10 with a 4-inches standard length blowpipe, as shown in FIG. 1, it just only has a single function—blowing dust. Due to 80-psi pressure of discharge press, the conventional air blowgun 10 sprays wind-stream so fast that dust and debris will be rejected as blowing on them directly to occur shooting the operator or other people standing nearby dangerously, therefore this kind of over-concentrated high-speed spraying is just only used in site of necessary heavy blowing, so it is a shortcoming of the conventional blowgun.
Because the conventional air blowgun employs a fixed blowpipe mechanism—the blowpipe is unable to be replaced, if operating in a narrow and deep site or meeting obstructer-can not extend the arm of the operator in the site, a long blowgun 20 has to be needed, as shown in FIG. 2, to the object, but the long blowgun 20 is difficult to work in a narrow short distance places, it hampers the wrist moving, so the user has to prepare long and short blowgun in the meantime for using in different working site. If the working site is a long distance in outside, the worker has to carry the different blowguns with him, it will bring him to inconvenience. This is another shortcoming of the conventional blowgun.
When the conventional air gun with single function is used in other purposes, such as inflating tire to connect to different air gate, and pumping up a ball to connect to vent wire and so on, the individual adapting connectors must be needed, and mounted or removed from the tip of the blowgun as rapid as possible in order to replace another for meeting to other purpose, but the shortcoming of the individual connectors is too big volume, or too long length to occupy too much space to bring up inconvenience of carryover.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore a main object of the present invention to provide an air blowgun having a connecting thread at the tip of the blowpipe for connecting different nozzles facilitating carryover and operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing a conventional short blowgun.
FIG. 2 is a side view of a conventional long blowgun.
FIG. 3 is an exploded view showing attaching a nozzle having a screen of the present invention.
FIG. 4 is a cross-section view showing the screen nozzle combined with the blowgun of the present invention.
FIG. 5 is a scheme showing guard function of the screen nozzle of the present invention.
FIG. 6 is a side view showing securing to a long blowpipe of the present invention.
FIG. 7 is a side view showing the long blowgun working in a narrow and deep side to pick up a part with attraction of inside magnet of the present invention.
FIG. 8 is an exploded view showing connecting to a charging adapter of the present invention.
FIG. 9 is a cross-section view showing a combined charging adapter of the present invention.
FIG. 10 is a cross-section view showing the working state of the charging adapter of the present invention.
FIG. 11 is a solid view showing a plug-in inflating nozzle of the present invention.
FIG. 12 is a cross-section view showing a plug-in inflating nozzle of the present invention.
FIG. 13 is a solid view showing a low-pressure nozzle of the present invention.
FIG. 14 is a side view of FIG. 13 .
FIG. 15 is a solid view showing a softy nozzle.
FIG. 16 is a cross-section view of FIG. 15 .
FIG. 17 is a cross-section view showing working state of the softy nozzle.
FIG. 18 is an exploded view showing connecting to a vent wire of the present invention.
FIG. 19 is a cross-section view of FIG. 18 .
FIG. 20 is a cross-section view showing the working state of cooperating with the vent wire of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 3 and FIG. 4, the present invention provides an air blowgun 30 comprising of a connecting thread 32 at the tip of the blowpipe 31 for connecting a screen nozzle 40 . Said screen nozzle 40 (as shown in FIG. 3 and FIG. 4) is comprised of a hollow main body 41 and a baffling key 42 contained in the hollow inside of the main body 41 . Said baffling key 42 is comprised of a threaded hole 421 at inside end for securing on the blowpipe 31 and leading compressed air in, and a magnet piece 423 embedded into the outside end, and a guide slot 422 crossing the both side and connecting with the threaded hole 421 for leading the compressed air into the inside of the main body 41 to form a ring wind-stream blowing out by the ring gap between the inside wall of the main body 41 and the baffling key 41 .
Referring to FIG. 4, said screen nozzle 40 may guide the compressed air to spray out in a hollow thin cone, meanwhile by means of the diffused air film to carry out shielding function for prevent dust, water and oil and so on from reflecting to shoot the operator, further to improve the safety of operation, as shown in FIG. 5 .
On the other hand, said magnet piece 43 embedded into the tip end of the baffling key 42 makes the screen nozzle 40 have attraction function of attracting steel parts. This kind of screen nozzle 40 can be used in narrow and deep space or the finger unable to touch to places for picking up steel part by the magnet piece 43 .
In accordance with above-described, due to employing the connecting thread 32 at the tip of the blowpipe 31 , the blowgun can secure with variety nozzle for meeting to different purposes.
Long and Short Blowgun Conversion Function
Referring to FIG. 6, securing an extending blowpipe 50 on the tip end of the blowgun 31 of the original short blowgun 30 is carried out said long blowgun conversion function for be used in narrow and deep space or hard touching place blocked by obstacles, and is converted so easily and simply. On the other hand, an extending blowpipe 50 is in convenience of carryover without the bother of carrying two conventional blowguns.
Magnet Attraction Function
Said magnet piece 43 embedded into the tip end of the screen nozzle 40 can pick up steel parts falling into a narrow and deep space hard touching place by arm. In general cases, the screen nozzle 40 secured on the short blowgun can deal with shallow space site, but with regarding to narrow and deep places, as shown in FIG. 7, the screen nozzle 40 is secured on the tip end of the long extending blowpipe 50 to pick up the steel parts easily and simply.
Inflating Tire Function
Referring to FIG. 8 and FIG. 9, securing an charging adapter 60 on the tip end of the blowpipe 31 can be used for inflating variety tires of wheels. Said charging adapter 60 includes a main-body 61 having a hollow stepped hole with a internal thread 611 , a push key 62 that has a stepped pin end with a both flat sides 621 thereon two side flow holes connecting to the back end hole, placed in the inside of the main-body 61 , rubber washers 64 for putting on the stepped pin carrying on sealing function, and a connector 63 having a hollow hole 631 , an outside thread at the front end for securing on the back end of the main-body 61 , and a back inside thread 632 for securing on the tip end of the blowpipe 31 . Referring to FIG. 10, when push said charging adapter 60 on the knockout pin 651 of the charging valve 65 of the tire so that the rubber washers 64 are pressed down to allow the compressed air give out from the side flow holes and via the vent hole 622 of the knockout pin 62 entering the inside of the tire to meet the necessary of inflating tire.
Plug-in Pumping Up Function
Referring to FIG. 11 and FIG. 12, a plug-in charging connector 70 has an internal thread 71 at the back end for securing on the tip end of the blowpipe 31 , and a cone anti-slip plug-in charging connecting end for plugging into the charging valves of inflating ring, air bed or swimming ring and so on to pump it up directly.
Low-pressure Nozzle Function
Referring to FIG. 13 and FIG. 14, a low-pressure nozzle 80 securing on the tip end of the blowpipe 31 of the present invention has two inlets 81 at both sides absorbing outside air as the compressed air passing through to reduce the spraying pressure and to increase air flow of blowing and spreading area of spraying.
Soft Nozzle Function
Referring to FIG. 15 and FIG. 16, a soft nozzle 90 securing on the tip end of the blowpipe 31 provided by the present invention can protect the surface of metal or coated with layer without occurring sketching harm as touching against by the soft head. Referring to FIG. 17, when the cone soft head of the soft nozzle 90 is put into the inside of a pipe to blow out the dust at inside of the pipe, the soft nozzle 90 not only can seal the pipe, but also protect the interconnecting surface of the pipe, and join on or off rapidly and facilitating operating.
Vent Wire Inflating Function
Referring to FIG. 18 and FIG. 19, a vent wire secured on the tip end of the blowpipe 31 provided by the present invention can inflate every kind of balls (as shown in FIG. 20) directly, wherein a main body 911 connects a needle valve 912 to the tip end of the blowpipe 31 . Said main body 91 provides a threaded end for securing on the tip end of the blowpipe 31 , and the another threaded end for securing in the needle valve 912 , and an escape orifice 913 formed on the proper side position for taking out the compressed air to avoid the danger of operation as the spraying hole of the needle valve is blocked.
In accordance with above-described, the air blowgun provided by the present invention not only has all the functions of a conventional blowgun, but also by means of the connecting thread at the tip end of the blowpipe can be connected with variety nozzles to meet different necessaries in different working sites and purposes. The feathers of it are occupation small volume, mounting and replacing rapidly, facilitating operation, good practicability, and convenient for carryover, improving the professional function of the blowgun, meanwhile integrating multiple functions in one blowgun and saving a quite mount of money for equipping attachments for meeting to carry out other purposes. It has quite huge practicability and great value of industry. | The present invention relates to an air blowgun, and more particularly to an innovated blowpipe mechanism of the air blowgun, which can secure with variety nozzles individually for meeting to different purposes. Wherein a thread is set on the tip end of the blowpipe, thereby to connect with an extending long blowpipe, a screen nozzle, a charging adapter, a plug-in charging connector, a low-pressure nozzle, a soft nozzle, or a vent wire and so on to form multifunction tool, and it has small volume, easy mounting and replacing operation and facilitating carryover feathers. | 8 |
REFERENCE TO RELATED APPLICATION
This application is a Non Provisional application based upon Provisional Application serial No. 60/056,614 filed on Aug. 20, 1997.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to vehicle seat belts and more particularly to a portable seat belt which is carried on the person of a rider using public transportation such as school buses.
There have been a significant number of tragic accidents involving school buses, which are not normally equipped with seat belts. It is believed that the extent of injuries or fatalities in such accidents would be significantly reduced if the students carried their own seat belts which they could attach to the seat and remove from the seat at each trip. An obvious difficulty with this is to get the students to attach and use such a seat belt. If it is to be used it must be very quickly and easily attached to the bus seat. The belt must also not be burdensome to carry.
A harness for attachment to school bus seats is shown in U.S. Pat. No. 4,205,670 which was issued in 1980. This patent shows two straps which are fastened around the back of a school bus seat and which have loops through which are fed horizontal straps which buckle around the student. The time required to install such a harness would seem to stand in the way of its wide acceptance.
The inventors have provided seat belt arrangements in which the seat belt is carried in a belly pack of the type in common use among students today. Since many students carry such belly packs, the appearance of the belly pack carrying the seat belts of the invention is little different from many others. When the student arrives at the bus, he or she simply opens the pack, unfolds the belt, opens the buckle if not already open and either passes the belt loop over the back of the seat in one embodiment, or attaches hooks having spring closures on the ends of two belt sections to the legs or other frame parts of the seat, as in a second embodiment. Depending upon the seat configuration, the hooks might be attached to legs of the seat with the seat belt across the student's abdomen. They also could be attached diagonally between an exposed upper seat frame member and a leg or lower support member. Following this simple installation, the student simply sits on the seat and closes the buckle with the belt across his or her abdomen or diagonally across his or her chest if the seat has exposed upper frame members.
Upon arrival, the student opens the buckle to stand up, closes the buckle, lifts the belt over the seat back, wraps the belt around the buckle and places the belt and buckle back in the belly pack which is then closed with any convenient closure such as hook and hoop fasteners, snap fasteners or a zipper. Alternatively, with the second embodiment the student would open the buckle, get up from the seat, close the buckle, and move around the seat as required to unhook the hooks from the seat frame. The student can often unhook both hooks from a sitting position. In either case, the student would then wrap the belt around the buckle and put the buckle, belt and hooks into the belly pack.
Applicants have also devised portable seat belt configurations including a single retractor or pairs of retractors which are carried in a student's belly pack. These belts are pulled out of the pack against the spring force of the retractors and wrapped around the back of the seat, then buckled at the side of the pack as described above. They may be made of lengths for individual seats or for dual size seats. After buckling the belt ends together, the belt end is pulled up to tighten the belt, thereby securing the student to the seat.
Obviously all students will not perform all the steps in the exact order set forth above, but the steps listed are all that is required.
It is believed that the present generation of students, having been accustomed to the use of seat belts and similar restraints since infancy will not find the use of the described arrangement excessively difficult or cumbersome.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be more clearly understood with the following detailed description and by reference to the drawings in which:
FIG. 1 is a perspective view of a student wearing one embodiment of belly pack and seat belt according to the invention;
FIG. 2 is a perspective view of a student wearing a second embodiment of belly pack and seat belt incorporating the invention;
FIG. 3 is a perspective view of either the embodiment of FIG. 1 or FIG. 2 with the belt completely folded into the belly pack;
FIG. 4 is a perspective view of the embodiment of FIG. 2 with the buckle and seat hooks open and ready to install on a seat such as a school bus seat;
FIG. 5 is a perspective view of the embodiments of FIGS. 1 or 2 with the seat belt ready to fold back into the belly pack;
FIG. 6 is a perspective view of the embodiment of FIGS. 1 or 2 with the seat belt folded into the belly pack and the belly pack ready to close;
FIG. 7 is a perspective view of another embodiment of the invention;
FIG. 8 is a perspective view showing the seat belts of the invention installed on another type of school bus seat;
FIG. 9 is a perspective view showing the seat belts of the invention installed on still another type of school bus seat;
FIG. 10 is a perspective view of another embodiment of belly pack and seat belt which incorporates a retractor;
FIG. 11 is a perspective view of a further embodiment of belly pack and seat belt incorporating a pair or retractors and with the pack shown in phantom;
FIG. 12 is a perspective view of the embodiment of FIG. 11 with the retractors fully open and the seat belt fully extended;
FIG. 13 is a perspective view of still another embodiment of belly pack and seat belt incorporating a retractor;
FIG. 14 is a rear perspective view of the embodiment of FIG. 13;
FIG. 15 is a top view, partly in section, of the embodiment of FIGS. 13 and 14;
FIG. 16 is a perspective view of a further embodiment of the invention; and
FIG. 17 is an exploded view of the embodiment of FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of a student wearing one embodiment of the belly pack and seat belt according to the invention. A student S is shown seated on a seat 10 in a school bus 12 . The seat includes a bench part 14 , a pair of rear legs 16 , front legs 17 , and seat back 18 . The student S is wearing a belly pack 20 having a waist belt (not shown), the pack having the usual pouch for incidentals and a separate compartment to which is secured a seat belt 22 . As shown, the seat belt includes a buckle assembly 24 and the seat belt 22 has been looped over the back of seat 10 . Typically the student S would open the compartment of the belly pack 20 having the folded seat belt 22 and loop the belt around the back of the seat while holding the long end of the belt. The shorter end of the belt extends only a short distance from the belly pack 20 . The student S then sits down and connects the buckle assembly 24 together. Alternatively, the seat belt may be passed under the bench part of the seat 14 but behind the back seat legs 16 . Obviously, this same arrangement can be utilized using a shorter belt for an individual seat.
A second embodiment of the invention is shown in FIG. 2 which is a perspective view of another student S′ sitting on a seat 30 in a bus 32 , the seat having a bench part 34 secured to the side of the bus and seat back 38 . The bench part 34 is attached to the side of the bus through the use of diagonal braces 36 secured to the bus sidewall 32 , so there are no legs, as such. The student S′ is wearing a belly pack 40 in which is carried a seat belt 42 which includes two separate sections each of which includes large hooks 46 and 46 A, respectively, which the student hooks together. (See FIG. 4) The seat belt 42 is then wrapped around the seat back 38 or, preferably, below the back of the bench part 34 . The student S′ then sits down and buckles the sections of seat belt 42 together.
FIG. 3 is a perspective view of the FIG. 1 embodiment as it would appear with the belt 22 folded into the belly pack 20 . In this view is shown the waist belt 21 of belly pack 20 . The embodiment of FIG. 2 would look essentially the same except that the compartment for the belt must be large enough to accommodate hooks 46 and 46 A.
FIG. 4 is a perspective view of the belly pack seat belt arrangement of FIG. 2 showing details of the separate belt and hook sections. Seat belt part 42 A of seat belt 42 is sewn to pack 40 . Seat belt part 42 A includes the female part of the buckle assembly 44 on one end and on the other end a large hook 46 having a spring closure 48 . Seat belt part 42 B includes the male part of buckle assembly 44 and a large hook 46 A having a spring closure 48 A. Also shown is the waist belt 41 for belly pack 40 with clasp 43 and a flap 50 having a hook and loop fastener for securing the seat belt 42 in the belly pack.
The student S′ arrives at seat 30 with the belly pack 40 fastened around his waist, so that the clasp 43 of waist belt 41 will be closed. After sitting on the seat, the student S′ may attach either hook 46 or hook 46 A to one of the rear legs 16 of seat 10 (FIG. 1 ). Following this he will attach the other hook to the opposite rear leg 16 and will then close the buckle assembly 44 . He might in some instances have folded the belt 42 into the pack 40 with the buckle assembly closed. In such case, the belt 42 is simply unfolded and hooks 46 and 46 A fastened to the rear seat legs 16 .
When it is desired to leave the seat 30 , the student S′ opens buckle assembly 44 , disconnects the hooks 46 , 46 A from the seat, and rolls the seat belt parts 42 A and 42 B back into the pouch of pack 40 . As shown in FIG. 5, the short part of belt part 42 A has been rolled back into the belly pack. Belt part 42 A has been rolled toward pack 40 and needs about two more full turns to be placed entirely within the pouch of the belly pack. Belt part 42 B is then rolled and placed in the pack 40 . When this is done, the flap 50 , which typically has a hook and loop type of fastener, is closed as shown in FIG. 6, securing both parts of the seat belt in the belly pack. If the student S can reach the hooks 46 , 46 A he or she may choose to simply disconnect the hooks, leaving buckle assembly 44 connected and roll the belt parts 42 A and 42 B into the pack 40 .
A modification is shown in FIG. 7 wherein the belly pack 40 includes a separable compartment 40 A which is secured to the main pack 40 by means of hook and loop fasteners 52 . Other types of fasteners could be used such as snap fasteners.
Shown in FIGS. 8 and 9 are installations of seat belts according to the invention on school bus seats having different support structures from those described above. The seat shown in FIG. 8 has leg structures 54 and 55 supporting bench 56 and seat back 58 wherein the rear leg portion extends up the back of the seat on both sides becoming an upper frame member 60 extending across the top of the seat back 58 . An additional support 62 may extend downwardly from frame member 60 for attachment to another seat frame member in or adjacent to seat back 58 . A pair of seat belts 42 of the type shown in FIGS. 4 and 5 having large hooks 46 , 46 A and buckle assemblies 44 are shown with hooks 46 fastened to the front leg portions of leg structures 54 , 55 and hooks 46 A secured to upper frame member 60 and to support 62 . Preferably, hooks 46 A could be fastened directly to support 62 . This provides an “across the chest” restraint providing significant protection.
The seat 66 of FIG. 9 is significantly different from those of FIGS. 1, 2 and 8 in that it includes a metal frame 68 having supports 70 attached to its lower side near the center of the seat and which are welded to a single metal post 72 secured to the bus floor. The inside edge of frame 68 is attached by means of an H-shaped support post 76 to a ledge 78 running along an interior sidewall of the bus. The back 67 of seat 66 includes an exposed upper frame member 80 . An additional frame member 81 may extend between frame member 80 and a support running along the back of seat 66 or to the back of supports 70 . With this seat design there may not be sufficient clearance between H-shaped post 76 and the bus sidewall to attach hooks 46 , 46 A. In such case, hooks 46 may be attached to supports 70 and hooks 46 A to upper frame members 80 and/or 81 . Alternatively, hooks 46 could be attached to the outside ends of underseat brace 71 which are secured to support 70 . The inside end of brace 71 may not be accessible because seat back 67 is too close to the bus sidewall, in which case belt 42 used by a student in the seat nearest the bus sidewall would be hooked between support 70 and upper frame member 80 .
FIG. 10 is a perspective view of a belly pack and seat belt according to the invention in which a belt retractor is incorporated. In this embodiment, a belt pack 40 includes waist belt 41 the ends of which are secured together around the waist of a student by means of clasp 43 . A flap 50 having hook and loop fasteners 52 secures seat belt 42 in the belly pack 40 . Belt 42 is stitched to the pack 40 and includes male and female ends of a buckle assembly 44 . A single retractor 82 is secured into the pack and includes a spring for winding the extended end of belt 42 back into itself. The female end of buckle assembly 44 is preferably folded back into the pack 40 as shown in FIG. 5, for storing.
Use of the belt of FIG. 10 is essentially as described for the embodiment of FIG. 1 . After opening the flap 50 , the student pulls the belt 42 out of the retractor 82 as required to go around the back of the bus seat or under the seat and behind the back legs if this arrangement is available. The student, while holding the belt end, then turns around, sits on the seat, closes the buckle assembly 44 , and pulls the free end of belt 42 such that it is tight. When he or she is ready to leave the bus, the buckle assembly 44 is released, allowing the extended end of belt 42 to be rewound into the retractor 82 . The shorter end of belt 42 with part of buckle assembly 44 is folded into the pack as shown in FIG. 5 .
FIG. 11 is a perspective view of another embodiment of seat belt/belly pack arrangement with the belt and pack incorporating a pair of retractors. In this embodiment, the belt 42 is stitched into the pack 40 and includes waist belt 41 and clasp 43 as described above. Much of the length of belt 42 is wound on two separate retractors 84 and 86 which are generally not secured to the pack 40 . The ends of belt 42 are shown connected at buckle assembly 44 .
FIG. 12 is a perspective view of the embodiment of FIG. 11 with the belt 42 almost fully extended, as it might be if it were wrapped around the back of a two-person bench seat such as that shown at numeral 10 (FIG. 1 ). Slightly less than half the length of belt 42 is carried on each of retractors 84 and 86 which move outward of the pack as belt 42 is extended. Retractors 84 and 86 are each substantially smaller and lighter than retractor 82 and may be preferred for this reason. Either the FIG. 10 or FIGS. 11 and 12 embodiments would appear as in FIG. 3 when not in use. Because of the additional weight of the retractors 82 , 84 and 86 it is desirable to incorporate some additional padding 45 on the rear sides of belly pack 40 under the retractors.
A somewhat different embodiment is shown in FIGS. 13, 14 and 15 . In this embodiment, a belly pack 88 is shown including a waist belt 90 having a clasp 92 , a seat belt 42 with a buckle assembly 44 and a retractor 82 secured in a separate chamber 94 (See FIG. 15) within pack 88 . At the front of pack 88 is a compartment 96 for carrying incidentals and which is closed with a zipper fastener 98 . Inertia type retractor 82 is secured in chamber 94 accessed by a separate zipper 100 . Because of the weight and hardness of retractor 82 , a layer of padding 102 is placed in the back wall of chamber 94 or the wall closest to the wearer. This padding could also be placed on the exterior wall 104 of pack 88 , the object simply being to minimize the feeling on the part of the wearer of a hard pressure point at a concentrated position along the wall of pack 88 . An additional chamber 106 may be placed between chamber 94 and exterior inside wall 104 . This chamber may be accessed by means of a zipper 108 . With this embodiment, the wearer, who will already be wearing pack 88 with waist belt 90 secured, will pull the end of belt 42 having the male end of buckle assembly 44 to whatever length is required to go around the seat back such as seat 30 of FIG. 2, place the belt around the seat back, sit on the seat and fasten the buckle assembly 44 together, leaving the wearer between the seat and seat belt 42 .
A further embodiment is shown on FIGS. 16 and 17 wherein a rolled-up seat belt 42 is carried in a typical camera case of the type which is used to carry many types of 35-mm cameras. Such cases are carried by large numbers of people and certainly are seen so frequently that they give little reason for special remarks or comments. Thus, it is believed that students will have little objection to carrying a seatbelt in such a camera case. FIG. 16 is a perspective view of a camera case 110 including a pouch 112 having a top closure flap 114 and a closure strap with a clasp 116 . A section of web belt 118 is secured to opposite sides of pouch 112 each of which terminate in a D-ring 120 . Only one such belt 118 and D-ring 120 are visible in FIGS. 16 and 17. A separate carry strap 122 includes on each end a hook 124 having a spring closure for engagement with D-rings 120 . A separate pair of D-rings 126 are secured to the sides of pouch 112 which may be fastened to a waist belt (not shown), if desired. FIG. 17 shows pouch 112 with flap 114 open and with the rolled-up seat belt 42 pulled out of pouch 112 . With this embodiment, the student simply unrolls the seat belt, wraps it around the back of the seat, sits down and fastens the buckle assembly 44 in front of him.
A number of modifications will be apparent to those skilled in the art. While the embodiments have been described in connection with a belly pack having a pouch for the usual articles carried in such packs plus a pouch for the seat belt, the belly pack could be made with just a pouch for the seat belt. The seat belt pouch is preferably open at the sides so that the belt parts can be rolled in and out as discussed above. Also, it is preferable that the belt, or part of it as in FIG. 4, be stitched to the belly pack, although it is apparent that the belt, if separate, can be rolled separately and then placed in a pouch of a belly pack. Other means of closing the pouch such as snap fasteners may be employed. For any of the described embodiments, an aircraft-type quick release buckle could be used in place of buckle assembly 44 .
The above-described embodiments of the present invention are merely descriptive of its principles and are not to be considered limiting. The scope of the present invention instead shall be determined from the scope of the following claims including their equivalents. | A portable seat belt assembly for school buses and the like which includes a belly pack with a seat belt secured thereto. A student wearing the belly pack approaching a school bus seat opens the belly pack, unwinds the seat belt wrapping it around the back of the seat, turns around, sits down and closes the seat belt buckle assembly. When leaving the bus, the student unbuckles the buckle assembly releasing the belt from the seat, folds the belt back into the belly pack and closes the belly pack. Another embodiment includes a seat belt arrangement carried in the belly pack including a pair of straps each having large hooks with spring clasps for attachment to the seat frame. The student must attach these hooks to the seat frame then sit down and close the buckle assembly. Other embodiments include retractors on the seat belt to assist the student in retrieving the belt after use and a camera case for housing the seat belt. | 1 |
[0001] This application claims priority from Australian Provisional Patent Application No. 2005900919 filed on 1 Mar. 2005, and the contents of that application are to be taken as incorporated herein by this reference.
FIELD OF THE INVENTION
[0002] The present invention relates to removable coatings for ophthalmic lenses and lens blanks (“lens elements”). More particularly, the invention relates to protective coatings for ophthalmic lens elements having a hydrophobic surface. The invention also provides methods for coating ophthalmic lens elements having a hydrophobic topcoat.
BACKGROUND OF THE INVENTION
[0003] Ophthalmic lenses are formed from materials such as glass and transparent plastics. Some of the plastics that are used for the manufacture of ophthalmic lenses include thermoplastic polycarbonate and thermoset materials such as CR-39™, Finalite™ (a registered trademark of Sola International Inc.) and Spectralite™ (a registered trademark of Sola International Inc.).
[0004] It has become customary to coat ophthalmic lenses with coatings to provide an improvement in properties. For example, abrasion resistant coatings are used to form a hard coating on an ophthalmic lens, whilst anti-reflection coatings including a hydrophobic surface are used to reduce residual reflections. The hydrophobic surface in the latter coatings makes the surface of the anti-reflection coating easier to clean, as it is easier to remove greasy markings or stains such as those caused by touching the lens. A range of ophthalmic lenses having a hard (abrasion resistant) coating, an anti-reflection coating and a hydrophobic topcoat are now available commercially.
[0005] Protective coatings are generally used to protect one or more surfaces (or coatings thereon) of a lens during the normal shipping, handling and processing steps that occur after lens manufacture. Usually, once the lens has reached its destination, the protective coating is removed to reveal a lens surface that is relatively unaffected by the shipping, handling and processing steps. Protective coatings can also be used to mask a surface of a lens during post processing steps. For example, there is often a need to carry out further processing steps on the edge of a lens after lens manufacture without affecting the front or back surfaces of the lens. In this case, protective coatings are used to mask the front and/or back surface of the lens to prevent alteration or damage during the edge treatment. An example of an edge treatment where protective coatings may be used is edge coloring wherein a lens edge may need to be coated with a colored coating for aesthetic purposes. During application of the edge coating, the lens surface needs to be protected to prevent inadvertent application of the colored coating material to the optical surface of the lens.
[0006] An example of a temporary protective coating is disclosed in French patent application FR2860303, wherein a peelable film is adhered electrostatically to an outer layer of an optical lens. The outer layer is an anti-slip inorganic layer that is mechanically damaged or removed by friction and/or contact. In this case, the inorganic layer provides anti-slip properties to enable the lens to be edged, whilst the peelable film protects the anti-slip layer from inadvertent damage or removal by friction during normal transport and handling.
[0007] However, the use of hydrophobic topcoats on ophthalmic lenses has led to problems with the use of protective coatings on lenses. More specifically, there have been difficulties associated with protective coatings not adhering sufficiently to the hydrophobic topcoats, so that the protective properties of the coating may be compromised.
[0008] To the best of the Applicant's knowledge there is no removable coating for a hydrophobic surface of a lens element that is robust enough for normal handling of the lens element, and that does not interfere with further processing such as power checks, marking, edging and edge colouring. The present invention aims to provide a coating that overcomes or reduces at least one of the problems with known coatings and processes.
[0009] Throughout this specification reference may be made to documents for the purpose of describing various aspects of the invention. However, no admission is made that any reference cited in this specification constitutes prior art. In particular, it will be understood that the reference to any document herein does not constitute an admission that any of these documents forms part of the common general knowledge in the art in any country. The discussion of the references states what their authors assert, and the applicant reserves the right to challenge the accuracy and pertinency of any of the documents cited herein.
SUMMARY OF THE INVENTION
[0010] The present invention provides a method of forming a removable protective coating on a hydrophobic surface of an ophthalmic lens element, the method including:
providing an ophthalmic lens element having a hydrophobic surface; applying a non-aqueous coating composition so as to coat at least part of the hydrophobic surface, said composition including a film forming coating polymer and a compatible non-aqueous solvent; and removing a substantial portion of the solvent from the composition to form a removable protective coating on the ophthalmic lens element that adheres to the hydrophobic surface.
[0014] The present invention also provides an ophthalmic lens element having a hydrophobic surface and a removable protective coating formed from a film forming coating polymer adhered to at least part of the hydrophobic surface.
[0015] The present invention also provides a removable protective coating for an ophthalmic lens element having a hydrophobic surface, the coating including a film forming coating polymer that adheres to the hydrophobic surface.
[0016] The film forming polymer may be a polymer selected from the list including vinyl polymers, styrene polymers, cellulose polymers and poly(meth)acrylate polymers. Preferred vinyl polymers include poly vinyl acetate, polyvinyl phenol, polyvinyl pyrrolidone, and poly (vinyl pyrolidone co-vinyl acetate). Preferred styrene polymers include polystyrene. Preferred cellulose polymers include ethyl cellulose and hydroxy propyl cellulose. Preferred poly(meth)acrylate polymers include poly (methyl methacrylate) and poly (ethyl methacrylate).
[0017] As previously described, there has been a problem in the past with forming coatings on hydrophobic surfaces of ophthalmic lens elements. However, the inventors have now found that it is possible to form a protective coating that adheres sufficiently to a hydrophobic surface of an ophthalmic lens element to allow the lens element to be handled and processed without the protective coating detaching therefrom. The protective coating is robust enough for normal handling, and it does not interfere with further processing steps such as power checks, marking, edging and edge colouring. However, the adhesion of the coating to the hydrophobic surface is also such that the coating can be removed to expose the hydrophobic surface after the further processing steps have been carried out. For example, the protective coating may be removed from the lens element by peeling it away from the surface or washing the lens element with water after the further processing steps have been completed.
[0018] The present invention permits a number of processing operations to be carried out on ophthalmic lens elements without the difficulties that have been associated with having a hydrophobic surface on the lens element. For example, the protective coating of the present invention provides an anti-slip surface. Hydrophobic surfaces present difficulties during edging of lenses because the hydrophobic surface tends to make the lens slip when the lens is clamped in an edging machine. However, by forming a protective coating of the present invention on the hydrophobic surface, the adherence between an adhesive pad on a clamping member of the edging machine and the lens surface can be improved significantly.
[0019] It has also been discovered that the protective coating of the present invention can be removed from a lens element without removing ink markings on the surface of the lens element. This enables lens elements to be marked for further processing and subsequently overcoated with the protective coating prior to edging. After edging, the protective coating can be removed without significantly affecting the markings.
[0020] The protective coating of the present invention can also be used to protect the optical surfaces of lens elements during processing operations that could affect the optical surfaces of the lens elements. For example, in a lens edge colouring process, a lens edge colour material is applied by brushing, rubbing or spraying it onto an edge of a lens. However, the optical surfaces of the lens can easily be marred by any edge colouring material that is inadvertently applied. This is especially a problem when the edge colour material is sprayed onto the edges of the lens because the over-spray can easily contaminate the optical surfaces. When this happens a cleaning step has to be added to clean the lenses. With the protective coating of the present invention, after edging, the lens edge is exposed and the edge colour material can be more readily applied on the edge only. The protective coating can be removed later so that contamination of the optical surfaces can be prevented.
[0021] Another example of a use of a removable coating for hydrophobic coated lens element is the protection of a lens element surface, while the second surface is being coated. In a vacuum deposition procedure such as the one used for the application of antireflection lens element surfaces, the first surface of a lens element is coated with the antireflection layers, the lens element is then flipped to expose the uncoated side for coating. During the deposition of the layers on the second side, it is often observed that the surface properties of the coated layers on the first surface of the lens element can be modified. A protective removable coating prevents such an undesirable effect. The protective coating may also be used to prevent surfaces from back spray during vacuum deposition of anti-reflection layers.
GENERAL DESCRIPTION OF THE INVENTION
[0022] The present invention, and embodiments thereof, will now be described in more detail. However, before proceeding it is important to note that various terms that will be used throughout the specification have meanings that will be well understood by a skilled addressee. However, for ease of reference, some of these terms will now be defined.
[0023] The term “lens element” as used herein refers to a finished or unfinished ophthalmic lens or lens blank manufactured from an optically transparent glass or plastic material. Plastic materials useful in preparation of lens elements are well known in the art and include, by way of example, polycarbonates, polymethacrylates, and the like. The particular plastic material employed is not critical. A ‘lens blank’ is a lens element that requires some form of treatment, such as cutting a given geometry to deliver a given magnification power, or deposition of a coating. Once all of the cutting and coating steps are completed, the lens blank is termed a ‘lens’. The present invention is applicable to both lens blanks and lenses and for the sake of clarity in the following description, the term ‘lens element’ is used to describe both lenses and lens blanks. However, certain processing operations, such as edging, will normally only be conducted on a lens, whilst other processes, such as coating, will normally only be carried out on lens blank. With that distinction in mind, the terms lens and lens blank are used herein for the purpose of describing the present invention.
[0024] The term “hydrophobic surface” refers to a surface having a hydrophobic character. Hydrophobic surfaces of the type referred to herein typically have a contact angle above about 60 degrees using standard tests. Hydrophobic surfaces are usually formed on lens elements by coating at least part of a lens element surface with a hydrophobic coating. Hydrophobic coatings that are known in the art and are typically formed from silane and silazane based compounds having fluorocarbon, perfluorocarbon, polyfluorocarbon, fluoropolyether, or perfluoropolyether groups. Methods for forming hydrophobic coatings are described, for example, in U.S. Pat. No. 6,183,872.
[0025] The term “polymer” refers to homopolymers, which are formed from the same type of monomeric units, or copolymers, which are formed from two or more different types of monomeric units.
[0026] The term “adheres” refers to a component sticking to a substrate to a degree that permits the substrate to undergo normal handling and processing operations without the component detaching from the substrate. For the purposes of the present invention, a coating can be said to adhere to a hydrophobic surface if the coating does not detach from a lens surface during handling, transportation and/or edging. This may be tested by subjecting a lens element to conditions that replicate normal processing, handling and transport conditions for the lens element.
[0027] As discussed, the present invention provides a method of forming a removable protective coating on a hydrophobic surface of an ophthalmic lens element, the method including:
providing an ophthalmic lens element having a hydrophobic surface; applying a non-aqueous coating composition so as to coat at least part of the hydrophobic surface, said composition including a film forming coating polymer and a compatible non-aqueous solvent; and removing a substantial portion of the solvent from the composition to form a removable protective coating on the ophthalmic lens element that adheres to the hydrophobic surface.
[0031] The present invention also provides an ophthalmic lens element having a hydrophobic surface and a removable protective coating formed from a film forming coating polymer adhered to at least part of the hydrophobic surface.
[0032] The present invention also provides a removable protective coating for an ophthalmic lens element having a hydrophobic surface, the coating including a film forming coating polymer that adheres to the hydrophobic surface.
[0033] The ophthalmic lens element may be of any type intended for any purpose. This includes lens elements with or without optical corrections. The ophthalmic lens element may be a single integral body ophthalmic lens element or a laminated ophthalmic lens element fabricated by bonding two lens wafers together in a suitable manner, such as by use of a transparent adhesive.
[0034] The ophthalmic lens element may have a functional coating on one or more optical surfaces. Functional coatings include abrasion resistant coatings, anti-reflection coatings, anti-static coatings, photochromic layers or coatings, polarized layers or coatings, interference coats, impact primer layers, adhesion primer layers, UV cut-off layers, and the like. The functional coating may be a multi-layer coating. For example, the functional coating may be an anti-reflection coating having from 2 to 12 layers. Typically, the functional coating will have a hydrophobic topcoat layer, which will be the outermost layer and hence will form a hydrophobic surface on the lens element.
[0035] The hydrophobic surface may be on any part of the lens element. Typically, the hydrophobic surface will be on both the convex and concave optical surfaces of the ophthalmic lens element. The hydrophobic surface generally will cover substantially all of the optical surface. However, it is possible that the hydrophobic surface may not cover all of the optical surface of the lens element and, in that case, the protective coating of the present invention will cover at least part of the hydrophobic surface.
[0036] Hydrophobic surfaces may be prepared from silane and silazane based compounds having fluorocarbon, perfluorocarbon, polyfluorocarbon, fluoropolyether, or perfluoropolyether groups. Typically, hydrophobic coatings are formed by evaporation under vacuum or liquid application using standard dip or spin coating techniques. Methods for forming hydrophobic coatings are described, for example, in U.S. Pat. No. 6,183,872.
[0037] The film forming coating polymer may be any polymer that can be coated onto a hydrophobic surface and form a coating layer that has relatively strong adhesion to the hydrophobic surface. By their nature, hydrophobic surfaces have relatively low surface energy and therefore it is difficult to adhere a coating onto such a surface. The adhesion between the polymer coating and the hydrophobic surface is therefore important. If the adhesion of the protective coating with the hydrophobic surface is too weak the coating will be easily peeled off, torn off or detached from the lens element during the transport, handling and/or further processing. Therefore the protective coating has to have sufficient adhesion with the hydrophobic surface of the lens element.
[0038] However, it is also desirable for the protective coating to be removable from a lens element after the transport, handling and/or lens processing steps have been carried out. This means that the coating must adhere to the hydrophobic surface sufficiently for the coating to stay on the lens element during handling, transport and/or processing, but the adhesion must also be such that the protective coating can be peeled away from or otherwise removed from the lens element if necessary without substantially altering the properties of the surface of the lens element.
[0039] The film forming coating polymer forms the bulk of the protective coating and provides the adhesive properties of the coating. The film forming coating polymer may be present in an amount of about 1% to about 30% (w/w) in the coating composition. In practice, the suitability of any particular polymer may be determined empirically and the person skilled in the art will recognize that certain classes of polymer materials will be more suitable than others for forming the coating layer. The film forming coating polymer may be a homopolymer, a copolymers or mixture of polymers.
[0040] Vinyl polymers, styrene polymers, cellulose polymers and poly(meth)acrylate polymers have been found suitable for forming protective coatings. Preferred vinyl polymers include poly vinyl acetate, polyvinyl phenol, polyvinyl pyrrolidone, and poly (vinyl pyrolidone co-vinyl acetate). Preferred styrene polymers include polystyrene. Preferred cellulose polymers include ethyl cellulose and hydroxy propyl cellulose. Preferred poly(meth)acrylate polymers include poly (methyl methacrylate) and poly (ethyl methacrylate). However, the person skilled in the art will appreciate that there are a large number of poly(meth)acrylate polymers available and some of these may be used to form removable coating according to the present invention. As used herein the term “(meth)acrylate” means either an acrylate group or a methacrylate group.
[0041] Some polar hydrophilic polymers that have a strong adhesion with hydrophobic surfaces include polyvinyl pyrrolidone, poly(vinyl pyrolidone co-vinyl acetate) and polyvinyl phenol. These polymers are able to form films with sufficient adhesion to a hydrophobic surface. In contrast, some hydrophobic polymers, like polystyrene and polyvinyl chloride have weak adhesion with a hydrophobic surface. By blending solutions of the polymers with weak adhesion with the solution of polymers with strong adhesion, sufficient adhesion of polymer coating with the hydrophobic surface can be achieved.
[0042] The presence of hydrophilic groups in the polymer can facilitate the protection of ink markings on the surface of lens elements. In most cases, coatings formed from polymers with strong adhesion with a hydrophobic lens surface will remove ink marks when the film is peeled off the lens elements. However, the hydrophilic polymers described herein can be easily wetted by water, and the wetted protective coating can be easily removed by peeling, in which case the ink marks will not be removed.
[0043] The solvent is a non-aqueous solvent that is chosen so as to be compatible with the hydrophobic surface and also with the film forming coating polymer. It is relatively difficult to form a film on a hydrophobic surface. Aqueous polymer systems like polyvinyl alcohol in water and aqueous polymer emulsions will not form a film on a hydrophobic surface. However, the present inventors have found that uniform films can be formed on hydrophobic surfaces using polymers dissolved in organic solvents. It will be appreciated that there may be problems with a protective coating that is not formed from a relatively uniform film. Thus, the compatible solvent may be any non-aqueous solvent in which the coating polymer is soluble and which does not have a detrimental effect on the substrate material. Suitable solvents may be selected from the group consisting of lower alkyl alcohols (e.g. methanol, ethanol, n-propranol, i-propanol, n-butanol, sec-butanol, t-butanol etc), ketones (e.g. acetone, butanone, etc), esters (e.g. ethyl acetate, methyl acetate, amyl acetate, butyl acetate etc.), and hydrocarbon solvents, more especially aromatic hydrocarbon solvents (e.g. toluene, xylene etc). Specific solvents that are suitable for this purpose include methanol, ethanol, ethyl acetate, amyl acetate, butyl acetate, acetone, toluene, and compatible mixtures thereof.
[0044] In a preferred form of the invention, the non-aqueous coating composition is selected from one of the compositions listed in Table 1 or Table 2.
[0000]
TABLE 1
Polymer solutions that can be used to form
polymer films on hydrophobic surfaces
Polymer
Polymer
Solvent
concentration (w/w)
Poly vinyl acetate
Mw = 12,800
Ethyl acetate
10%
Poly vinyl acetate
Mw = 12,800
Ethyl acetate
15%
Poly vinyl acetate
Mw = 12,800
Ethyl acetate
20%
Poly vinyl acetate
Mw = 83,000
Ethyl acetate
10%
Poly vinyl acetate
Mw = 83,000
Ethyl acetate
15%
Poly vinyl acetate
Mw = 83,000
Ethyl acetate
30%
Poly styrene
Mw = 280,000
Ethyl acetate
10%
Poly styrene
Mw = 280,000
Ethyl acetate
5%
Poly styrene
Mw = 280,000
Ethyl acetate
1%
Polyvinyl phenol
Mw = 20,000
Ethyl acetate
10%
Polyvinyl phenol
Mw = 20,000
Ethanol
10%
Polyvinyl phenol
Mw = 20,000
Ethanol
20%
Polyvinyl
Mw = 29,000
Ethanol
1%
pyrrolidone
Ethyl cellulose
46% ethoxy content
Ethyl acetate
5%
Ethyl cellulose
46% ethoxy content
Toluene
5%
Hydroxy propyl
Mw = 1,000,000
Ethanol
10%
cellulose
Poly(vinyl
1.3:1, Mw = 50,000
Ethanol
10%
pyrolidone co-vinyl
acetate)
Poly(vinyl
1.3:1, Mw = 50,000
Ethanol
15%
pyrolidone co-vinyl
acetate)
Poly(vinyl
1.3:1, Mw = 50,000
Ethanol
20%
pyrolidone co-vinyl
acetate)
Poly (methyl
Mw = 996000
Ethyl acetate
5%
methacrylate)
Poly (ethyl
Mw = 515000
Ethyl acetate
10%
methacrylate)
[0000]
TABLE 2
Solutions of mixed polymers that can be used
to form films on hydrophobic surfaces
Polymer
Polymer
Solvent
Solvent
Poly vinyl pyrrolidone (5%)
Poly vinyl acetate (5%)
Methanol(90%)
Poly vinyl acetate (5%)
Polystyrene(5%)
Ethyl
acetate(90%)
Poly vinyl acetate (8%)
Polystyrene(2%)
Ethyl
acetate(90%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Acetone(78%)
molecular weight (20%)
co-vinyl acetate)
1.3:1 Mw = 50,000
(2%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Acetone(76%)
molecular weight (20%)
co-vinyl acetate)
1.3:1, Mw = 50,000
(4%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Acetone(74%)
molecular weight (20%)
co-vinyl acetate)
1.3:1, Mw = 50,000
(6%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Ethyl
Ethanol(9.5%)
molecular weight (15%)
co-vinyl acetate)
acetate(75%)
1.3:1, Mw = 50,000
(0.5%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Ethyl
Ethanol(10%)
molecular weight (15%)
co-vinyl acetate)
acetate(74%)
1.3:1, Mw = 50,000
(1%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Ethyl
Ethanol(13%)
molecular weight (20%)
co-vinyl acetate)
acetate(65%)
1.3:1, Mw = 50,000
(2%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Ethyl
Ethanol(12%)
molecular weight (20%)
co-vinyl acetate)
acetate(64%)
1.3:1, Mw = 50,000
(4%)
Poly vinyl acetate, low
Poly(vinyl pyrolidone
Ethyl
Ethanol(11%)
molecular weight (20%)
co-vinyl acetate)
acetate(63%)
1.3:1, Mw = 50,000
(6%)
[0045] The coating composition will normally be applied so as to provide a substantially uniform application of the coating composition onto the surface of the ophthalmic lens element. The coating composition can be applied by any suitable means, including spin coating, painting, roll coating, spraying and dip coating. After coating the composition onto the surface of the ophthalmic lens element that contains the hydrophobic surface, the coating is dried to remove most of the solvent from the coating composition. In this way, a coating is formed which remains attached until it is peeled off and the ophthalmic lens element is ready for further processing.
[0046] The coating composition prepared as above may be applied to at least one surface of a lens element. If the protective coating is used as an anti-slip coating, the coating composition will be applied to the convex surface only or to both surfaces of a lens which are in contact with a clamping member of an edging machine. For ease of application, the coating will generally be applied so that it is coextensive with the surface of the lens element. However, it may not be necessary for the coating to cover the whole of the surface of the lens element and, for example, it may be sufficient to coat only that part of the surface of a lens that will be in abutment with the clamping member when a lens is being edged.
[0047] Sufficient amounts of the coating composition are applied onto the surface or surfaces of the ophthalmic lens element to provide for a coating thickness, after solvent removal, of about 1 micron to about 20 microns.
[0048] The coating composition can optionally contain additives such as plasticisers. Plasticisers may be used to improve coating flexibility and peelability. Suitable plasticisers include, by way of example, dipropylene glycol dibenzoate, butyl benzyl phthalate, diethylene glycol dibenzoate, and the like.
[0049] After the coating composition has been applied a substantial amount of the solvent is removed from the composition so as to form the protective coating in the form of a film on the hydrophobic surface. Typically, the solvent can be removed by drying the coating composition at room temperature or at elevated temperature. The coating composition could also be dried at reduced pressure, if necessary.
[0050] After the protective coating has been applied, standard processing operations can be carried out on the lens element. Also, the lens element can be transported and handled in the normal way with physically affecting the hydrophobic surface(s) of the lens element.
[0051] As discussed, the protective coating of the present invention may also be used to provide an anti-slip surface, which can assist with the edging of lenses. There have been difficulties with edging and fitting lenses having hydrophobic topcoats in frames. The final stage in the preparation of an ophthalmic lens is an edging or trimming (hereinafter referred to as “edging”) step in which an edge or periphery of the lens is machined so that it can mate with a frame into which the lens is to be fitted. The edging step involves securing the lens in the chuck of an edging machine, rotating the lens and then grinding the edge or periphery. Typically, the lens is secured between axial clamping members with one of the clamping members having a double-sided adhesive pad which bears axially on the convex surface towards the centre of the lens, and a support which bears axially on the concave surface of the lens. With lenses having hydrophobic topcoats on the convex side of the lens, the double-sided adhesive pad has to bear against the hydrophobic surface and the poor adhesion of the double-sided adhesive pad on the slippery lens surface gives rise to a tendency for the lens to slip during the edging process which can result in the lens shape being incorrect and the lens being ruined.
[0052] In an attempt to overcome this problem, commercially available adhesive stickers are often applied to the lens surface having the hydrophobic topcoat. The adhesive surface of the sticker usually provides sufficient adhesion to the hydrophobic surface, whilst the opposing surface of the sticker also delivers sufficient adhesion with the double-sided adhesive pad on the clamping member of the edging machine. However, a problem arises with this commonly used technique because adhesion of the stickers can be reduced if they are not handled carefully or if the stickers are used on highly curved lens surfaces because the flat sticker tends to wrinkle when it is placed on the surface. Also, the adhesive used in the sticker is usually hazy and does not allow routine lens power checks to be performed while the sticker is on the lens. Additionally, when the sticker is removed from the lens surface after completion of the edging, ink markings, such as those applied on the lens surface to facilitate the positioning of the edged lenses in the frame, are removed with the sticker.
[0053] A further attempt to overcome difficulties with the handling of hydrophobic coated lenses is described in published United States patent application 20030049370 which has been assigned to Essilor International Compagnie General d'Optique. This specification discloses a temporary anti-slip layer that can be applied over hydrophobic topcoats to minimize or prevent slipping during edging. The anti-slip layer is a mineral layer of magnesium fluoride or alumina and praseodyme oxides that is deposited by evaporation in a vacuum treatment chamber in a step immediately following deposition of the hydrophobic layer.
[0054] In practice, it has been found that an anti-slip coating that is formed according to the disclosure of United States patent application 20030049370 is difficult to handle as it can be affected by finger marks and it is relatively easy to remove, for instance, by wiping with a dry tissue. This presents problems during handling of the lens because the anti-slip layer can be wiped off accidentally. In practice, this layer also does not deliver the anti-slip benefit on freshly coated lenses. To overcome these issues, a solution has been suggested in International patent application WO2004110946 where an additional process step is added to reduce this effect. However, there may be further processing difficulties with ophthalmic lenses having an anti-slip layer that is formed in accordance with the disclosures of United States patent application 20030049370 and International patent application WO2004110946. Typically, lenses contain markings on a surface to assist in alignment of a lens during further processing to form a prescription lens. The markings are applied to the surface of the lens with ink. In practice, the ink marking would have to be applied before the aforementioned anti-slip layer is applied, but this is not possible as the aforementioned anti-slip layer is applied in vacuum immediately after the hydrophobic layer. If the ink markings are applied after the aforementioned anti-slip layer is applied, the markings will be wiped off with the anti-slip layer.
[0055] In addition to the above uses, the protective coating of the present invention can also be used to protect the optical surfaces in a lens edge colouring process.
[0056] Using the compositions and methods described herein, it is also possible to form a protective coating that is highly transparent. The transparency of the coating may be important if the operator needs to check refractive properties of the lens, such as the “through power” of the lens with the protective coating in place. More particularly, it has been found that a coating formed from polyvinyl pyrrolidone or poly(vinyl pyrolidone co-vinyl acetate) has very good transparency.
[0057] After the transport, handling and/or processing steps have been carried out, the protective coating can be removed. For this reason, the protective coating may be referred to as a temporary coating. The protective coating may be removed by physically peeling the coating from the lens element surface. Alternatively, the presence of hydrophilic polymers in the coating means that the coating can be wetted. After wetting, the coating can be peeled away from the lens element surface, or the coating can be washed off with water.
[0058] The protective coating can be removed from a lens element without removing ink markings on the lens element surface. This enables lens elements to be marked for further processing and subsequently overcoated with the protective coating prior to edging. After edging, the protective coating can be removed without affecting the markings.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0059] The present invention will now be described in relation to examples of preferred embodiments. However, it must be appreciated that the following description is not to limit the generality of the above description.
Example 1
General Procedure
[0060] A coating composition according to any one of the compositions given in Table 1 or Table 2 can be prepared by mixing the polymer component with the solvent in the prescribed amounts.
[0061] The coating composition can then be spin coated onto a surface of a lens having a hardcoat, and AR coating and a hydrophobic topcoat. The hydrophobic topcoat may be similar to the one described in U.S. Pat. No. 6,183,872. The coating can then be dried at room temperature to form the protective coating.
[0062] The coated lens can then be handled, transported or further processing steps can be carried out, as required.
[0063] When necessary, the protective coating can be removed by peeling it from the lens. Alternatively, if the coating is water-soluble it can also be removed by contacting the coating with water.
Example 2
[0064] A coating composition comprising 10 parts polyvinylacetate (low molecular weight); 1 part poly(vinylpyrollidone-co-vinyl acetate); 100 parts ethyl acetate and 7 parts ethanol was prepared by mixing.
[0065] The coating composition was then spin coated at 1000 rpm onto the convex surface of CR-39™ lens with hardcoat, AR coating and hydrophobic topcoat. The hydrophobic topcoat was similar to the one described in U.S. Pat. No. 6,183,872. The coating was then dried for 20 seconds at room temperature.
[0066] The coated lens could then be edged using typical settings on a suitable edging machine. The clamp pressure and speed settings for the edging step were the same as those used for non-slippery lenses and no slippage of the lens was observed during the edging step.
[0067] After edging, the anti-slip coating can be removed by peeling it from the lens. Upon removal of the coating, any ink markings on the surface of the lens were not altered. Alternatively, the coating itself is water-soluble and therefore it can also be removed by contacting the coating with water. The anti-slip coating may be removed automatically in wet edging machines.
Example 3
[0068] A coating composition comprising 10 parts polyvinylacetate (low molecular weight); 1 part poly(vinylpyrollidone-co-vinyl acetate); 100 parts ethyl acetate and 7 parts ethanol was prepared by mixing.
[0069] Hard and AR coated polycarbonate lenses with a hydrophobic topcoat similar to the one described in U.S. Pat. No. 6,183,872 were spin coated with above coating solution on both sides. A thin layer polymeric coating was formed on the lenses after drying for 20 seconds at room temperature.
[0070] The coated lens was then edged using typical settings on a suitable edging machine. The clamp pressure and speed settings for the edging step were the same as those used for non hydrophobic coated lenses and no slippage of the lens was observed during the edging step.
[0071] After edging, the lens edge was sprayed with a UV curable edge colouring coating, then the edge colouring coating was cured by UV light. The over spray of the edge colouring coating on the optical surfaces of the lenses was easily cleaned off the lens by peeling off the protective coating.
Example 4
[0072] A coating composition comprising 10 parts polyvinylacetate (low molecular weight); 1 part poly(vinylpyrollidone-co-vinyl acetate); 100 parts acetone was prepared by stirring for three hours at room temperature.
[0073] A CR-39™ lens with hardcoat, AR coating and a hydrophobic topcoat similar to the one described in U.S. Pat. No. 6,183,872 was dipped in the above coating solution for ten seconds, then the lens was pulled out of the solution slowly. A uniform coating was formed on the lens after drying at room temperature for 20 seconds. The coating thickness was about 2 microns.
[0074] The coated lens was then edged using typical settings on a suitable edging machine. The clamp pressure and speed settings for the edging step were the same as those used for non-slippery lenses and no slippage of the lens was observed during the edging step.
[0075] After edging, the anti-slip coating can be removed by peeling it from the lens. Upon removal of the coating, any ink markings on the surface of the lens were not altered. Alternatively, the coating itself is water-soluble and therefore it can also be removed by contacting the coating with water. The anti-slip coating may be removed automatically in wet edging machines.
Example 5
[0076] A multilayer anti-reflection coating including a hydrophobic surface was deposited by evaporation under vacuum on the front surface of two hardcoated CR39™ lenses with an oval shape, held by a spring-clamp on the sectors of the coater's calotte. The first lens was then spin-coated on the front surface with the coating of Example 2. The second lens was not treated.
[0077] Both lenses were inserted back in the vacuum chamber, held by a spring-clamp on the sectors of the coater's calotte to coat the concave side of the lenses with the multilayer anti-reflection coating including a hydrophobic surface. After deposition and removal with water of the protective layer on the front surface of the first lens, the hydrophobic properties of the lenses were checked using acetone wettability. The acetone droplets beaded on any point on the front surface of the first lens over the whole area of the surface, indicating it was hydrophobic while the acetone spread on front surface of the second indicating that the second lens surface was not homogenously hydrophobic. Therefore the coating of the invention was effective in protecting the hydrophobic surface of the lens coated with this coating.
Example 6
[0078] A protective coating composition comprising 5 parts polyvinylacetate (medium molecular weight) and 50 parts ethyl acetate was prepared by stirring at room temperature for 10 hours
[0079] The coating composition was then spin coated at 1000 rpm onto the convex surface of CR-39™ lens with hardcoat, AR coating and a hydrophobic topcoat (similar to the one described in U.S. Pat. No. 6,183,872). The coating was then dried for 20 seconds at room temperature.
[0080] The coated lens was then edged using typical settings on a suitable edging machine. The clamp pressure and speed settings for the edging step were the same as those used for non hydrophobic coated lenses and no slippage of the lens was observed during the edging step.
[0081] After edging, the protective coating could be removed by peeling it from the lens.
Example 7
[0082] A protective coating composition comprising 5 parts poly(ethyl methacrylate) (Mw=515000) and 50 parts ethyl acetate was prepared by stirring at room temperature for 10 hours
[0083] The coating composition was then spin coated at 1000 rpm onto the convex surface of CR-39™ lens with hardcoat, AR coating and a hydrophobic topcoat (similar to the one described in U.S. Pat. No. 6,183,872). The coating was then dried for 20 seconds at room temperature.
[0084] Coated lenses were then tested together with the control lenses using standard packaging and transportation conditions. After testing, the protective coating was removed by peeling it from the lens. The lenses were inspected for scratches. We found the lenses having protective coating had less scratches caused by packaging and transportation than the control lenses (without a protective coating).
Example 8
[0085] A protective coating composition comprising 2.5 parts poly(methyl methacrylate) (Mw=996000) and 50 parts ethyl acetate was prepared by stirring at room temperature for 10 hours
[0086] The coating composition was then spin coated at 1000 rpm onto the convex surface of CR-39™ lens with hardcoat, AR coating and a hydrophobic topcoat (similar to the one described in U.S. Pat. No. 6,183,872). The coating was then dried for 20 seconds at room temperature.
[0087] The coated lens could was then edged using typical settings on a suitable edging machine. The clamp pressure and speed settings for the edging step were the same as those used for non hydrophobic coated lenses and no slippage of the lens was observed during the edging step.
[0088] After edging, the protective coating could be removed by peeling it from the lens.
[0089] Finally, it will be appreciated that various modifications and variations of the described compositions, methods and articles of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention, which are apparent to those skilled in the relevant field are intended to be within the scope of the present invention. | The present disclosure provides a method of forming a removable protective coating on a hydrophobic surface of an ophthalmic lens element. The method includes providing an ophthalmic lens element having a hydrophobic surface. A non-aqueous coating composition is applied so as to coat at least part of the hydrophobic surface. The composition includes a film forming coating polymer and a compatible non-aqueous solvent. A substantial portion of the solvent is removed from the composition to form a removable protective coating on the ophthalmic lens element that adheres to the hydrophobic surface. The disclosure also provides a removable protective coating, and an ophthalmic lens element having the coating. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a granulator mill which comprises a mill housing in which a rotary knife unit is disposed, and a receptacle box for ground material, the receptacle box being removably secured in the mill housing.
BACKGROUND ART
[0002] Granulator mills of various constructions and sizes are previously known in the art. Small-scale granulator mills, which are easily transported, are generally built on a wheeled chassis. The granulator mill has a mill housing with a rotary knife unit and a number of fixed knives. On the underside of the mill housing, there is a grill or screen which determines particle size of the ground material so that excessively large particles are prevented from entering into a receptacle box for ground material—the granulate box—which is disposed beneath the mill housing.
[0003] On the upper side of the mill housing, there is an infeed section or hopper via which the plastic material that is to be ground or granulated is fed in. The infeed hopper is of such a length and height that the interior of the mill housing is inaccessible to the mill operator. The infeed hopper serves a further function, namely to prevent material which is in the process of being ground from being ejected out rearwardly.
[0004] The above-mentioned grill or screen that separates the interior of the mill housing from the granulate box guarantees that only particles of a certain maximum size may pass. On the other hand, there is no lower size limit for the particles which pass through the grill. In the grinding process proper, a wide range of particle sizes occurs, ranging from extremely small dust particles up to the maximum particle size that may pass through the grill. This implies that the ground material that arrives in the granulate box also displays a corresponding particle size distribution. In particle the smaller particle fractions may cause severe problems in pollution if they were to get outside the granulate box.
[0005] In many prior art mills, it is common practice that the granulate box is suspended in the mill housing on its underside, quite simply in that the mill housing has been provided with sliding beads or strips along which the granulate box is slidable. Such a design and construction does not permit sealing of the interior of the granulate box and naturally entails that quite large quantities of, above all, fine particle fractions “leak out” from the mill housing and the granulate box. Considerable problems involving pollution and fouling occur.
[0006] In older prior art mills, it is also common practice that the granulate box is emptied manually, quite simply by lifting down from the mill housing. This also gives rise to considerable inconvenience when the granulate box is emptied, since fine particulate fractions eddy up into the air.
PROBLEM STRUCTURE
[0007] The present invention has for its object to design the granulator mill intimated by way of introduction such that the drawbacks inherent in prior art technology are obviated, in particular problems involving pollution and fouling of the ambient surroundings of the granulator mill. In particular, the present invention has for its object to design the granulator mill so that at a satisfactory sealing is obtained between the mill housing and the granulate box, at the same time as the design and construction are simple and economical in manufacture and easy to serve and operate.
SOLUTION
[0008] The objects forming the basis of the present invention will be attained if the granulator mill intimate by way of introduction is characterised in that the mill housing displays sections which extend interiorly in the receptacle or granulate box and seal against inner surfaces therein.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0009] The present invention will now be described in greater detail hereinbelow, with particular reference to the accompanying Drawings. In the accompanying Drawings:
[0010] FIG. 1 is a perspective view of a mill housing according to the present invention with a receptacle or granulate box mounted thereon;
[0011] FIG. 2 shows, in a view corresponding to that of FIG. 1 , the mill housing with a partly open receptacle box;
[0012] FIG. 3 is a vertical cross section at right angles to that axis about which the rotary knife unit of the mill housing rotates, the receptacle box being in the closed position;
[0013] FIG. 4 is a view corresponding to that of FIG. 3 of the apparatus according to the present invention, the receptacle box being, however, in the partly open position;
[0014] FIG. 5 is a vertical cross section at right angles in relation to the sections according to FIGS. 3 and 4 through the axis of rotation of the rotary knife unit disposed in the mill housing;
[0015] FIG. 6 is a perspective view corresponding to FIGS. 1 and 2 of the receptacle box;
[0016] FIG. 7 is a cross section through an edge portion of the mill housing in a first embodiment;
[0017] FIG. 8 is a cross section corresponding to FIG. 7 of a second embodiment; and
[0018] FIG. 9 is a cross section corresponding to FIGS. 7 and 8 of a third embodiment.
DESCRIPTION OF PREFERRED EMBODIMENT
[0019] In the following description, positional indications will be employed. These refer to the situation where the granulator mill is located in its normal position of use. In this context, the term “front” relates to that side of the mill which is turned to face towards the mill operator, while the term “rear” relates to that side of the mill which is turned to face away from the mill operator.
[0020] FIG. 1 shows, in perspective seen obliquely from the rear and above, a mill housing 1 on whose underside is removably secured a receptacle box for ground material, a granulate box. For purposes of clarity, the mill housing is shown without the fixed knives disposed therein and the rotary knife unit journalled in the mill housing. However, broken lines 3 intimate the axis of rotation about which the rotary knife unit rotates.
[0021] The mill housing 1 has a first end wall 4 and a second end wall 5 . The two end walls 4 and 5 are united by the intermediary of a front transverse section 6 and a rear transverse section 7 . The end walls have edge surfaces 15 ( FIG. 4 and also FIGS. 7 to 9 ).
[0022] In its most generic form, the present invention entails that the mill housing 1 has sections 8 which extend interiorly in the granulate box 2 and seal against inner surfaces 9 therein.
[0023] The granulate box 2 has a front wall 20 which, in the closed position of the granulate box ( FIGS. 2 and 4 ), on the one abuts and seals against the outside of the front section 6 and, on the other hand, against upper regions of the edge surfaces 15 of the end walls 4 and 5 .
[0024] It will further be apparent from FIGS. 3, 4 and 6 that the granulate box 2 has an outlet 21 for connection of an emptying conduit so that emptying by machine may readily be put into effect. As a result, the risk of pollution and fouling caused by manual emptying, when the ground material or granulate is poured out of the granulate box, is avoided.
[0025] In FIG. 1 a joint area 10 has been marked between the lower edge portion of the first end wall 4 and the sealing edge portion 11 of the granulate box 2 . The same area is also marked in FIG. 5 and shown in cross section in FIG. 8 . It will be apparent from this Figure that the mill housing 11 and in particular its end walls 4 and 5 at those sections 8 which extend into the granulate box 2 , has recesses 12 in which the sealing edge portions 11 of the granulate box are accommodated. The granulate box is thereby formed in such a manner that it straddles, at least partly, the mill housing and in particular its two opposing end walls 4 and 5 .
[0026] It will be apparent from FIG. 8 that there is a narrow gap between the bottom of the recess 12 and the upper edge portion 11 of the granulate box. Despite the presence of this gap, extremely good sealing will be obtained between the interior of the granulate box and its surroundings, since the seal is of the nature of a gap and/or labyrinth seal. Further, the gap has, at the bottom of the recess 12 , its discharge opening 13 located interiorly in the granulate box turned to face downwards, which implies that at least such particles as are transported by force of gravity fall away from the gap.
[0027] FIG. 7 shows a simplified variation of the construction according to FIG. 8 . In this variation, the recess is absent and instead the edge portion 11 of the granulate box extends up a distance along the outer surface 14 of the end wall 4 .
[0028] The variation illustrated in FIG. 9 entails that a groove 16 has been provided from the edge surface 15 of the end wall 4 in which the edge portion 11 of the granulate box is accommodated.
[0029] For suspending the granulate box 2 on the mill housing 1 , but also for sealing along the upper edge of the rear wall 17 of the granulate box, the rear wall has, along its upper edge, an inwardly bent flange 18 which serves the function of sealing- and support surface (see FIGS. 2, 4 and 6 ). This inwardly bent flange 18 is substantially horizontal in the mounted position of the granulate box 2 and rests on and seals against a corresponding outwardly bent flange 19 along the lower, rear edge of the mill housing. This outwardly bent flange 19 also serves the function of sealing and support surface and is formed in that a rear cover plate 22 which, under the rear transverse section 7 , extends between and unites the two end walls 4 and 5 , has an outwardly directed bend along its lower edge.
[0030] In a comparison between FIGS. 3 and 4 , it will be apparent that the granulate box is pivotal about a pivot axis which is defined by the two flanges 18 and 19 . For dismounting the granulate box from the position illustrated in FIG. 3 , a lock disposed on the front side of the granulate box is first opened, whereafter the granulate box is pivoted to the position illustrated in FIG. 4 where it may simply be slid in a rearward direction so that the flanges 18 and 19 are free from one another.
[0031] Mounting of the granulate box 2 on the mill housing 1 takes place in the reverse sequence. | A granulator mill comprises a mill housing with a rotary knife unit. Beneath the mill housing, a removable granulate box is disposed for accumulating ground material. The mill housing has sections which extend interiorly into the granulate box and seal against its interior surfaces. The granulate box is designed so that it overlaps the mill housing, a gap seal being formed between edge portions of the receptacle box and recesses in the mill housing. | 1 |
BACKGROUND OF THE INVENTION
Alzheimer's disease (AD) is the most common cause of dementia in the elderly and is characterised by a decline in cognitive function, that progresses slowly and results in symptoms such as memory loss and disorientation. Death occurs, on average, 9 years after diagnosis. The incidence of AD increases with age, so that while about 5% of people over the age of 70 are sufferers, this figure increases to 20% of those over 80 years old.
Existing treatments exclusively target the primary symptoms of AD. Diseased neurons may release insufficient or excessive amounts of particular neurotransmitters, and so current drugs are aimed at increasing neurotransmitter levels or at reducing the stimulation of nerve cells by neurotransmitters. Although these drugs provide some improvement in the symptoms of AD, they fail to address the underlying cause of the disease.
The classic clinical and neuropathological features of AD consist of senile or neuritic plaques and tangled bundles of fibers (neurofibrillary tangles) [Verdile, G., et al, Pharm. Res. 50:397-409 (2004)]. In addition, there is a severe loss of neurons in the hippocampus and the cerebral cortex. Neuritic plaques are extracellular lesions, consisting mainly of deposits of β-amyloid peptide (Aβ), surrounded by dystrophic (swollen, damaged and degenerating) neurites and glial cells activated by inflammatory processes. In contrast, neurofibrillary tangles (NFTs) are intracellular clusters composed of a hyperphosphorylated form of the protein tau, which are found extensively in the brain (e.g. mainly in cortex and hippocampus in AD). Tau is a soluble cytoplasmic protein which has a role in microtubule stabilisation. Excessive phosphorylation of this protein renders it insoluble and leads to its aggregation into paired helical filaments, which in turn form NFTs.
The amyloid cascade hypothesis proposes that abnormal accumulation of Aβ peptides, particularly Aβ42, initiates a cascade of events leading to the classical symptoms of AD and ultimately, to the death of the patient. There is strong evidence [e.g. Rapoport, M., et al (2002) Proc. Natl. Acad. Sci. USA 99:6364-6369] that dysregulation of tau function is a key step in the cascade of Alzheimer's disease pathology leading ultimately to neuronal death. Furthermore, tau mutations and NFTs are found in other dementias in which Aβ pathology is absent, such as frontotemporal dementia, Pick's disease and parkinsonism linked to chromosome 17 (FTDP-17) [Mizutani, T. (1999) Rinsho Shikeigaku 39: 1262-1263]. Also, in AD the frequency of NFTs correlates to the degree of dementia better than that of senile plaques [Arriagada, P. V., et al (1992) Neurology 42:631-639], while significant numbers of amyloid plaques are often found in the brains of non-demented elderly people, suggesting that amyloid pathology on its own is not sufficient to cause dementia. For these reasons, normalisation of tau function (in particular prevention of hyperphosphorylation) is seen as a desirable therapeutic goal for the treatment of AD and other dementing conditions.
Tau is a 352-441 amino acid protein encoded by the Mapt (Microtubule-associated protein tau) gene which is widely expressed in the central nervous system (CNS) with localisation primarily in axons [Binder et al J. Cell Biol. 1985, 101(4), 1371-1378]. The major function of tau is regulation of the stability of microtubules (MTs), intracellular structural components comprised of tubulin dimers which are integral in regulating many essential cellular processes such as axonal transport and elongation as well as generation of cell polarity and shape. Tau binding to tubulin is a key factor in determining the rates of polymerisation/depolymerization (termed dynamic instability) of MTs, and tau is therefore key to the regulation of many essential cellular processes [see, for example, Butner, K. A., Kirschner, M. W. (1991) J. Cell. Biol. 115: 717-730].
Tau is a basic protein with numerous serine and threonine residues, many of which are susceptible to phosphorylation. While normal tau has two to three phosphorylated amino acid residues, hyperphosphorylated tau found in AD and other tauopathies typically has eight or nine phosphorylated residues. A variety of kinases promote phosphorylation of these sites, including proline-directed kinases such as glycogen synthase kinase 3β (GSK3β) and cyclin dependent kinase 5 (cdk5), and non-proline-directed kinases such as protein kinase A (PKA) and calmodulin (CaM) kinase II, which phosphorylate tau at Lys-(Ile/Cys)-Gly-Ser sequences, also known as KXGS motifs. One KXGS motif is found in each of the MT binding repeats. Phosphorylation at these sites is important for the regulation of tau-MT binding and while the degree of phosphorylation is normally low, it has been shown to be increased in brain tissue from AD patients. Phosphorylation of one particular residue within the KXGS motifs, Ser-262 has been shown to be elevated in tau protein extracted from the NFTs in AD [Hasegawa, M. et al (1992) J. Biol. Chem. 267:17047-17054] and phosphorylation at this site also appears to dramatically reduce MT binding [Biernat, J. et al. (1993) Neuron 11: 153-163]. Nishimura et al. [Cell 116: 671-682 (2004)] demonstrated that overexpression of the kinase PAR-1 in Drosophila led to enhanced tau-mediated toxicity and an increase in the phosphorylation of tau on Ser-262, Ser-356, and other amino acid residues, including sites phosphorylated by GSK3β and Cdk5. Their findings suggest that PAR-1 kinase acts as a master kinase during the process of tau hyperphosphorylation, with the phosphorylation of the Ser-262 and Ser-356 sites being a prerequisite for the subsequent phosphorylation at downstream sites by other kinases.
The mammalian ortholog of PAR-1 is microtubule affinity-regulating kinase (MARK). There are four MARK isoforms and these form part of the AMP-dependent protein kinase (AMPK) family. Like PAR-1, MARK is thought to phosphorylate tau, perhaps in response to an external insult, such as the disruption of Ca 2+ homeostasis caused by Aβ, priming it for further phosphorylation events. It is not clear whether the phosphorylation of tau by MARK leads directly to its detachment from MTs or the subsequent phosphorylation events cause detachment. The resulting unbound, hyperphosphorylated tau is delocalised to the somatodendritic compartment and is then cleaved by caspases to form fragments prone to aggregation [Drewes, G. (2004). Trends Biochem. Sci 29:548-555; Gamblin, T. C., et al, (2003) Proc. Natl. Acad. Sci. U.S.A. 100:10032-10037]. These aggregates can grow into filaments, which are potentially toxic, eventually forming the NFTs found in AD.
For these reasons, it is proposed that MARK inhibitors will enable the prevention or amelioration of neurodegeneration in AD and other tauopathies.
This invention relates to methods and materials for the treatment or prevention of neurodegenerative diseases such as Alzheimer's disease. In particular, there is disclosed a particular class of imidazo[1,2-a]pyridine and imidazo[1,2-b]pyridazine derivatives which selectively inhibit microtubule affinity regulating kinase (MARK).
SUMMARY OF THE INVENTION
The invention encompasses imidazo[1,2-a]pyridine and imidazo[1,2-b]pyridazine derivatives which selectively inhibit microtubule affinity regulating kinase (MARK) and are therefore useful for the treatment or prevention of Alzheimer's disease. Pharmaceutical compositions and methods of use are also included.
DETAILED DESCRIPTION OF THE INVENTION
The invention encompasses a genus of compounds of formula I:
or a pharmaceutically acceptable salt or hydrate thereof; wherein:
W is selected from ═N— and ═C(X 3 )—;
X 1 is selected from the group consisting of: H, halogen, CF 3 , phenyl, and a monocyclic or bicyclic ring system comprising up to 10 ring atoms, of which 1-3 are selected from N, O and S(O) X and the remainder are C, said phenyl and ring system bearing 0-3 substituents independently selected from halogen and C 1-4 alkyl, optionally substituted with up to 3 halogen atoms;
X 2 is selected from the group consisting of: H, halogen and phenyl bearing 0 to 5 halogen substituents;
X 3 is selected from the group consisting of: H, OR 3 , N(R 3 ) 2 , C 1-6 alkyl and halogen;
X 4 is selected from the group consisting of H, halogen, phenyl-(CH 2 ) p —, C 3-6 cycloalkyl-(CH 2 ) q —, C 1-6 alkyl and C 2-6 alkenyl, said phenyl-(CH 2 ) p —, C 3-6 cycloalkyl-(CH 2 ) q —, C 1-6 alkyl and C 2-6 alkenyl optionally substituted with up to 3 halogen atoms, and p and q are independently 0, 1, 2 or 3;
Y is selected from the group consisting of: ═N— and ═CH—;
R 1 represents H or C 1-4 alkyl which is optionally substituted with OH, CN, CF 3 , C 1-4 alkoxy, amino, C 1-4 alkylamino or di(C 1-4 alkyl)amino;
R 2 is selected from:
(i) H;
(ii) C 1-8 alkyl or C 2-8 alkenyl, either of which optionally bears up to 3 substituents independently selected from halogen, OH, CN, CF 3 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 , NR 3 SO 2 R 4 and phenyl, said phenyl bearing 0 to 5 halogen substituents; and
(iii) C 3-10 cycloalkyl, C 3-10 cycloalkylC 1-4 alkyl, Het, HetC 1-4 alkyl, aryl or arylC 1-4 alkyl, any of which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 ; where “aryl” refers to phenyl or 5- or 6-membered heteroaryl, either of which phenyl or heteroaryl is optionally fused to a 5- or 6-membered carbocycle or heterocycle, and “Het” refers to a nonaromatic mono- or bicyclic heterocyclic system of up to 10 ring atoms, of which 1-3 are selected from N, O and S(O) X and the remainder are C;
or R 1 and R 2 together may complete a mono- or bicyclic heterocyclic system of up to 10 ring atoms which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 ;
each R 3 independently represents H or C 1-6 alkyl which is optionally substituted with up to 3 halogen atoms or with OH, CN, CF 3 , C 1-4 alkoxy, amino, C 1-4 alkylamino or di(C 1-4 alkyl)amino, or R 3 represents phenyl, benzyl or 5- or 6-membered heteroaryl, any of which optionally bears up to 3 substituents independently selected from halogen, OH, CN, CF 3 , C 1-4 alkyl, C 1-4 alkoxy, amino, C 1-4 alkylamino and di(C 1-4 alkyl)amino;
or two R 3 groups attached to the same nitrogen atom may complete a heterocycle of up to 6 ring atoms which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , C 1-4 alkyl, C 1-4 alkoxy, amino, C 1-4 alkylamino and di(C 1-4 alkyl)amino;
R 4 has the same definition as R 3 except that R 4 is not H; and
each x is independently 0, 1 or 2.
Within the genus, the invention encompasses a subgenus of compounds of formula I wherein W is ═N—.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein W is ═C(X 3 )— and X 3 is H.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein Y is ═CH—.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein Y is ═N—.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein X 1 is phenyl bearing 0 to 3 halogen substituents.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein X 1 is H.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein X 1 is halogen.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein X 1 is CF 3 .
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein X 2 is H.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein X 4 is selected from H, halogen, C 1-4 alkyl bearing 0 to 3 halogen substituents, cyclopropyl, cyclopropylmethyl and benzyl.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein R 1 is H.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein R 2 is C 3-10 cycloalkyl bearing up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 . Within this subgenus, the invention encompasses a class of compounds of Formula I wherein R 2 is cyclohexyl bearing up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 .
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein: W is ═N—; Y is —CH—; X 1 is selected from the group consisting of: H, halogen, phenyl bearing 0 to 3 halogen substituents and CF 3 ; X 2 is H; X 4 is selected from the group consisting of: H, halogen, C 1-4 alkyl bearing 0 to 3 halogen substituents, cyclopropyl, cyclopropylmethyl and benzyl; R 1 is H; and R 2 is C 3-10 cycloalkyl, C 3-10 cycloalkylC 1-4 alkyl, Het, HetC 1-4 alkyl, aryl or arylC 1-4 alkyl, any of which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 ; where “aryl” refers to phenyl or 5- or 6-membered heteroaryl, either of which phenyl or heteroaryl is optionally fused to a 5- or 6-membered carbocycle or heterocycle, and “Het” refers to a nonaromatic mono- or bicyclic heterocyclic system of up to 10 ring atoms, of which 1-3 are selected from N, O and S(O) X and the remainder are C.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein: W is ═C(X 3 )— and X 3 is H; Y is ═CH—; X 1 is selected from the group consisting of: H, halogen, phenyl bearing 0 to 3 halogen substituents and CF 3 ; X 2 is H; X 4 is selected from the group consisting of: H, halogen, C 1-4 alkyl bearing 0 to 3 halogen substituents, cyclopropyl, cyclopropylmethyl and benzyl; R 1 is H; and R 2 is C 3-10 cycloalkyl, C 3-10 cycloalkylC 1-4 alkyl, Het, HetC 1-4 alkyl, aryl or arylC 1-4 alkyl, any of which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 ; where “aryl” refers to phenyl or 5- or 6-membered heteroaryl, either of which phenyl or heteroaryl is optionally fused to a 5- or 6-membered carbocycle or heterocycle, and “Het” refers to a nonaromatic mono- or bicyclic heterocyclic system of up to 10 ring atoms, of which 1-3 are selected from N, O and S(O) X and the remainder are C.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein: W is ═N—; Y is ═N—; X 1 is selected from the group consisting of H, halogen, phenyl bearing 0 to 3 halogen substituents and CF 3 ; X 2 is H; 4 is selected from the group consisting of: H, halogen, C 1-4 alkyl bearing 0 to 3 halogen substituents, cyclopropyl, cyclopropylmethyl and benzyl; R 1 is H; and R 2 is C 3-10 cycloalkyl, C 3-10 cycloalkylC 1-4 alkyl, Het, HetC 1-4 alkyl, aryl or arylC 1-4 alkyl, any of which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 ; where “aryl” refers to phenyl or 5- or 6-membered heteroaryl, either of which phenyl or heteroaryl is optionally fused to a 5- or 6-membered carbocycle or heterocycle, and “Het” refers to a nonaromatic mono- or bicyclic heterocyclic system of up to 10 ring atoms, of which 1-3 are selected from N, O and S(O) X and the remainder are C.
Also within the genus, the invention encompasses a subgenus of compounds of formula I wherein: W is ═C(X 3 )— and X 3 is H; Y is ═N—; X 1 is selected from the group consisting of: H, halogen, phenyl bearing 0 to 3 halogen substituents and CF 3 ; X 2 is H; X 4 is selected from the group consisting of: H, halogen, C 1-4 alkyl bearing 0 to 3 halogen substituents, cyclopropyl, cyclopropylmethyl and benzyl; R 1 is H; and R 2 is C 3-10 cycloalkyl, C 3-10 cycloalkylC 1-4 alkyl, Het, HetC 1-4 alkyl, aryl or arylC 1-4 alkyl, any of which optionally bears up to 3 substituents independently selected from halogen, OH, oxo, CN, CF 3 , R 4 , OR 3 , SR 4 , SO 2 R 4 , SO 2 N(R 3 ) 2 , COR 3 , CO 2 R 3 , CON(R 3 ) 2 , N(R 3 ) 2 , NR 3 COR 4 and NR 3 SO 2 R 4 ; where “aryl” refers to phenyl or 5- or 6-membered heteroaryl, either of which phenyl or heteroaryl is optionally fused to a 5- or 6-membered carbocycle or heterocycle, and “Het” refers to a nonaromatic mono- or bicyclic heterocyclic system of up to 10 ring atoms, of which 1-3 are selected from N, O and S(O) X and the remainder are C.
The invention also encompasses a compound selected from the examples described below, including stereoisomers or mixtures thereof, or a pharmaceutically acceptable salt of any of these compounds or stereoisomers.
The invention also encompasses a pharmaceutical composition comprising a compound of formula I or a pharmaceutically acceptable salt or hydrate thereof, and a pharmaceutically acceptable carrier.
The invention further provides a method for treatment or prevention of a neurodegenerative disease associated with hyperphosphorylation of tau in a human patient, said method comprising administering to that patient an effective amount of a compound of formula I as defined above, or a pharmaceutically acceptable salt or hydrate thereof.
Neurodegenerative diseases associated with hyperphosphorylation of tau include AD, frontotemporal dementia, Pick's disease and parkinsonism linked to chromosome 17 (FTDP-17).
In a further aspect, the invention provides a method for reducing the production of hyperphosphorylated tau in a human patient, said method comprising administering to said patient an effective amount of a compound of formula I as defined above or a pharmaceutically acceptable salt or hydrate thereof.
As used herein, the expression “C 1-x alkyl” where x is an integer greater than 1 refers to straight-chained and branched alkyl groups wherein the number of constituent carbon atoms is in the range 1 to x. Particular alkyl groups are methyl, ethyl, n-propyl, isopropyl and t-butyl. Derived expressions such as “C 2-6 alkenyl”, “hydroxyC 1-6 alkyl”, “heteroarylC 1-6 alkyl”, “C 2-6 alkynyl” and “C 1-6 alkoxy” are to be construed in an analogous manner. Most suitably, the number of carbon atoms in such groups is not more than 6.
The term “halogen” as used herein includes fluorine, chlorine, bromine and iodine.
The expression “C 3-x cycloalkyl” as used herein, where x is an integer greater than 3, refers to nonaromatic hydrocarbon ring systems containing from 3 to x ring atoms. Said systems may be monocyclic or bicyclic if the magnitude of x allows it. Examples include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, bicycloheptyl and decalinyl.
Unless indicated otherwise, the term “bicyclic” includes bridged bicyclic and spiro-linked ring systems as well as fused ring systems. However, a bicyclic system in which one or both rings are aromatic is of necessity a fused ring system.
For use in medicine, the compounds of formula I may be in the form of pharmaceutically acceptable salts. Other salts may, however, be useful in the preparation of the compounds of formula I or of their pharmaceutically acceptable salts. Suitable pharmaceutically acceptable salts of the compounds of this invention include acid addition salts which may, for example, be formed by mixing a solution of the compound according to the invention with a solution of a pharmaceutically acceptable acid such as hydrochloric acid, sulphuric acid, methanesulphonic acid, benzenesulphonic acid, fumaric acid, maleic acid, succinic acid, acetic acid, trifluoroacetic acid, benzoic acid, oxalic acid, citric acid, tartaric acid, carbonic acid or phosphoric acid. Alternatively, where the compound of the invention carries an acidic moiety, a pharmaceutically acceptable salt may be formed by neutralisation of said acidic moiety with a suitable base. Examples of pharmaceutically acceptable salts thus formed include alkali metal salts such as sodium or potassium salts; ammonium salts; alkaline earth metal salts such as calcium or magnesium salts; and salts formed with suitable organic bases, such as amine salts (including pyridinium salts) and quaternary ammonium salts.
When the compounds useful in the invention have one or more asymmetric centres, they may accordingly exist as enantiomers. Where the compounds according to the invention possess two or more asymmetric centers, they may additionally exist as diastereoisomers. It is to be understood that all such isomers and mixtures thereof in any proportion are encompassed within the scope of the present invention. Any formulas, structures or names of compounds described herein that do not specify a particular stereochemistry are meant to encompass any and all existing isomers as described above in substantially pure form free of other isomers and mixtures thereof in any proportion. When stereochemistry is specified, the invention is meant to encompass that particular isomer, either in substantially pure form free of other isomers or as part of a mixture.
When a compound useful in the invention is capable of existing in tautomeric keto and enol forms, both of said forms are considered to be within the scope of the invention.
A nitrogen atom forming part of a heteroaryl ring may be in the form of the N-oxide. A sulphur atom forming part of a nonaromatic heterocycle may be in the form of the S-oxide or S,S-dioxide.
A heteroaryl group may be attached to the remainder of the molecule via a ring carbon or a ring nitrogen, provided that this is consistent with preservation of aromaticity.
In formula I, X 1 may represent a monocyclic or bicyclic ring system comprising up to 10 ring atoms, of which 1-3 are heteroatoms selected from N, O and S(O) X and the remainder are C. In the case of a bicyclic system comprising 2 or 3 heteroatoms, said heteroatoms may be confined to one of the rings or distributed over both of the rings. In the case of a bicyclic system, preferably at least one of the rings is aromatic, for example the ring which is bonded to the pyrazolopyridine system of formula I. In the case of a monocyclic system, the ring typically comprises 5 or 6 ring atoms and may be aromatic or nonaromatic, and in a particular embodiment such a ring is either aromatic or partially unsaturated.
Examples of aromatic monocyclic systems represented by X 1 include pyridine, pyrazole, imidazole, pyrrole, thiophene and furan.
Examples of nonaromatic monocyclic systems represented by X 1 include dihydropyridine and tetrahydropyridine.
Examples of bicyclic systems represented by X 1 include indole, benzofuran, quinoline, isoquinoline, 1H-pyrrolo[2,3-b]pyridine, 5,6-dihydro-4H-pyrrolo[1,2-b]pyrazole and 2,3-dihydro-1H-benzimidazole.
It will be apparent to those skilled in the art that a hydroxyl substituent on an unsaturated ring may be capable of tautomerising to a ketone. In such circumstances, both tautomers are to be considered equivalent. Thus, for example, 2-hydroxypyridine is considered equivalent to 2-oxo-1,2-dihydropyridine.
Specific examples of compounds in accordance with the invention are provided in the Examples hereinafter.
It will be apparent to those skilled in the art that individual compounds in accordance with formula I may be converted into other compounds in accordance with formula using standard synthetic techniques. For example, compounds in which X 1 is a fluoro-substituted aromatic moiety may be treated with primary or secondary amines in DMF in the presence of alkali at elevated temperatures to provide the corresponding amino-substituted derivatives. Similarly, compounds in which X 1 comprises a dihydro- or tetrahydropyridine ring or similar may be N-alkylated using standard methods. Such transformations may also be carried out on intermediates in the synthesis of compounds of formula I.
Where they are not themselves commercially available, the starting materials and reagents described above may be obtained from commercially available precursors by means of well known synthetic procedures and/or the methods disclosed in the Examples section herein.
Where the above-described processes for the preparation of the compounds of use in the invention give rise to mixtures of stereoisomers, these isomers may be separated by conventional techniques such as preparative chromatography. The compounds may be prepared in racemic form, or individual enantiomers may be prepared either by enantiospecific synthesis or by resolution. The compounds may, for example, be resolved into their component enantiomers by standard techniques such as preparative HPLC, or the formation of diastereomeric pairs by salt formation with an optically active acid, such as di-p-toluoyl-D-tartaric acid and/or di-p-toluoyl-L-tartaric acid, followed by fractional crystallization and regeneration of the free base. The compounds may also be resolved by formation of diastereomeric esters or amides, followed by chromatographic separation and removal of the chiral auxiliary
During any of the above synthetic sequences it may be necessary and/or desirable to protect sensitive or reactive groups on any of the molecules concerned. This may be achieved by means of conventional protecting groups, such as those described in Protective Groups in Organic Chemistry , ed. J. F. W. McOmie, Plenum Press, 1973; and T. W. Greene & P. G. M. Wuts, Protective Groups in Organic Synthesis , John Wiley & Sons, 1991. The protecting groups may be removed at a convenient subsequent stage using methods known from the art.
The compounds of formula I are suitably administered to patients in the form a pharmaceutical composition comprising the active ingredient (i.e. the compound of formula I or pharmaceutically acceptable salt or hydrate thereof) and a pharmaceutically acceptable carrier, and said pharmaceutical compositions constitute a further aspect of the invention.
Preferably these compositions are in unit dosage forms such as tablets, pills, capsules, powders, granules, sterile parenteral solutions or suspensions, metered aerosol or liquid sprays, drops, ampoules, transdermal patches, auto-injector devices or suppositories; for oral, parenteral, intranasal, sublingual or rectal administration, or for administration by inhalation or insufflation. The principal active ingredient typically is mixed with a pharmaceutical carrier, e.g. conventional tableting ingredients such as corn starch, lactose, sucrose, sorbitol, talc, stearic acid, magnesium stearate and dicalcium phosphate, or gums, dispersing agents, suspending agents or surfactants such as sorbitan monooleate and polyethylene glycol, and other pharmaceutical diluents, e.g. water, to form a homogeneous preformulation composition containing a compound of the present invention, or a pharmaceutically acceptable salt thereof. When referring to these preformulation compositions as homogeneous, it is meant that the active ingredient is dispersed evenly throughout the composition so that the composition may be readily subdivided into equally effective unit dosage forms such as tablets, pills and capsules. This preformulation composition is then subdivided into unit dosage forms of the type described above containing from 0.1 to about 500 mg of the active ingredient of the present invention. Typical unit dosage forms contain from 1 to 100 mg, for example 1, 2, 5, 10, 25, 50 or 100 mg, of the active ingredient. Tablets or pills of the composition can be coated or otherwise compounded to provide a dosage form affording the advantage of prolonged action. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids and mixtures of polymeric acids with such materials as shellac, cetyl alcohol and cellulose acetate.
The liquid forms in which the compositions useful in the present invention may be incorporated for administration orally or by injection include aqueous solutions, liquid- or gel-filled capsules, suitably flavoured syrups, aqueous or oil suspensions, and flavoured emulsions with edible oils such as cottonseed oil, sesame oil, coconut oil or peanut oil, as well as elixirs and similar pharmaceutical vehicles. Suitable dispersing or suspending agents for aqueous suspensions include synthetic and natural gums such as tragacanth, acacia, alginate, dextran, sodium carboxymethylcellulose, methylcellulose, poly(ethylene glycol), polyvinylpyrrolidone) or gelatin.
In one embodiment of the invention, the compound of formula I is administered to a patient suffering from AD, FTDP-17, Pick's disease or frontotemporal dementia, in particular AD.
In an alternative embodiment of the invention, the compound of formula I is administered to a patient suffering from mild cognitive impairment or age-related cognitive decline. A favourable outcome of such treatment is prevention or delay of the onset of AD. Age-related cognitive decline and mild cognitive impairment (MCI) are conditions in which a memory deficit is present, but other diagnostic criteria for dementia are absent (Santacruz and Swagerty, American Family Physician, 63 (2001), 703-13). (See also “The ICD-10 Classification of Mental and Behavioral Disorders”, Geneva: World Health Organisation, 1992, 64-5). As used herein, “age-related cognitive decline” implies a decline of at least six months' duration in at least one of: memory and learning; attention and concentration; thinking; language; and visuospatial functioning and a score of more than one standard deviation below the norm on standardized neuropsychologic testing such as the MMSE. In particular, there may be a progressive decline in memory. In the more severe condition MCI, the degree of memory impairment is outside the range considered normal for the age of the patient but AD is not present. The differential diagnosis of MCI and mild AD is described by Petersen et al., Arch. Neurol., 56 (1999), 303-8. Further information on the differential diagnosis of MCI is provided by Knopman et al, Mayo Clinic Proceedings, 78 (2003), 1290-1308. In a study of elderly subjects, Tuokko et al ( Arch, Neurol., 60 (2003) 577-82) found that those exhibiting MCI at the outset had a three-fold increased risk of developing dementia within 5 years.
Grundman et al ( J. Mol. Neurosci., 19 (2002), 23-28) report that lower baseline hippocampal volume in MCI patients is a prognostic indicator for subsequent AD. Similarly, Andreasen et al ( Acta Neurol. Scand, 107 (2003) 47-51) report that high CSF levels of total tau, high CSF levels of phospho-tau and lowered CSF levels of Aβ42 are all associated with increased risk of progression from MCI to AD.
Within this embodiment, the compound of formula I is advantageously administered to patients who suffer impaired memory function but do not exhibit symptoms of dementia. Such impairment of memory function typically is not attributable to systemic or cerebral disease, such as stroke or metabolic disorders caused by pituitary dysfunction. Such patients may be in particular people aged 55 or over, especially people aged 60 or over, and preferably people aged 65 or over. Such patients may have normal patterns and levels of growth hormone secretion for their age. However, such patients may possess one or more additional risk factors for developing Alzheimer's disease. Such factors include a family history of the disease; a genetic predisposition to the disease; elevated serum cholesterol; and adult-onset diabetes mellitus.
In a particular embodiment of the invention, the compound of formula I is administered to a patient suffering from age-related cognitive decline or MCI who additionally possesses one or more risk factors for developing AD selected from: a family history of the disease; a genetic predisposition to the disease; elevated serum cholesterol; adult-onset diabetes mellitus; elevated baseline hippocampal volume; elevated CSF levels of total tau; elevated CSF levels of phospho-tau; and lowered CSF levels of Aβ(1-42).
A genetic predisposition (especially towards early onset AD) can arise from point mutations in one or more of a number of genes, including the APP, presenilin-1 and presenilin-2 genes. Also, subjects who are homozygous for the ε4 isofolin of the apolipoprotein E gene are at greater risk of developing AD.
The patient's degree of cognitive decline or impairment is advantageously assessed at regular intervals before, during and/or after a course of treatment in accordance with the invention, so that changes therein may be detected, e.g. the slowing or halting of cognitive decline. A variety of neuropyschological tests are known in the art for this purpose, such as the Mini-Mental State Examination (MMSE) with norms adjusted for age and education (Folstein et al., J. Psych. Res., 12 (1975), 196-198, Anthony et al., Psychological Med., 12 (1982), 397-408; Cockrell et al., Psychopharmacology, 24 (1988), 689-692; Crum et al., J. Am. Med. Assoc'n. 18 (1993), 2386-2391). The MMSE is a brief, quantitative measure of cognitive status in adults. It can be used to screen for cognitive decline or impairment, to estimate the severity of cognitive decline or impairment at a given point in time, to follow the course of cognitive changes in an individual over time, and to document an individual's response to treatment. Another suitable test is the Alzheimer Disease Assessment Scale (ADAS), in particular the cognitive element thereof (ADAS-cog) (See Rosen et al., Am. J. Psychiatry, 141 (1984), 1356-64).
For treating or preventing Alzheimer's disease, a suitable dosage level is about 0.01 to 250 mg/kg per day, preferably about 0.01 to 100 mg/kg per day, and more preferably about 0.05 to 50 mg/kg of body weight per day, of the active compound. The compounds may be administered on a regimen of 1 to 4 times per day. In some cases, however, a dosage outside these limits may be used.
The compound of formula I optionally may be administered in combination with one or more additional compounds known to be useful in the treatment or prevention of AD or the symptoms thereof. Such additional compounds thus include cognition-enhancing drugs such as acetylcholinesterase inhibitors (e.g. donepezil and galanthamine), NMDA antagonists (e.g. memantine) or PDE4 inhibitors (e.g. Ariflo™ and the classes of compounds disclosed in WO 03/018579, WO 01/46151, WO 02/074726 and WO 02/098878). Such additional compounds also include cholesterol-lowering drugs such as the statins, e.g. simvastatin. Such additional compounds similarly include compounds known to modify the production or processing of Aβ in the brain (“amyloid modifiers”), such as compounds which modulate the secretion of Aβ (including γ-secretase inhibitors, γ-secretase modulators and β-secretase inhibitors), compounds which inhibit the aggregation of Aβ, and antibodies which selectively bind to Aβ. Such additional compounds further include growth hormone secretagogues, e.g. as described in WO 2004/080459.
In this embodiment of the invention, the amyloid modifier may be a compound which inhibits the secretion of Aβ, for example an inhibitor of γ-secretase (such as those disclosed in WO 01/90084, WO 02/30912, WO 01/70677, WO 03/013506, WO 02/36555, WO 03/093252, WO 03/093264, WO 03/093251, WO 03/093253, WO 2004/039800, WO 2004/039370, WO 2005/030731, WO 2005/014553, WO 2004/089911, WO 02/081435, WO 02/081433, WO 03/018543, WO 2004/031137, WO 2004/031139, WO 2004/031138, WO 2004/101538, WO 2004/101539 and WO 02/47671), or a 3-secretase inhibitor (such as those disclosed in WO 03/037325, WO 03/030886, WO 03/006013, WO 03/006021, WO 03/006423, WO 03/006453, WO 02/002122, WO 01/70672, WO 02/02505, WO 02/02506, WO 02/02512, WO 02/02520, WO 02/098849 and WO 02/100820), or any other compound which inhibits the formation or release of A including those disclosed in WO 98/28268, WO 02/47671, WO 99/67221, WO 01/34639, WO 01/34571, WO 00/07995, WO 00/38618, WO 01/92235, WO 01/77086, WO 01/74784, WO 01/74796, WO 01/74783, WO 01/60826, WO 01/19797, WO 01/27108, WO 01/27091, WO 00/50391, WO 02/057252, US 2002/0025955 and US2002/0022621, and also including GSK-3 inhibitors, particularly GSK-3α inhibitors, such as lithium, as disclosed in Phiel et al, Nature, 423 (2003), 435-9.
Alternatively, the amyloid modifier may be a compound which modulates the action of γ-secretase so as to selectively attenuate the production of Aβ(1-42). Compounds reported to show this effect include certain non-steroidal antiinflammatory drugs (NSAIDs) and their analogues (see WO 01/78721 and US 2002/0128319 and Weggen et al Nature, 414 (2001) 212-16; Morihara et al, J. Neurochem., 83 (2002), 1009-12; and Takahashi et al, J. Biol. Chem., 278 (2003), 18644-70), and compounds which modulate the activity of PPARα and/or PPARδ (WO 02/100836). Further examples of γ-secretase modulators are disclosed in WO 2005/054193, WO 2005/013985, WO 2005/108362, WO 2006/008558 and WO 2006/043064.
Alternatively, the amyloid modifier may be a compound which inhibits the aggregation of Aβ or otherwise attenuates is neurotoxicicity. Suitable examples include chelating agents such as clioquinol (Gouras and Beal, Neuron, 30 (2001), 641-2) and the compounds disclosed in WO 99/16741, in particular that known as DP-109 (Kalendarev et al, J. Pharm. Biomed. Anal., 24 (2001), 967-75). Other inhibitors of Aβ aggregation suitable for use in the invention include the compounds disclosed in WO 96/28471, WO 98/08868 and WO 00/052048, including the compound known as Apan™ (Praecis); WO 00/064420, WO 03/017994, WO 99/59571 (in particular 3-aminopropane-1-sulfonic acid, also known as tramiprosate or Alzhemed™); WO 00/149281 and the compositions known as PTI-777 and PTI-00703 (ProteoTech); WO 96/39834, WO 01/83425, WO 01/55093, WO 00/76988, WO 00/76987, WO 00/76969, WO 00/76489, WO 97/26919, WO 97/16194, and WO 97/16191. Further examples include phytic acid derivatives as disclosed in U.S. Pat. No. 4,847,082 and inositol derivatives as taught in US 2004/0204387.
Alternatively, the amyloid modifier may be an antibody which binds selectively to Aβ. Said antibody may be polyclonal or monoclonal, but is preferably monoclonal, and is preferably human or humanized. Preferably, the antibody is capable of sequestering soluble Aβ from biological fluids, as described in WO 03/016466, WO 03/016467, WO 03/015691 and WO 01/62801. Suitable antibodies include humanized antibody 266 (described in WO 01/62801) and the modified version thereof described in WO 03/016466. Suitable antibodies also include those specific to Aβ-derived diffusible ligands (ADDLS), as disclosed in WO 2004/031400.
As used herein, the expression “in combination with” requires that therapeutically effective amounts of both the compound of formula I and the additional compound are administered to the subject, but places no restriction on the manner in which this is achieved. Thus, the two species may be combined in a single dosage form for simultaneous administration to the subject, or may be provided in separate dosage forms for simultaneous or sequential administration to the subject. Sequential administration may be close in time or remote in time, e.g. one species administered in the morning and the other in the evening. The separate species may be administered at the same frequency or at different frequencies, e.g. one species once a day and the other two or more times a day. The separate species may be administered by the same route or by different routes, e.g. one species orally and the other parenterally, although oral administration of both species is preferred, where possible. When the additional compound is an antibody, it will typically be administered parenterally and separately from the compound of formula I.
EXAMPLES
MARK 3 Assay
MARK3 activity was assayed in vitro using a Cdc25C biotinylated peptide substrate (Cell Signalling Technologies). The phosphopeptide product was quantitated using a Homogenous Time-Resolved Fluorescence (HTRF) assay system (Park et al., 1999 , Anal. Biochem. 269:94-104). The reaction mixture contained 50 mM HEPES/Tris-HCl, pH 7.4; mM NaCl, 5 mM MgCl 2 , 0.2 mM NaVO 4 , 5 mM 3-glycerol phosphate, 0.1% Tween-20, 2 mM dithiothreitol, 0.1% BSA, 10 μM ATP, 1 μM peptide substrate, and 10 nM recombinant MARK3 enzyme (University of Dundee) in a final volume of 12 μL. The buffer additionally contained protease inhibitor cocktail (Roche EDTA-free, 1 tab per 50 ml). The kinase reaction was incubated for 2 hours at 25° C., and then terminated with 3 μl Stop/Detection Buffer (50 mM HEPES, pH 7.0, 16.6 mM EDTA, 0.5M KF, 0.1% Tween-20, 0.1% BSA, 2 μg/ml SLX ent 665 (CISBIO), and 2 μg/mL Eu 3+ cryptate label antibody (CISBIO)). The reaction was allowed to equilibrate overnight at 0° C., and relative fluorescent units were read on an HTRF enabled plate reader (e.g. TECAN GENios Pro).
Inhibitor compounds were assayed in the reaction described above to determine compound IC 50 s. Aliquots of compound dissolved in DMSO were added to the reaction wells in a third-log dilution series covering a range of 1 nM to 10 μM. Relative phospho substrate formation, read as HTRF fluorescence units, was measured over the range of compound concentrations and a titration curve generated.
Examples 1 to 29 described herein were tested in the above MARK 3 assay and gave IC 50 values of 20 μM or less, typically 1 μM or less, and highly active compounds giving values of 100 nM or less. The following table provides IC 50 values in the above assay for representative examples:
Example
IC 50 (nM)
1
20
8
0.5
14
15
24
140
29
720
pTau(S262) Cell Biochemical and Functional Assay
The cell biochemical potency of the below described MARK inhibitors was evaluated by measuring their ability to block the phosphorylation of Tau at S262 in primary cell culture of rat cortical neurons induced by the action of Okadaic acid.
Reagents:
Neurobasal (Invitrogen, cat. 21103-049)
B27 (Invitrogen, cat. 17504-044)
L-Glutamine (Invitrogen, cat. 25030-081)
Penicillin-Streptomycin (Invitrogen, cat. 15140)
Papain, sterile lyophilized (Worthington, cat. NC9212788)
10 mL 1M Hepes added for 10× solution
Tissue Culture plates:
384 well: BD FALCON BD BIOCOAT Poly-D-Lysine Black/Clear Microtest, Tissue-Culture Treated Polystyrene (cat. 354663)
E18 Primary Rat Cortical Cells: BrainBits, cat. cx2
Stock Media (NB): Neurobasal+B-27 (1:50)+0.5 mM L-Glutamine+1% Pen/Strep
Preparation of Isolated Neurons
1. Store tissue at 4° C. (1-2 days) until ready to use.
2. When ready to plate, make up 2 mL of enzymatic solution in Hibernate-Ca containing 1× papain. Filter sterile solution with 0.2 μm filter.
3. Transfer 2 mL of medium from tissue tube into 15 mL falcon tube while not disturbing tissue. Save media.
4. Add 2 mL enzymatic media (2) to tissue. Incubate for 30′ at 37° C.
5. Remove enzymatic solution while not disturbing tissue. Add back 1 mL of media from (3).
6. Using pipettor with sterile plastic tip, triturate ˜10 times until most of the cells are dispersed.
7. Let undispersed pieces settle by gravity 1 minute.
8. Transfer dispersed cells (supernatant) into 15 mL falcon tube containing 1 mL media from (3). Gently mix cells by swirling.
9. Spin cells at 1,100 rpm for 1 minute. Remove supernatant.
10. Flick tube to loosen cell pellet. Resuspend cells in 5 mL of NB.
11. Transfer to new 50 mL falcon tube using 40 μm cell strainer. Rinse 15 mL falcon tube with 5 mL media, add to strainer.
12. Count cells using hemacytometer.
13. Dilute cells to 7,000 cells/100 μL/well in NB.
14. Incubate cells at 37° C. with 5% CO 2 .
a. 4 DIV: Replace ½ volume (50 μL) NB per well. b. 6 DIV: Neurite Assay.
Tissue Culture/Compound Treatment
Primary rat cortical neurons plated @ 6Kcells/well in 384-well black/clear bottom Poly D-Lysine coated BD Falcon Biocoat plates.
Media: Neurobasal+1× B27+2 mM L-Glutamine (+10% FBS) at time of plating
Cells maintained at 37° C. and 5% CO 2 for *6 days in culture, w/½ media change every 3-4 days.
Compound treatment:
Prepare first plate: 200× compound in 100% DMSO with subsequent 3 fold serial dilution Prepare intermediate plate: 1:40 dilution of 200× compound in media (2.5% DMSO) Add 5× compound to cell in media at 1:5 dilution (0.5% final DMSO) Incubate for 30 min. at 37° C.
Okadaic Acid (OA) Treatment:
Dilute OA stock (240 μM in 100% DMSO) to 6× final concentration in media (0.5% DMSO) Add 6× OA to cells at 1:6 dilution (200 nM final).
Incubate for 1.5 hrs. at 37° C.
Fix and Immunostaining
Fix: 1% PFA, diluted in PBS
Wash 1× with PBS, residual 30 μl/well.
Add 30 μL/well warmed 2% PFA and incubate 30 min. at RT (1% PFA final)
Wash 3× with PBS, 300/well residual
Permeabilize & Block.
Add 30 μl/well PBS+0.2% Triton X-100+10% normal goat serum (0.1% Triton & 5% NGS final). Incubate 1 hr at RT or O/N at 4° C. Wash 3× with PBS, 30 μL/well residual Primary antibody: add 30 μL/well 2× final concentration antibody diluted in PBS
Mouse anti-tau-3R Rabbit anti-tau-pS 262 Incubate O/N at 4° C.
Wash 4× with PBS, 30 μL/well residual
Secondary antibody & nuclear staining: add 30 μl/well 2× final concentration stain diluted in PBS
AlexaFluor goat anti mouse 488 AlexaFluor goat anti rabbit 594 Hoechst
Incubate in dark 1 hr. at RT
Wash 4× with PBS 300/well residual, protect from light Acquire images in INCell Analyzer 1000 & Opera.
Examples 1 to 29 described herein were tested in the above assay measuring inhibition of phosphorylation of Tau at 5262, and examples 1 to 8, 11 to 14, 16 to 18, and 20 to 29 gave 1050 values of 10 μM or less, typically 1,000 nM or less, and highly active compounds giving values of 250 nM or less. Examples 9, 10, 15, and 19 gave IC 50 values of greater than 10 μM in the above assay.
Methods of Synthesis
The 3-bromoimidazo[1,2-b]pyridazine or 3-bromoimidazo[1,2-a]pyridine A was coupled to the thiophene boronic ester B to afford the coupled product C via Suzuki reaction (Scheme 1). In case of an ester, compound C was hydrolyzed with potassium hydroxide in methanol, and the amide G was formed employing BOP as a coupling reagent. Alternatively, compound C was brominated on the thiophene with thionyl bromide, then a second Suzuki coupling with either potassium alkyltrifluoroborate or boronic ester provided compound F. In case of an ester, compound F was hydrolyzed and coupled with an amine to afford compound H.
The 5-vinylthiophene I was selectively reduced with Pd/C and ammonium formate in n-propanol to afford the 5-ethylthiophene J (Scheme 2). Basic hydrolysis followed by amide formation provided amide K. The vinylthiophene I was also subjected to dihydroxylation conditions (OsO 4 , NMO, THF/water) to provide the 1,2-diol L, which was then converted to aldehyde M with NaIO 4 in THF/water. Fluorination of M with Deoxo-Fluor afforded the difluoromethylthiophene N, Hydrolysis with sodium hydroxide and a coupling with an amine provided the amide O.
To install the thiazole moiety, the 3-bromoimidazo[1,2-b]pyridazine or 3-bromoimidazo[1,2-a]pyridine A was coupled to tributyl(1-ethoxyvinyl)tin under Stile reaction conditions (Scheme 3). The enol ether was hydrolyzed with aqueous hydrochloric acid to afford ketone P. Bromination with Br 2 and HBr afforded the gem-dibromoketone Q, which was then condensed with ethylthiooxamate to provide thiazole R. After basic hydrolysis of the ester, thionyl chloride treatment of compound S at 100° C. converted the acid to the acid chloride and installed a chlorine on the thiazole at the same time. Acid chloride T was coupled with an amine to afford compound U.
Preparation of 3-Bromoimidazo[1,2-B]Pyridazines
The following methods were used to prepare 3-bromoimidazo[1,2-b]pyridazines that were not available from commercial sources or literature.
Intermediate 1
3-Bromo-7-(4-fluorophenyl)imidazo[1,2-b]pyridazine
Step 1. 2-Benzyl-4,5-dichloropyridazin-3(2H)-one
A stirred mixture of 4,5-dichloropyridazin-3(2H)-one (26.7 g, 160 mmol), benzyl bromide (19.3 mL, 160 mmol), tetrabutylammonium bromide (2.61 g, 8.10 mmol), and potassium carbonate (56.0 g, 405 mmol) in acetonitrile (405 mL) was heated to reflux for 2 h. The mixture was cooled to room temperature, filtered through a fitted glass, concentrated, and purified by flash chromatography to afford the title compound as a white solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.23 (s, 1H); 7.27-7.35 (m, 5H); 5.27 (s, 2H). LRMS (APCI) calc'd for (C 11 H 9 Cl 2 N 2 O) [M÷H] + , 255.0. found 255.0.
Step 2. 2-Benzyl-5-iodopyridazine-3(2H)-one
2-Benzyl-4,5-dichloropyridazin-3(2H)-one (32.3 g, 127 mmol) was dissolved in hydriodic acid (223 mL) and the mixture was refluxed at 115° C. overnight. The mixture was poured into dichloromethane and 30% sodium thiosulphate (250 mL), and extracted with dichloromethane (3×250 mL). The combined organics were washed with 30% sodium thiosulphate several times (total 1 L), dried (sodium sulfate), and concentrated. Dichloromethane was added to the residue and the precipitate was collected by filtration to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.17 (s, 1H); 7.61 (s, 1H); 7.23-7.33 (m, 5H); 5.17 (s, 2H). LRMS (APCI) calc'd for (C 11 H 10 IN 2 O) [M+H] + , 313.0. found 313.0.
Step 3. 2-Benzyl-5-(4-fluorophenyl)pyridazin-3(2H)-one
2-Benzyl-5-iodopyridazine-3(2H)-one (5.0 g, 16 mmol), 4-fluorophenyl boronic acid (2.91 g, 20.8 mmol), Pd(Ph 3 P) 4 (0.93 g, 0.80 mmol), and potassium carbonate (6.64 g, 48.1 mmol) were combined in dioxane (120 ml) and Water (40 ml). The reaction mixture was refluxed at 100° C. for 3 h, cooled to room temperature, and poured into ethyl acetate (200 mL) and water (200 mL). The mixture was extracted with ethyl acetate (3×200 mL). The combined organics were washed with water, dried (sodium sulfate), concentrated, and purified by flash chromatography to afford the title compound as a white solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.38 (d, 1H); 7.25-7.92 (m, 10H); 5.27 (s, 2H). LRMS (APCI) calc'd for (C 17 H 14 FN 2 O) [M+H] + , 281.1. found 281.1.
Step 4. 5-(4-Fluorophenyl)pyridazin-3(2H)-one
Aluminum chloride (11.4 g, 86 mmol) was added to a stirred mixture of 2-benzyl-5-(4-fluorophenyl)pyridazin-3(2H)-one (4.0 g, 14.3 mmol) in toluene (285 ml) and the mixture was stirred at 70° C. for 1 h. After cooling, the reaction was cooled in an ice bath and quenched slowly with water (50 mL). The precipitate was filtered, washed with water, and dried under high-vacuum to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.28 (d, 1H); 7.88 (dd, 2H); 7.35 (t, 2H); 7.13 (d, 1H). LRMS (APCI) calc'd for (C 10 H 8 FN 2 O) [M+H] + , 191.1. found 191.1.
Step 5. 3-Chloro-5-(4-fluorophenyl)pyridazine
5-(4-Fluorophenyl)pyridazin-3(2H)-one (2.15 g, 11.3 mmol) was dissolved in POCl 3 (133 ml) and the mixture was refluxed at 110° C. for 30 min. The reaction was cooled in an ice bath and slowly quenched with aqueous sodium hydrogen carbonate (200 mL). The mixture was extracted with ethyl acetate (3×200 mL). The combined organics were washed with water and brine, dried over anhydrous MgSO 4 , filtered, and concentrated under reduced pressure to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 9.67 (d, 1H); 8.28 (d, 1H); 8.07 (dd, 2H); 7.42 (t, 2H).
Step 6. 2-{[5-(4-Fluorophenyl)pyridazin-3-yl]amino}ethanol
Ethanolamine (4.82 mL, 80 mmol) was added to a stirred mixture of 3-chloro-5-(4-fluorophenyl)pyridazine (2.08 g, 9.97 mmol) in Dioxane (40 mL) in a sealed tube. The mixture was heated to 120° C. overnight, treated with additional ethanolamine (1.2 mL, 20 mmol), and heated to 150° C. for 2 h. The mixture was cooled and poured into ethyl acetate (100 mL) and water (100 mL). The precipitate was filtered and dried to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.76 (d, 1H); 7.78 (dd, 2H); 7.36 (t, 2H); 7.02 (d, 1H); 6.85 (t, 1H); 4.78 (t, 1H); 3.58 (q, 2H); 3.45 (q, 2H). LRMS (APCI) calc'd for (C 12 H 13 FN 3 O) [M+H] + , 234.1. found 234.1.
Step 7. 7-(4-Fluorophenyl)imidazo[1,2-b]pyridazine
Oxalyl chloride (3.33 mL, 38.1 mmol) was slowly added to a stirred mixture of DMSO (2.70 mL, 38.1 mmol) in Dichloromethane (25 mL) at −78° C. The mixture was stirred at −78° C. for 10 min before 2-{[5-(4-fluorophenyl)pyridazin-3-yl]amino}ethanol (888 mg, 3.81 mmol) in 3.5 mL DMSO was added. The reaction mixture was left to stir at −78° C. for 20 min, treated with triethylamine (5.31 ml, 38.1 mmol), left to stir at −78° C. for 10 min, and allowed to warm to room temp. The mixture was treated with isopropanol (9 mL), diluted with ethyl acetate (200 mL), and washed with 2% sodium hypochlorite (200 mL) and water (200 mL). The aqueous layer was extracted with chloroform:isopropanol (3:1). The combined organics were dried over anhydrous MgSO 4 , filtered, and concentrated under reduced pressure to afford the title compound. LRMS (APCI) calc'd for (C 12 H 9 FN 3 ) [M+H] + , 214.1. found 214.0.
Step 8. 3-Bromo-7-(4-fluorophenyl)imidazo[1,2-b]pyridazine
Bromine (0.12 mL, 2.34 mmol) was added dropwise to a stirred mixture of 7-(4-fluorophenyl)imidazo[1,2-b]pyridazine (500 mg, 2.34 mmol) and sodium acetate (289 mg, 3.52 mmol) in Acetic Acid (12 mL) and the mixture was stirred at room temperature for 1 h. The mixture was poured into ethyl acetate and aqueous sodium hydrogen carbonate (50 mL) and extracted with ethyl acetate (3×50 mL). The combined organics were washed with water, dried over anhydrous MgSO 4 , filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography to afford the title compound as a white solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 9.10 (d, 1H); 8.49 (d, 1H); 7.98 (dd, 2H); 7.96 (s, 1H); 7.38 (t, 2H). LRMS (APCI) calc'd for (C 12 H 8 BrFN 3 ) [M+H] + , 292.0. found 292.0.
Intermediate 2
3-Bromo-7-(trifluoromethyl)imidazo[1,2-b]pyridazine
Step 1. 3-Chloro-5-(trifluoromethyl)pyridazine
5-(Trifluoromethyl)pyridazin-3(2H)-one (20.0 g, 111 mmol) was dissolved in 1,4-dioxane (222 mL) and POCl 3 (31.0 mL, 333 mmol) added. The reaction was left to stir at 80° C. for 3 h. After consumption of the starting material, the reaction was cooled to room temperature. The reaction mixture was added to ice and quenched with ammonium hydroxide. The aqueous layer was extracted with dichloromethane (×3) and the organic layers combined, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography to afford the title compound as an orange oil. 1 H NMR (500 MHz, CDCl 3 ) δ 9.37 (s, 1H); 7.76 (s, 1H).
Step 2. 5-(Trifluoromethyl)pyridazin-3-amine
3-Chloro-5-(trifluoromethyl)pyridazine (28.0 g, 153 mmol) was dissolved in ammonia in isopropanol (200 mL, 400 mmol, 2.0 M) and heated at 80° C. in a pressure vessel for 3 days. The reaction was cooled to room temperature and concentrated under reduced pressure to take the isopropanol off. The residue was purified by flash chromatography to afford the title compound as an off white solid, 1 H NMR (500 MHz, CDCl 3 ) δ 8.83 (s, 1H); 6.91 (s, 1H); 5.00 (s, 2H, br). LRMS (APCI) calc'd for (C s H 4 F 3 N 3 ) [M+H] + , 164.1. found 164.1.
Step 3. 7-(Trifluoromethyl)imidazo[1,2-b]pyridazine
5-(Trifluoromethyl)pyridazin-3-amine (6.79 g, 41.6 mmol) was dissolved in a mixture of ethanol (133 mL) and water (33.3 mL) and 50% aq. solution of chloroacetylaldehyde (26.9 mL, 208 mmol) and sodium bicarbonate (17.5 g, 208 mmol) was added. The reaction was sealed in a pressure vessel and heated to 130° C. for 6 h. The reaction was then cooled to room temperature. Water was added and the mixture filtered through celite. The aqueous layer was extracted with a 3:1 mixture of CHCl 3 :Isopropanol (×3). The organic layers were collected, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography to afford the title compound as an orange solid. 1 H NMR (500 MHz, CDCl 3 ) δ 8.52 (s, 1H); 8.27 (s, 1H); 8.13 (s, 1H); 7.97 (s, 1H). LRMS (APCI) calc'd for (C 7 H 4 F 3 N 3 ) [M+H] + , 187.1. found 187.1.
Step 4,3-Bromo-7-(trifluoromethyl)imidazo[1,2-b]pyridazine
7-(Trifluoromethyl)imidazo[1,2-b]pyridazine (4.32 g, 23.1 mmol) was dissolved in acetic acid (46 mL) and bromine (1.31 mL, 25.4 mmol) added dropwise. The mixture was stirred at room temperature for 1 h. After the reaction was complete, ice was added and the reaction quenched with ammonium hydroxide. The aqueous layer was extracted with ethyl acetate (×3). The organic layers were combined, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by column chromatography to afford the title compound as a yellow solid. 1 H NMR (500 MHz, CDCl 3 ) δ 8.65 (s, 1H); 8.25 (s, 1H); 7.98 (s, 1H). LRMS (APCI) calc'd for (C 7 H 3 BrF 3 N 3 ) [M+H] + , 266.0. found 266.0.
Preparation of [5-(Methoxycarbonyl)Thiophen-3-yl]Boronic Esters
The following methods were used to prepare [5-(methoxycarbonyl)thiophen-3-yl]boronic esters that were not available from commercial sources or literature.
Intermediate 3
Methyl 5-methyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophene-2-carboxylate
Step 1. Methyl 4-bromo-5-methylthiophene-2-carboxylate
To a stirred solution of 4-bromo-5-methylthiophene-2-carboxylic acid (45 g, 204 mmol) in methanol (225 mL) was added concentrated H 2 SO 4 (4.0 g, 41 mmol). The reaction mixture was heated to reflux overnight, cooled to room temperature, poured into saturated NaHCO 3 (800 mL), and left to stir for 30 min. The precipitate was filtered, washed with water, and dried under high-vacuum to afford the title compound. 1 H NMR (500 MHz, CDCl 3 ) δ 7.61 (s, 1H); 3.88 (s, 3H); 2.45 (s, 3H). LRMS (APCI) calc'd for (C 7 H 8 BrO 2 S) [M+H] + , 234.9. found 234.9.
Step 2. Methyl 5-methyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophene-2-carboxylate
A mixture of methyl 4-bromo-5-methylthiophene-2-carboxylate (47.6 g, 202 mmol), 4,4,4′,4′,5,5,5′,5′-octamethyl-2,2′-bi-1,3,2-dioxaborolane (77 g, 304 mmol), and potassium acetate (59.6 g, 607 mmol) in dioxane (300 mL) was evacuated and flushed with nitrogen twice. DPPF (3.37 g, 6.07 mmol) and 1,1′-bis(diphenylphosphino)ferrocene-palladium(II) dichloride dichloromethane complex (4.96 g, 6.07 mmol) were added to the reaction, and the resultant mixture was evacuated and flushed with nitrogen twice. The mixture was heated at 85° C. for 2 days, cooled to room temperature, and poured into a mixture of water (2 L) and EtOAc (1 L). The organic layer was washed with water and brine, dried over magnesium sulfate, concentrated, and purified by flash chromatography to afford the title compound. 1 H NMR (500 MHz, CDCl 3 ) δ 7.96 (s, 1H); 3.86 (s, 3H); 2.73 (s, 3H). LRMS (APCI) calc'd for (C 13 H 20 BO 4 S) [M+H] + , 283.1. found 283.1.
According to Intermediate 3, the following [5-(methoxycarbonyl)thiophen-3-yl]boronic ester was prepared from the corresponding 4-bromothiophene-2-carboxylic acid:
Methyl 5-ethyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophene-2-carboxylate
Preparation of Amines
The following methods were used to prepare amines that were not available from commercial sources or literature.
Intermediate 4
tert-Butyl[(1R,2R)-2-amino-3,3-difluorocyclohexyl]carbamate
Step 1. 2,2-Difluoro-7-oxabicyclo[4.1.0]heptane
To a solution of 7-oxabicyclo[4.10]heptan-2-one (55.8 g, 0.5 mol) in dichloromethane (200 mL) cooled to 0° C. was added 1,1,1-trifluoro-N,N-bis(2-methoxyethyl)silanamine (Deoxofluor, 202 mL, 1.1 mol) and the resulting reaction was warmed to ambient temperature and stirred for 16 hours. The reaction was cooled to −20° C. and carefully quenched with water (10 mL, slow addition). The reaction was then partitioned between water/dichloromethane and the organics were passed through a plug of silica gel. This crude organic solution of the title compound was carried into the next reaction.
Step 2. (1S,6R)-2,2-Difluoro-6-{[(1R)-1-phenylethyl]amino}cyclohexanol
A solution of (1R)-1-phenylethanamine (72 mL, 0.57 mol) in dichloromethane (200 mL) was cooled to 0° C. and treated with trimethylaluminum (260 mL, 0.52 mol) and the resulting solution was stirred for 1 hour at 0° C. To this solution was added a solution of 2,2-difluoro-7-oxabicyclo[4.1.0]heptane (66 g, 0.49 mol) in dichloromethane (200 mL) and the resulting mixture stirred at 0° C. for 3 hours. The reaction was then warmed to ambient temperature for 16 hours. The reaction was cooled to 0° C., treated with 103 g of sodium fluoride and then quenched with water (90 mL, slow addition). The reaction was warmed to ambient temperature, the solids filtered and the solution evaporated in vacuo. Purification by flash chromatography afforded the title compound as a white solid: 1 H NMR (500 MHz, CDCl 3 ) δ 7.32 (s, 5H); 3.90 (q, 1H); 3.39 (ddd, 1H); 2.70 (m, 1H); 2.11 (m, 1H); 1.80 (m, 1H); 1.62 (m, 2H); 1.43 (m, 1H); 1.36 (d, 3H); 0.96 (m, 1H).
Step 3. (1S,6R)-6-Amino-2,2-difluorocyclohexanol
A solution of (1S,6R)-2,2-difluoro-6-{[(1R)-1-phenylethyl]amino}cyclohexanol (2.0 g, 7.8 mmol) in methanol (100 mL) was degassed with nitrogen, treated with Pd(OH) 2 /C (0.55 g) and then placed under an atmosphere of hydrogen and stirred vigorously for 16 hours. The reaction was filtered, washed with methanol, and the filtrate evaporated in vacuo to afford the title compound as a white solid: 1 H NMR (500 MHz, CD 3 OD) δ 3.34 (m, 1H); 2.74 (m, 1H); 2.07 (m, 1H); 1.89 (m, 1H); 1.73 (m, 2H); 1.50 (m, 1H); 1.27 (m, 1H).
Step 4. tert-Butyl[(1R,2S)-3,3-difluoro-2-hydroxycyclohexyl]carbamate
A solution of (1S,6R)-6-amino-2,2-difluorocyclohexanol (2.0 g, 7.54 mmol) in dichloromethane (60 mL) was treated with triethylamine (5.26 mL, 37.7 mmol) and Boc anhydride (1.81 g, 8.30 mmol) and the resulting solution was stirred at ambient temperature for 16 hours. The reaction was evaporated in vacuo and purified by flash chromatography to afford the title compound as a white solid: 1 H NMR (500 MHz, CDCl 3 ) δ 4.67 (br s, 1H); 3.67 (m, 1H); 3.50 (m, 1H); 3.21 (br s, 1H); 2.15 (m, 1H); 2.03 (m, 1H); 1.62 (m, 3H); 1.45 (s, 9H); 1.34 (m, 1H).
Step 5. (1S,6R)-6-[(tert-Butoxycarbonyl)amino]-2,2-difluorocyclohexyl trifluoromethanesulfonate
A solution of text-butyl[(1R,6S)-3,3-difluoro-2-hydroxycyclohexyl]carbamate (1.78 g, 7.08 mmol) in dichloromethane (50 mL) was treated with pyridine (12.5 mL) and cooled to 0° C. Triflic anhydride (4.43 mL, 26.2 mmol) was added dropwise and the reaction was stirred at 0° C. for 2 hours and quenched with water. The reaction was partitioned between water and ether, the organics were dried over sodium sulfate, filtered and evaporated in vacuo. Purification by flash chromatography afforded the title compound as a white solid: 1 H NMR (500 MHz, CDCl 3 ) δ 4.77 (m, 1H); 4.69 (d, 1H); 3.92 (m, 1H); 2.28 (m, 1H); 2.08 (m, 1H); 1.79 (m, 2H); 1.64 (m, 2H); 1.45 (s, 9H).
Step 6. tert-Butyl[(1R,2R)-2-azido-3,3-difluorocyclohexyl]carbamate
is A solution of (1S,6R)-6-[(tert-butoxycarbonyl)amino]-2,2-difluorocyclohexyl trifluoromethanesulfonate (2.32 g, 6.05 mmol) and sodium azide (2.36 g, 36.3 mmol) in DMF was sealed and heated to 100° C. for 3 hours in a microwave reactor. The reaction was partitioned between water and ethyl acetate. The organics were washed with water, dried over magnesium sulfate, filtered and evaporated in vacuo. Purification by flash chromatography afforded the title compound as a white solid: 1 H NMR (500 MHz, CDCl 3 ) δ 4.75 (m, 1H); 3.98 (br s, 1H); 3.88 (m, 1H); 1.96 (m, 2H); 1.70 (m, 2H); 1.46 (s, 9H); 1.37 (m, 2H). tert-Butyl[(1R,6S)-6-azido-2,2-difluorocyclohexyl]carbamate was also obtained from this procedure: 1 H NMR (500 MHz, CDCl 3 ) 4.82-4.80 (d, 1H); 3.93-3.89 (dt, 1H); 3.31-3.27 (m, 1H); 2.24-2.19 (m, 1H); 2.13-2.10 (m, 1H); 1.86-1.67 (m, 2H); 1.55-1.52 (m, 2H); 1.48-1.41 (m, 11H). 19 F NMR (CDCl 3 , 564 MHz) −102.2-−102.7 (d, 1F); −113.9-−114.5 (m, 1F).
Step 7. tert-Butyl[(1R,2R)-2-amino-3,3-difluorocyclohexyl]carbamate
A solution of tert-butyl[(1R,6R)-2-azido-3,3-difluorocyclohexyl]carbamate (0.94 g, 3.40 mmol) in methanol (20 mL) was degassed with nitrogen and treated with 10% Pd/C (72 mg). The resulting heterogenous solution was exposed to a hydrogen atmosphere and stirred vigorously for 16 hours. The reaction was filtered, washed with methanol, and the filtrate evaporated in vacuo to afford the title compound as a white solid: 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 6.67 (d, 1H); 3.55 (br s, 1H); 3.07 (br s, 1H); 2.03 (m, 1H); 1.62 (m, 3H); 1.45 (m, 1H); 1.36 (m, 12H).
Intermediate 5
tert-Butyl[(1S,2R)-2-amino-3,3-difluorocyclohexyl]carbamate
Step 1. tert-Butyl[(1R,6S)-6-amino-2,2-difluorocyclohexyl]carbamate
A solution of tert-butyl[(1R,6S)-6-azido-2,2-difluorocyclohexyl]carbamate (18.84 g, 68.2 mmol) in methanol (400 mL) was degassed and purged (3× with N 2 ) before the addition of Pd/C (1.45 g). The reaction was stirred for 2 d under 1 atm of hydrogen. Upon reaction completion, the reaction was filtered through a plug of celite and concentrated to dryness to afford the title compound as a white solid. 1 H NMR (CDCl3, 500 MHz) 4.76-4.74 (d, 1H); 3.61-3.56 (m, 1H); 2.63-2.59 (dd, 1H); 2.2-2.0 (m, 2H); 1.8-1.68, (m, 2H); 1.53-1.42 (m, 11H); 1.29-1.21 (m, 2H). 19 F NMR (CDCl 3 , 564 MHz) −101.7-−102.1 (d, 1F); −114.3-−114.9 (m, 1F).
Step 2, (1S,2R)-3,3-Difluorocyclohexane-1,2-diaminium bis(trifluoroacetate)
A mixture of tert-butyl[(1R,6S)-6-amino-2,2-difluorocyclohexyl]carbamate (5 g, 19.98 mmol) and TFA (6.16 mL, 80 mmol) in dichloromethane (50 mL) was left to stir overnight, and concentrated to afford the title compound as a brown oil. 19 F NMR (CDCl 3 , 564 MHz) −81.07 (s, 6F); −99.7-−100.1 (d, 1F); −111.1-−111.5 (d, 1F).
Step 3. tert-Butyl[(1S,2R)-2-amino-3,3-difluorocyclohexyl]carbamate
To a stirred solution of (1S,2R)-3,3-difluorocyclohexane-1,2-diaminium bis(trifluoroacetate) (7.5 g, 19.8 mmol) in dichloromethane (100 mL) was added triethylamine (11.1 mL, 79.0 mmol) followed by BOC 2 O (5.52 mL, 23.8 mmol). The reaction was stirred for 10 hr at ambient temperature. Concentrated, and purified by flash chromatography to afford the title compound. 1 H NMR (CDCl 3 , 500 MHz) 4.76 (br s, 1H); 3.39 (m, 1H); 2.71-2.64 (m, 1H); 2.2-2.1 (m, 2H); 1.7-1.59 (m, 2H); 1.56-1.51 (m, 2H); 1.45 (s, 9H); 1.29-1.21 (m, 2H). 19 F NMR (CDCl 3 , 564 MHz) −100.4-−100.9 (d, 1F); −114.35-−114.87 (d, 1F).
Intermediate 6
9H-Fluoren-9-ylmethyl[(1S,2R)-2-amino-3,3-difluorocyclohexyl]carbamate
Step 1. tert-Butyl 9H-fluoren-9-ylmethyl[(1S,2R)-3,3-difluorocyclohexane-1,2-diyl]biscarbamate
To a slurry of tert-butyl[(1R,6S)-6-amino-2,2-difluorocyclohexyl]carbamate (48 g, 192 mmol) and NaHCO 3 (32.2 g, 384 mmol) in acetonitrile (500 mL) and water (500 mL) was slowly added FmocCl in acetonitrile (300 mL) over 1.5 h. To the slurry was added water (500 mL) and the solid was filtered off and washed with water (250 mL) and hexane (500 mL), then dried under high-vacuum to afford the title compound. 1 H NMR (CDCl 3 , 400 MHz) δ 7.75 (d, 2H); 7.56 (d, 2H); 7.37 (m, 2H); 7.27 (m, 2H); 5.38 (d, 1H); 5.00 (d, 1H); 4.75 (s, 1H); 4.31 (m, 1H); 4.15 (m, 1H); 4.60-4.85 (m, 2H); 1.25-2.20 (series of m, 6H); 1.36 (s, 9H).
Step 2. (1R,6S)-6-{[(9H-Fluoren-9-ylmethoxy)carbonyl]amino}-2,2-difluorocyclohexanaminium chloride
To a slurry of tert-butyl 9H-fluoren-9-ylmethyl[(1S,2R)-3,3-difluorocyclohexane-1,2-diyl]biscarbamate (90 g, 190 mmol) in doixane (500 ml) was added 250 mL of 4 N HCl in dioxane. The solution was warmed to 50° C. for 2 h. Hexanes (600 mL) was added to the warm slurry over 15 min, then the mixture was cooled to 15° C. The precipitate was filtered, washed with hexanes (400 mL), and dried under high-vacuum to afford the title compound.
EXAMPLES
Example 1
N-[(1R,6R)-6-Amino-2,2-difluorocyclohexyl]-4-(imidazo[1,2-b]pyridazin-3-yl)-5-methylthiophene-2-carboxamide
Step 1. 3-Bromoimidazo[1,2-b]pyridazine
Bromine (0.649 mL, 12.6 mmol) was added dropwise to a stirred mixture of Imidazo[1,2-b]pyridazine (1.0 g, 8.39 mmol) in acetic acid (42 ml) and the mixture was stirred at room temperature for 1 h. The mixture was neutralized with 1 N sodium hydroxide (100 mL) and solid sodium hydroxide, poured into ethyl acetate and sodium bicarbonate solution, and extracted with ethyl acetate (3×200 mL). The combined organics were washed with brine, dried (MgSO 4 ), and concentrated to afford the title compound. 1 H NMR (600 MHz, CD 3 SOCD 3 ) δ 8.66 (d, 1H); 8.17 (d, 1H); 7.93 (s, 1H); 7.31 (dd, 1H). LRMS (APCI) calc'd for (C 6 H 5 BrN 3 ) [M+H] + , 198.0. found 198.0.
Step 2. Methyl 4-(imidazo[1,2-b]pyridazin-3-yl)-5-methylthiophene-2-carboxylate
3-Bromoimidazo[1,2-b]pyridazine (0.40 g, 2.02 mmol), methyl-5-methyl-3-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophene-2-carboxylate (0.86 g, 3.03 mmol), Pd 2 (dba) 3 (0.19 g, 0.20 mmol), tricyclohexylphosphine (0.14 g, 0.51 mmol), aqueous tribasic potassium phosphate (1.27 M, 1.45 mL, 6.85 mmol), and 1,4-dioxane (10.1 mL) were placed in a flask and purged with nitrogen for five minutes. The solution was heated to 100° C. for four hours. The solution was cooled to room temperature, poured into an aqueous solution of saturated sodium bicarbonate, and extracted with ethyl acetate (×3). The combined organic layers were dried with magnesium sulfate, filtered, and concentrated and the residue purified by flash chromatography to afford the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.62 (d, 1H); 8.24 (s, 1H); 8.21 (d, 1H); 8.06 (s, 1H); 7.30 (dd, 1H); 3.83 (s, 3H); 2.58 (s, 3H). LRMS (APCI) calc'd for (C 13 H 11 N 3 O 2 S) [M+H] + , 274.0. found 274.0.
Step 3. 4-(Imidazo[1,2-b]pyridazin-3-yl)-5-methylthiophene-2-carboxylic acid
Methyl 4-(imidazo[1,2-b]pyridazin-3-yl)-5-methylthiophene-2-carboxylate (0.54 g, 1.98 mmol) was dissolved in methanol (9.88 mL) and THF (9.88 mL) and a solution of KOH in methanol was added (1 M, 5.93 mL, 5.93 mmol). The reaction mixture was left to stir overnight at 60° C. The reaction mixture was then cooled to room temperature, concentrated, and acidified with aqueous 1N HCl. The aqueous layer was extracted three times with ethyl acetate, then extracted one time with a 3:1 CHCl 3 :isopropanol mixture. The combined organics were dried with magnesium sulfate, filtered, and concentrated to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.77 (d, 1H); 8.34 (d, 1H); 8.25 (s, 1H); 8.11 (s, 1H); 7.51 (dd, 1H); 2.56 (s, 3H). LRMS (APCI) calc'd for (C 12 H 9 N 3 O 2 S) [M+H] + , 260.0. found 260.0.
Step 4. N-[(1R,6R)-6-Amino-2,2-difluorocyclohexyl]-4-(imidazo[1,2-b]pyridazin-3-yl)-5-methylthiophene-2-carboxamide
To a mixture of 4-(imidazo[1,2-b]pyridazin-3-yl)-5-methylthiophene-2-carboxylic acid (0.06 g, 0.24 mmol) and BOP (0.16 g, 0.36 mmol) was added tert-butyl[(1R,2R)-2-amino-3,3-difluorocyclohexyl]carbamate (0.06 g, 0.26 mmol) followed by diisopropylethylamine (0.09 mL, 0.49 mmol). The mixture was allowed stir at room temperature overnight. The resulting solution was diluted with water and extracted three times with dichloromethane. The combined organic layers were dried with magnesium sulfate, filtered, concentrated and to the resulting residue was added dichloromethane and trifluoroacetic acid (1 mL, 53 mmol). The compound was purified by prep HPLC. The compound was neutralized by taking the fractions and adding an aqueous saturated sodium bicarbonate solution and extracting three times with ethyl acetate. The combined organics were dried with magnesium sulfate, filtered, and concentrated to afford the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.62 (d, 1H); 8.28 (s, 1H); 8.21 (d, 1H); 7.99 (s, 1H); 7.90 (d, 1H); 7.29 (dd, 1H); 4.55 (m, 1H); 3.08 (m, 1H); 2.47 (s, 3H); 2.11 (m, 1H); 1.85 (m, 1H); 1.71 (m, TH); 1.59 (m, 2H); 1.45 (m, 1H). LRMS (APCI) calc'd for (C 18 H 19 F 2 N 5 OS) [M+H] + , 392.1. found 392.1.
According to Example 1, the following compounds were prepared from the corresponding 3-bromoimidazo[1,2-b]pyridazine or 3-bromoimidazo[1,2-a]pyridine, thiophene boronic ester, and amine.
Ex.
Structure
Name
MS
2
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-b]pyridazin- 3-yl)-5-methylthiophene-2- carboxamide
calc'd (M + H) + 392.1; found (M + H) + 392.1
3
cis-2-({[4-(imidazo[1,2- b]pyridazin-3-yl)thiophen- 2- yl]carbonyl}amino)cyclohex- anaminium trifluoroacetate
calc'd (M + H) + 342.1; found (M + H) + 342.1
4
N-[cis-2- aminocyclohexyl]-4-[7-(4- fluorophenyl)imidazo[1,2- b]pyridazin-3- yl]thiophene-2- carboxamide
calc'd (M + H) + 436.2; found (M + H) + 436.1
5
(1R,2R)-3,3-difluoro-2- ({[4-(imidazo[1,2- b]pyridazin-3-yl)thiophen- 2- yl]carbonyl}amino)cyclohex- anaminium trifluoroacetate
calc'd (M + H) + 378.1; found (M + H) + 378.1
6
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-b]pyridazin- 3-yl)thiophene-2- carboxamide
calc'd (M + H) + 378.1; found (M + H) + 378.1
7
4-[7-(4- fluorophenyl)imidazo[1,2- b]pyridazin-3-yl]-N-(2,2,2- trifluoroethyl)thiophene-2- carboxamide
calc'd (M + H) + 421.1; found (M + H) + 421.0
8
(1R,2R)-3,3-difluoro-2- [({4-[7-(4- fluorophenyl)imidazo[1,2- b]pyridazin-3-yl]thiophen- 2- yl}carbonyl)amino]cyclohex- anaminium trifluoroacetate
calc'd (M + H) + 472.1; found (M + H) + 472.1
9
N-[(cis-4-amino-1,1- dioxidotetrahydro-2H- thiopyran-3-yl]-4- (imidazo[1,2-b]pyridazin- 3-yl)-5-methylthiophene-2- carboxamide
calcd'd (M + H) + 406.1; found (M + H) + 406.1
10
N-[cis-3-amino-1,1- dioxidotetrahydro-2H- thiopyran-4-yl]-4- (imidazo[1,2-b]pyridazin- 3-yl)-5-methylthiophene-2- carboxamide
calc'd (M + H) + 406.1; found (M + H) + 406.1
11
N-[cis-2- aminocyclopentyl]-4- (imidazo[1,2-b]pyridazin- 3-yl)thiophene-2- carboxamide
calc'd (M + H) + 328.1; found (M + H) + 328.0
12
N-[(1S)-1-(3- fluorophenyl)ethyl]-4- (imidazo[1,2-b]pyridazin- 3-yl)-5-methylthiophene-2- carboxamide
calcd'd (M + H) + 381.1; found (M + H) + 381.1
13
N-[(1R,6R)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-a]pyridin-3 yl)thiophene-2- carboxamide
calc'd (M + H) + 377.1; found (M + H) + 377.1
14
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-a]pyridin-3- yl)thiophene-2- carboxamide
calc'd (M + H) + 377.1; found (M + H) + 377.1
15
N-[(1R,6R)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-a]pyridin-3- yl)-5-methylthiophene-2- carboxamide
calc'd (M + H) + 391.1; found (M + H) + 391.1
16
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-a]pyridin-3- yl)-5-methylthiophene-2- carboxamide
calc'd (M + H) + 391.1; found (M + H) + 391.1
17
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-4-(7- chloroimidazo[1,2- a]pyridin-3-yl)-5- methylthiophene-2- carboxamide
calcd'd (M + H) + 425.1; found (M + H) + 425.0
Example 18
N-[(1R,6R)-6-Amino-2,2-difluorocyclohexyl]-5-ethyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
Step 1. Methyl 4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate
3-Bromoimidazo[1,2-b]pyridazine (700 mg, 3.53 mmol), methyl 5-methyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophene-2-carboxylate (1.04 g, 3.89 mmol), Pd 2 (dba) 3 (324 mg, 0.353 mmol), tricyclohexylphosphine (248 mg, 0.884 mmol), aqueous tribasic potassium phosphate (2.54 mL, 12.0 mmol, 1.27 M), and 1,4-dioxane (17.7 mL) were placed in a sealed tube and purged with nitrogen for 5 minutes. The solution was heated to 100° C. for 1.5 h, after which the reaction was cooled to room temperature. Saturated aqueous sodium bicarbonate was added to the mixture. The aqueous layer was then extracted with ethyl acetate (×3). The combined organic layers were then dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography affording the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.70 (d, 1H); 8.68 (s, 1H); 8.54 (s, 1H); 8.42 (s, 1H); 8.22 (d, 1H); 7.31 (dd, 1H); 3.86 (s, 3H). LRMS (APCI) calc'd for (C 12 H 9 N 3 O 2 S) [M+H] + , 260.0. found 260.0.
Step 2. Methyl 5-bromo-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate
Methyl 4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate (690 mg, 2.66 mmol) was dissolved in thionyl bromide (5 mL, 64.5 mmol) and heated at 50° C. in a sealed tube for 4 h. The solution poured over ice and quenched with ammonium hydroxide. The aqueous layer was extracted with dichloromethane (×3). The organic layers put together, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography to afford the title compound as a light brown solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.66 (d, 1H); 8.27 (s, 1H); 8.25 (s, 1H); 8.25 (d, 1H); 7.35 (dd, 1H); 3.85 (s, 3H). LRMS (APCI) calc'd for (C 12 H 8 BrN 3 O 2 S) [M+H] + , 338.0. found 337.9.
Step 3. Methyl 5-ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate
Methyl-5-bromo-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate (200 mg, 0.591 mmol), potassium vinyltrifluoroborate (119 mg, 0.887 mmol), PdCl 2 (dppf)-CH 2 Cl 2 adduct (48 mg, 0.059 mmol), and triethylamine (0.165 mL, 1.18 mmol) was dissolved in n-propanol (5.91 mL) and purged with nitrogen for 5 minutes in a sealed tube. The solution was heated at 100° C. for 18 h. the reaction was cooled to room temperature and quenched with saturated sodium bicarbonate. The aqueous layer was extracted with ethyl acetate (×3) and the organic layers combined, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography to afford the title compound as an orange solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.61 (d, 1H); 8.23 (d, 1H); 8.16 (s, 1H); 7.95 (s, 1H); 7.32 (dd, 1H); 6.94 (dd, 1H); 5.87 (d, 1H); 5.44 (d, 1H); 3.85 (s, 3H). LRMS (APCI) calc'd for (C 14 H 11 N 3 O 2 S) [M+11] + , 286.1. found 286.0.
Step 4. 5-Ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylic acid
Methyl 5-ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate (130 mg, 0.456 mmol) was dissolved in methanol (2.28 mL) and THF (2.28 mL) and 1M KOH in MeOH (1.38 mL, 1.38 mmol) was added to the mixture. The solution was left to stir at 60° C. for 18 h. The reaction was cooled to room temperature and concentrated under reduced pressure. 1N HCl was added to the residue and the precipitate filtered. The precipitate was then dried under high vacuum affording the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 13.37 (s, 1H, br); 8.62 (d, 1H); 8.23 (d, 1H); 8.07 (s, 1H); 7.96 (s, 1H); 7.33 (dd, 1H); 6.91 (dd, 1H); 5.84 (d, 1H); 5.41 (d, 1H). LRMS (APCI) calc'd for (C 13 H 9 N 3 O 2 S) [M+H] + , 272.0. found 272.0.
Step 5. tert-Butyl[(1R,2R)-2-({[5-ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate
To a mixture of 5-ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylic acid (105 mg, 0.387 mmol) and BOP (257 mg, 0.581 mmol) in DMF (5.2 mL) was added tert-butyl [(1R,2R)-2-amino-3,3-difluorocyclohexyl]carbamate (145 mg, 0.581 mmol) followed by diisopropylethyl amine (0.169 mL, 0.968 mmol). The mixture was allowed to stir at room temperature for 18 h. After the reaction was complete, water was added and the aqueous layer extracted with ethyl acetate (×3). The organic layers were combined, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography giving the title compound as an orange solid. LRMS (APCI) calc'd for (C 24 H 27 F 2 N 5 O 3 S) [M+H] + , 504.2. found 504.1.
Step 6. N-[(1R,6R)-6-Amino-2,2-difluorocyclohexyl]-5-ethyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
tert-Butyl[(1R,2R)-2-({[5-ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate (103 mg, 0.205 mmol), ammonium formate (128 mg, 2.04 mmol), and 10% Pd/C (109 mg, 0.102 mmol) were dissolved in n-propanol (4.1 mL) and left to stir at 100° C. for 18 h. The solution was cooled to room temperature and filtered through celite. The filtrate was concentrated under reduced pressure and taken up in dichloromethane (2 mL). Trifluoroacetic acid (1 mL, 13.0 mmol) was added to the mixture and stirred for 4 h at room temperature. The solution was then neutralized with aqueous saturated sodium bicarbonate and extracted with dichloromethane (×3). The organic layers were collected and dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was then purified by prep HPLC. The compound was neutralized by taking the fractions and adding an aqueous saturated sodium bicarbonate solution and extracting three times with dichloromethane. The combined organics were dried with magnesium sulfate, filtered, and concentrated to afford the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.60 (d, 1H); 8.22 (s, 1H); 8.21 (d, 1H); 7.95 (s, 1H); 7.90 (d, 114, br); 7.29 (dd, 1H); 4.56 (m, 1H); 3.08 (m, 1H); 2.83 (q, 2H); 2.10 (m, 1H); 1.86 (m, 1H); 1.71 (m, 1H); 1.59 (m, 2H); 1.44 (m, 1H); 1.20 (t, 3H). LRMS (APCI) calc'd for (C 19 H 21 F 2 N 5 OS) [M+H] + , 406.1. found 406.1.
According to Example 18, the following compounds were prepared from the corresponding 3-bromoimidazo[1,2-b]pyridazine or 3-bromoimidazo[1,2-a]pyridine, borate salt or boronic ester, and amine.
Ex.
Structure
Name
MS
19
N-[(1R,6R)-6-amino-2,2- difluorocyclohexyl]-5- benzyl-4-(imidazo[1,2- b]pyridazin-3-yl)thiophene- 2-carboxamide
calc'd (M + H) + 468.2; found (M + H) + 468.1
20
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-4- (imidazo[1,2-b]pyridazin- 3-yl)-5-(prop-1-en-2- yl)thiophene-2- carboxamide
calc'd (M + H) + 418.1; found (M + H) + 418.1
21
N-[(1R,6R)-6-amino-2,2- difluorocyclohexyl]-5- cyclopropyl-4- (imidazo[1,2-b]pyridazin- 3-yl)thiophene-2- carboxamide
calc'd (M + H) + 418.1; found (M + H) + 418.1
22
N-[(1R,6R)-6-amino-2,2- difluorocyclohexyl]-5- ethyl-4-(imidazo[1,2- a]pyridin-3-yl)thiophene-2- carboxamide
calc'd (M + H) + 405.1; found (M + H) + 405.1
Example 23
N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-ethyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
Step 1. 9H-Fluoren-9-ylmethyl[(1S,2R)-2-{[(4-bromo-5-ethylthiophen-2-yl)carbonyl]amino}-3,3-difluorocyclohexyl]carbamate
4-Bromo-5-ethylthiophene-2-carboxylic acid (300 mg, 1.15 mmol) and BOP (762 mg, 1.72 mmol) were dissolved in DMF (11.5 mL) and stirred at room temperature for 5 minutes. (1R,6S)-6-{[(9H-fluoren-9-ylmethoxy)carbonyl]amino}-2,2-difluorocyclohexanaminium chloride (432 mg, 1.16 mmol) was added followed by diisopropylethyl amine (0.50 mL, 2.87 mmol) and the solution was stirred at room temperature for 18 h. The solution was diluted with water, and extracted with dichloromethane (×3). The organic layers were collected, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography affording the title compound as an orange oil. 1 H NMR (500 MHz, CDCl 3 ) δ 7.72 (d, 2H); 7.46 (dd, 2H); 7.36 (s, 1H); 7.35 (d, 2H); 7.23 (dd, 2H); 6.36 (d, 1H); 5.14 (d, 1H); 4.36 (dd, 1H); 4.29 (dd, 1H); 4.13 (dd, 1H); 4.01 (dd, 1H); 3.86 (dd, 1H); 2.70 (q, 2H); 2.82 (m, 1H); 2.17 (m, 1H); 1.86 (m, 2H); 1.65 (m, 1H); 1.43 (m, 1H); 1.18 (t, 3H). LRMS (APCI) calc'd for (C 28 H 27 BrF 2 N 2 O 3 S) [M+H] + , 589.1. found 589.1.
Step 2. 9H-Fluoren-9-ylmethyl[(1S,2R)-2-({[5-ethyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate
9H-Fluoren-9-ylmethyl[(1S,2R)-2-{[(4-bromo-5-ethylthiophen-2-yl)carbonyl]amino}-3,3-difluorocyclohexyl]carbamate (677 mg, 1.15 mmol), bis(pinacolato)diboron (321 mg, 1.26 mmol), PdCl 2 (dppf)-CH 2 Cl 2 adduct (56 mg, 0.07 mmol), dppf (38 mg, 0.07 mmol), and potassium acetate (451 mg, 4.59 mmol) were placed into a sealed tube and 1,4-dioxane added (11.5 mL) and the tube purged with nitrogen for 15 minutes. The solution was heated at 85° C. for 18 h. The solution was cooled to room temperature and additional bis(pinacolato)diboron (146 mg, 0.58 mmol), PdCl 2 (dppf)-CH 2 Cl 2 adduct (56 mg, 0.07 mmol), dppf (38 mg, 0.07 mmol), and potassium acetate (225 mg, 2.3 mmol) were added. The solution was purged with nitrogen for 15 minutes and heated at 85° C. for 18 h. The solution was cooled to room temperature, diluted with water, and extracted with dichloromethane (×3). The organic layers were collected, dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by column chromatography affording the title compound as an orange solid. LRMS (APCI) calc'd for (C 34 H 39 BF 2 N 2 O 5 S) [M+H] + , 637.3. found 637.3.
Step 3. 9H-Fluoren-9-ylmethyl[(1S,2R)-2-({[5-ethyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate
3-Bromoimidazo[1,2-b]pyridazine (53 mg, 0.27 mmol), 9H-fluoren-9-ylmethyl[(1S,2R)-2-({[5-ethyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate (187 mg, 0.294 mmol), Pd 2 (dba) 3 (25 mg, 0.03 mmol), tricyclohexylphosphine (19 mg, 0.07 mmol), and aqueous tribasic potassium acetate (0.71 mL, 0.91 mmol, 1.27 M) were placed into a sealed tube and 1,4-dioxane (5.4 mL) added. The sealed tube was purged with nitrogen for 5 minutes and heated at 100° C. for 18 h. The solution was cooled to room temperature and additional 9H-fluoren-9-ylmethyl[(1S,2R)-2-({[5-ethyl-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate (85 mg, 0.13 mmol), Pd 2 (dba) 3 (12 mg, 0.01 mmol), tricyclohexylphosphine (8 mg, 0.03 mmol), and aqueous tribasic potassium acetate (0.42 mL, 0.54 mmol, 1.27 M) were added. The sealed tube was purged with nitrogen for 5 minutes and heat at 100° C. for 4 h. The solution was then cooled to room temperature and quenched with aqueous saturated sodium bicarbonate and extracted with dichloromethane (×3). The combined organic layers were dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was taken on to the deprotection step without purification. LRMS (APCI) calc'd for (C 34 H 31 F 2 N 5 O 3 S) [M+H] + , 628.2. found 628.2.
Step 4. N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-ethyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
9H-Fluoren-9-ylmethyl[(1S,2R)-2-({[5-ethyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate (168 mg, 0.268 mmol) was dissolved in DMF (2.68 mL) and piperidine added (0.265 mL, 2.68 mmol). The solution was stirred at room temperature for 2 h. The solution was then subjected to prep HPLC for purification. The compound was neutralized by taking the fractions and adding an aqueous saturated sodium bicarbonate solution and extracting three times with dichloromethane. The combined organics were dried with magnesium sulfate, filtered, and concentrated to afford the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.61 (d, 1H); 8.41 (d, 1H); 8.21 (d, 1H); 8.19 (s, 1H); 7.95 (s, 1H); 7.29 (dd, 1H); 4.07 (m, 1H); 2.86 (m, 1H); 2.85 (q, 2H); 2.07 (m, 1H); 1.88 (m, 1H); 1.86 (m, 1H); 1.70 (m, 1H); 1.36 (m, 2H); 1.21 (t, 3H). LRMS (APCI) calc'd for (C 19 H 21 F 2 N 5 OS) [MA-1] + , 406.1. found 406.1.
According to Example 23, the following compounds were prepared from the corresponding 3-bromoimidazo[1,2-b]pyridazine and amine.
Ex.
Structure
Name
MS
24
N-[(1R,6R)-6-amino-2,2- difluorocyclohexyl]-5- ethyl-4-[7- (trifluoromethyl)imidazo[1, 2-b]pyridazin-3- yl]thiophene-2- carboxamide
calc'd (M + H) + 474.1; found (M + H) + 474.1
25
N-[(1R,6S)-6-amino-2,2- difluorocyclohexyl]-5- ethyl-4-[7- (trifluoromethyl)imidazo[1, 2-b]pyridazin-3- yl]thiophene-2- carboxamide
calc'd (M + H) + 474.1; found (M + H) + 474.1
Example 26
N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
Step 1. Methyl 5-formyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate
To a stirred solution of methyl 5-ethenyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate (160 mg, 0.56 mmol) in THF (1.9 mL) and water (0.95 mL) were added OsO 4 (4% in water, 0.36 mL, 0.056 mmol) and NMO (79 mg, 0.67 mmol). The reaction mixture was left to stir for 5 h, treated with additional 0504 (4% in water, 0.36 mL, 0.056 mmol) and NMO (79 mg, 0.67 mmol), and left to stir overnight. Additional OsO 4 (4% in water, 0.36 mL, 0.056 mmol) and NMO (79 mg, 0.67 mmol) were added and the resultant solution was left to stir for 1 d, treated with aqueous sodium thiosulfate, and left to stir for 2 h. The mixture was extracted with dichloromethane (×3). The combined organics were dried (sodium sulfate), and concentrated. The residue was dissolved in THF (6 mL) and water (3 mL), and treated with sodium periodate (143 mg, 0.67 mmol). The mixture was left to stir overnight, diluted with water, and extracted with dichloromethane (×3). The combined organics were dried (sodium sulfate), concentrated, and purified by flash chromatography to afford the title compound as a yellow solid. LRMS (APCI) calc'd for (C 13 H 10 N 3 O 3 S) [M+H] + , 288.0. found 288.0.
Step 2. Methyl 5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate
To a stirred solution of methyl 5-formyl-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate (80 mg, 0.28 mmol) in dichloromethane (5.6 mL) was added Deoxo-Fluor (50%, 616 mg, 1.39 mmol). The reaction mixture was left to stir overnight, treated with aqueous sodium bicarbonate solution, and extracted with dichloromethane (×3). The combined organics were washed with brine, dried (sodium sulfate), concentrated, and purified by flash chromatography to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.66 (dd, 1H); 8.32 (t, 1H); 8.26 (dd, 1H); 8.01 (s, 1H); 7.45 (t, 1H); 7.37 (dd, 1H); 3.89 (s, 3H). LRMS (APCI) calc'd for (C 13 H 10 F 2 N 3 O 2 S) [M+H] + , 310.0. found 310.0.
Step 3. 5-(Difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylic acid
To a stirred solution of methyl 5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylate (57 mg, 0.18 mmol) in methanol (1 mL) and water (0.5 mL) was added NaOH (2 N, 0.28 mL, 0.56 mmol). The mixture was heated to 50° C. for 1 h, cooled to room temperature, and acidified with 1 N HCl. The resultant mixture was concentrated, and used in the next step without further purification. LRMS (APCI) calc'd for (C 12 H 8 F 2 N 3 O 2 S) [M+H] + , 296.0. found 296.0.
Step 4. N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
To 5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxylic acid (26 mg, 0.088 mmol) in DMF (0.4 mL) were added BOP (58 mg, 0.13 mmol) and DIEA (0.062 mL, 0.35 mmol). The mixture was left to stir for 5 min, treated with (1R,6S)-6-{[(9H-fluoren-9-ylmethoxy)carbonyl]amino}-2,2-difluorocyclohexanaminium chloride (36 mg, 0.088 mmol), and left to stir for 2 h. The mixture was diluted with water and extracted with EtOAc (×3). The combined organics were dried (sodium sulfate), concentrated, and purified by flash chromatography to afford 9H-fluoren-9-ylmethyl[(1S,2R)-2-({[5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate. LRMS (APCI) calc'd for (C 33 H 28 F 4 N 5 O 3 S) [M+H] + , 650.2. found 650.2.
To a stirred solution of 9H-fluoren-9-ylmethyl[(1S,2R)-2-({[5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophen-2-yl]carbonyl}amino)-3,3-difluorocyclohexyl]carbamate (27 mg, 0.042 mmol) in DMF (0.8 mL) was added piperidine (0.08 mL, 0.83 mmol). The mixture was left to stir for 1 h, diluted with water, and extracted with EtOAc. The organic layer was dried, concentrated, and purified by flash chromatography to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.38 (s, 1H); 8.72 (d, 1H); 8.68 (dd, 1H); 8.43 (s, 1H); 8.27 (dd, 1H); 7.97 (s, 1H); 7.38 (dd, 1H); 7.35 (t, 1H); 4.05 (m, 1H); 2.82 (m, 1H); 1.30-2.10 (m, 6H). LRMS (APCI) calc'd for (C 18 H 18 F 4 N 5 OS) [M+H] + , 428.1. found 428.1.
According to Example 26, Example 27 was prepared from the corresponding amine.
Example 27
N-[(1R,6R)-6-Amino-2,2-difluorocyclohexyl]-5-(difluoromethyl)-4-(imidazo[1,2-b]pyridazin-3-yl)thiophene-2-carboxamide
calc'd. (M+H) + 428.1. found (M+H) + 428.1
Example 28
N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-chloro-4-(imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carboxamide
Step 1. 1-(Imidazo[1,2-b]pyridazin-3-yl)ethanone
3-Bromoimidazo[1,2-b]pyridazine (1.0 g, 5.05 mmol), tributyl(1-ethoxyvinyl)tin (3.41 mL, 10.1 mmol), and PdCl 2 (PPh 3 ) 2 (354 mg, 0.505 mmol), were added to a sealed tube. DMF (25.2 mL) was added and the reaction purged with nitrogen for 5 minutes. The reaction was heated at 100° C. for 18 h. The reaction was cooled to room temperature and quenched with aqueous saturated sodium bicarbonate. The aqueous layer was extracted with ethyl acetate (×3) and the combined organic layers were dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was diluted with methanol (10 mL) and HCl in 1,4-dioxane (1.26 mL, 5.05 mmol, 4M) was added. The solution was stirred at room temperature for 1 h. The reaction was then quenched with aqueous saturated sodium bicarbonate and extracted with ethyl acetate (×3). The combined organic layers were dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was purified by flash chromatography to afford the title compound. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.76 (d, 1H); 8.55 (s, 1H); 8.31 (d, 1H); 8.49 (dd, 1H); 2.64 (s, 3H). LRMS (APCI) calc'd for (C 8 H 7 N 3 O) [M+H] + , 162.1. found 162.1.
Step 2. 2,2-Dibromo-1-(imidazo[1,2-b]pyridazin-3-yl)ethanone
1-(Imidazo[1,2-b]pyridazin-3-yl)ethanone (502 mg, 3.11 mmol) was dissolved in acetic acid (7.8 mL) and 33% HBr in acetic acid (0.564 mL, 3.11 mmol) was added. Bromine (0.177 mL, 3.43 mmol) was added and the solution stirred at 60° C. for 1.5 h. After stirring for 1.5 h, added more bromine (0.08 mL, 1.56 mmol) and 33% HBr in acetic acid (0.282 mL, 1.56 mmol). The solution was stirred at 60° C. for 3 h. The solution was then cooled to room temperature and quenched with 10% aqueous sodium thiosulfate. The aqueous layer was extracted with dichloromethane (×3). The organic layers were combined and washed with aqueous saturated sodium bicarbonate. The organic layer was collected and dried with magnesium sulfate, filtered, and concentrated under reduced pressure. The residue was taken on to the next step without further purification. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.88 (d, 1H); 8.83 (s, 1H); 8.40 (d, 1H); 7.66 (s, 1H); 7.61 (dd, 1H). LRMS (APCI) calc'd for (C 8 H 5 Br 2 N 3 O) [M+H] + , 317.9. found 317.9.
Step 3. Ethyl 4-(imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carboxylate
2,2-Dibromo-1-(imidazo[1,2-b]pyridazin-3-yl)ethanone (790 mg, 2.48 mmol) and ethyl thiooxamate (547 mg, 3.96 mmol) were dissolved in 1,4-dioxane (24.8 mL) and heated to 100° C. for 4 h. The solution was cooled to room temperature and water was added. The aqueous layer was extracted with ethyl acetate (×3). The organic layers were combined and dried with magnesium sulfate, filtered, and concentrated under reduced pressure to give the title compound as an orange solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.79 (s, 1H); 8.77 (d, 1H); 8.33 (s, 1H); 8.30 (d, 1H); 7.39 (dd, 1H); 4.43 (q, 2H); 1.36 (t, 3H). LRMS (APCI) calc'd for (C 12 H 10 N 4 O 2 S) [M+H] + , 275.1. found 275.0.
Step 4. 4-(Imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carboxylic acid
Ethyl 4-(imidazo[1,2-b]pyridazin-3-yl)-1,3-triazole-2-carboxylate (100 mg, 0.365 mmol) was dissolved in methanol (0.91 mL) and THF (0.91 mL) and KOH in methanol (1.09 mL, 1.09 mmol, 1M) was added. The solution was left to stir at 60° C. for 18 h. The reaction was then cooled to room temperature and concentrated under reduced pressure. To the residue was added 1N HCl. The precipitate was filtered and dried under high vacuum to afford the title compound as an orange solid. LRMS (APCI) calc'd for (C 14 H 6 N 4 O 2 S) [M+H] + , 247.0. found 247.0.
Step 5. 5-Chloro-4-(imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carbonyl chloride
4-(Imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carboxylic acid (49 mg, 0.20 mmol) and thionyl chloride (3.0 mL, 41 mmol) were placed in a sealed tube and heated at 80° C. for 42 h. The reaction was cooled to room temperature and concentrated under reduced pressure to give an orange solid. The residue was used immediately in the next step. LRMS (APCI) calc'd for the methyl ester of the title compound (C 11 H 7 ClN 4 O 2 S) [M+H] + , 295.0. found 295.0.
Step 6. N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-chloro-4-(imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carboxamide
5-Chloro-4-(imidazo[1,2-b]pyridazin-3-yl)-1,3-thiazole-2-carbonyl chloride (59.5 mg, 0.199 mmol) and tert-butyl[(1S,2R)-2-amino-3,3-difluorocyclohexyl]carbamate (54.8 mg, 0.219 mmol) were dissolved in dry dichloromethane (3 mL). The reaction mixture was left to stir at room temperature for 42 h. After consumption of the starting material, trifluoroacetic acid (2 mL) was added to the reaction mixture and left to stir at room temperature for 2 h. The solution was then concentrated and the residue purified by prep HPLC. The compound was neutralized by taking the fractions and adding an aqueous saturated sodium bicarbonate solution and extracting three times with ethyl acetate. The combined organics were dried with magnesium sulfate, filtered, and concentrated to afford the title compound as a yellow solid. 1 H NMR (500 MHz, CD 3 SOCD 3 ) δ 8.73 (d, 1H); 8.66 (s, 1H); 8.24 (d, 1H); 7.45 (dd, 1H); 4.05 (m, 1H); 2.85 (m, 1H); 2.08 (m, 1H); 1.22-2.08 (m, 6H). LRMS (APCI) calc'd for (C 16 H 15 ClF 2 N 6 OS) [M+H] + , 413.1. found 413.0.
According to Example 28, Example 29 was prepared from 3-bromoimidazo[1,2-a]pyridine.
Example 29
N-[(1R,6S)-6-Amino-2,2-difluorocyclohexyl]-5-chloro-4-(imidazo[1,2-a]pyridin-3-yl)-1,3-thiazole-2-carboxamide
calc'd (M+H) + 412.1. found (M+H) 30 412.0 | The invention encompasses imidazo[1,2-a]pyridine and imidazo[1,2-b]pyridazine derivatives which selectively inhibit microtubule affinity regulating kinase (MARK) and are therefore useful for the treatment or prevention of Alzheimer's disease. Pharmaceutical compositions and methods of use are also included. | 2 |
FIELD OF THE INVENTION
This invention relates generally to article handling apparatus and is particularly concerned with magnetic article sorting, parts handling, and/or parts storage apparatus and systems.
DESCRIPTION OF RELATED ART
In many industrial processes, it is necessary to separate magnetically attractive parts from nonmagnetic material. Generally, the parts are bathed in a liquid slurry and it is necessary to recover the metal parts.
The U.S. Pat. No. 3,759,367 to Elliott, the inventor of the present invention, issued Sept. 18, 1973 discloses a magnetic conveyor having a single helix wound around an elongated hollow casing of nonmagnetic material. Magnetic means, which can comprise either electromagnets or permanent magnets, are housed within the nonmagnetic casing. Other examples of patents disclosing assemblies magnetically separating parts and not including a rotating spiral helix are the U.S. Pat. Nos. 1,605,117 to Koizumi, issued Nov. 2, 1926 and 4,062,443 to Wallace, issued Dec. 13, 1977.
The prior art patent provides means for separating a ferromagnetic material from a nonmagnetic material by selectively advancing the ferromagnetic material from a non-ferromagnetic material. However, present day assembling procedures would benefit from a means for segregating different or the same ferromagnetic materials in a single process by a single apparatus. In view of this problem, the present invention provides means for selectively advancing ferromagnetic material along a nonmagnetic tube from separate in-feed stations to separate discharge stations on a single tubular structure.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for handling parts by magnetic attraction including a cylindrical casing of nonmagnetic material having an uninterrupted surface throughout its length and magnetizing means for magnetically attracting parts to the casing. Nonmagnetic ramp means are spirally wound around the casing. Drive means rotates the magnetic means relative to the ramp means to cause the parts to rotate about the axis of the casing while the ramp means causes the parts to advance along the length of the casing. The ramp means includes multiple parts segregating means for segregating parts received and discharged along the length of the casing.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is an elevational view partially in section of an apparatus embodying the invention; and
FIG. 2 is a cross sectional view taken on lines 2--2 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus for handling parts by magnetic attraction constructed in accordance with the present invention is generally shown at 10 in the Figures.
The apparatus 10 is used to transfer parts a,a' from a supply schematically shown at 12 at the lower end of the apparatus 10 to a plurality of removable discharge chutes 14,16 at the upper end of the apparatus 10.
The apparatus 10 includes an elongated hollow cylindrical casing 18 made from a nonmagnetic material. For example, the casing 18 can be made from a stainless steel tube. The casing 18 has an uninterrupted surface throughout its length. An elongated magnetic core assembly 20 is disposed within the casing 18, the magnetic core 20 being rotatably received in the casing 18.
As shown in FIG. 2, a plurality of rollers 22 are mounted on the magnetic core assembly 20 and engage the inner surface of the casing 18 to provide support for the magnetic core 20 in a direction transverse to the axis of the casing 18, and to prevent the casing 18 from collapsing inwardly from the force exerted by the articles a,a' due to the attraction of the magnetic core 20.
The magnetic core assembly 20 includes a driven shaft 24 operatively connected with a motor 26. Energization of the motor 26 causes rotation of the shaft 24. A magnetic core 28 is secured to the shaft 24. As disclosed in the U.S. Pat. No. 3,759,367, the magnetic core can include a pair of elongated steel support bars mounted on diametrically opposed sides of the axis of the shaft 24, or may comprise a magnetic mounted on support arms in such a manner that the north pole of the magnet of one of the arms is adjacent to the south pole of the magnet of an adjacent support arm. Other arrangements of the magnets may be utilized in conjunction with the present invention wherein the magnets magnetically attract parts a,a' to the casing 18.
The assembly 10 includes ramp means generally indicated at 30 for causing the parts a,a' to advance along the length of the casing 18. The ramp means 30 includes multiple parts segregating means for segregating parts advancing along the length of the casing 18.
More specifically, the multiple part segregating means includes a pair of ramps 32,34 of nonmagnetic material wound spirally along the length of the casing 18. The ramps 32,34 are wound spirally about the outer surface of the casing 18 although other orientations of the ramps to the casing are possible. Ramp 32 collects and discharges parts a and ramp 34 collects and discharges parts a', the ramps 32,34 keeping the parts a,a' separated throughout the length of travel along the length of the assembly 10.
Each of the ramps 32,34 has an in-feed end 36,38 and a discharge end 40,42, respectively. The in-feed ends 36,38 are operatively connected to an in-feed part source 12 and the discharge ends 40,42 are operatively connected to the removable discharge chutes 14,16, respectively, for receiving the discharged parts a,a'.
As shown in FIG. 1, both in-feed ends 36,38 are contained in a single in-feed part source 12. Alternatively, each in-feed end 36,38 could receive different parts from different part sources anywhere along the length of the assembly 10. Each of the discharge ends 40,42 are operatively connected to separate discharge chutes 14,16. Alternatively, one or both of the ramps 36,38 can extend over only a portion of the casing 18 and either pick up or discharge parts from portions of the casing 18 intermediate the ends of the casing 18.
A discharge sweeper 44,46 may be necessary to assist gravity for the removal of light ferrous chips and fines that are slow to fall free from the magnetic field and discharge chute upon rotation of the magnets 20. The magnets 20 are made up of one, two or more separate magnetic fields (depending on the number magnets used). The elements rely upon the nonmagnetic areas between the magnetic fields for a release and discharge. The discharge sweepers 44,46 are made from small strips (one or more) of ferrous steel, wire, cable, or chain, (as illustrated in the Figures) and are attached at one end 48,50 and free at the other ends 52,54 to swing into and out of the discharge areas 40,42.
The discharge sweepers 44,46 are made from ferrous material and suspended in front of the discharge areas 40,42. The discharge sweepers 44,46 utilize the interior sealed rotating magnetic elements 20 as its means of motion. The magnetic elements 20 rotating inside of the tube 18 held collected ferrous chips and fines for movement up the exterior spiral 30 of the device 10. When collected ferrous material reaches the discharge areas 40,42 the strong magnetic field pulls the ferrous sweepers 44,46 into the path of the collected ferrous material that are ready for discharge. The ferrous chips and fines attach themselves directly to the discharge sweeper because the metallic discharge sweepers 44,46 remain in the magnetic field. Thus, all the metal chips and fines are transferred onto the sweeper 44,46. The sweeper 44,46 then moves around the tube 18 with the rotating interior magnetic element 20 to discharge deadplate 56. At this point, the heavy, fast falling discharge sweepers 44,46 is released from the magnetic field and is free to fall away thereby discharging the collected chips and fines. The discharge sweepers 44,46 then hang in a neutral position until a magnetic element once again pulls the discharge sweepers 42,46 back into the strong magnetic field to repeat the cycle over again.
Unlike prior art assemblies wherein parts are carried from a single source and discharged at a single discharge end, the present invention provides ramp means allowing too, three or more individual ramps in the form of helixes or spiral ramps to be spaced onto the cylindrical tube 18 so that each of the ramps has a common or separate in-feed end and discharge area located at desired points along the length of the casing 18. Individual discharge trays or chutes can be removable and be positioned by the attachment of metal screws anywhere along the tube 18.
The multiple ramp assembly allows a single apparatus to carry two, three, or more different parts on the same cylindrical casing 18 while keeping them separated for discharge. Further, the apparatus can feed the same part of multiple collection bins or assembly stations with a smooth meter discharge from each discharge chute.
The apparatus can operate in any position, vertical to horizontal, the only limitation being the relationship to the weight of the carried part to the force of the magnetic field directed along the length of the casing 18.
As disclosed in the previously cited Elliott patent, the ramps can be positioned further apart at the in-feed area and merged closer to one another at the discharge ends to thin out parts into a single lane off of the discharge.
The multiple ramps increase the capacity of the apparatus because each ramp carries a maximum amount of parts for the full length of the apparatus. Accordingly, the apparatus can run at a slower RPM in comparison to prior art apparatus having single ramps.
When the apparatus is used in parts washing or parts coating applications, tanks for washing or coating can be much smaller in size because the part traveling on the casing is approximately four feet around the casing to one foot of linear travel along the casing. The conveyor may operate at an almost horizontal position for this application.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
While specific embodiments of the invention have been illustrated in the accompanying drawings and described in the foregoing specification, it should be understood that the invention is not limited to the specific construction shown. Alternatives in the construction and arrangement of parts, all falling within the scope and spirit of the invention, will be apparent to those skilled in the art. | An apparatus (10) for handling parts (a,a') by magnetic attraction includes a cylindrical casing (18) of nonmagnetic material having an uninterrupted surface throughout its length and a magnet (20) for magnetically attracting parts (a,a') to the casing (18). Nonmagnetic ramps are spirally wound around the casing (18). A drive mechanism (26) rotates the magnet (20) relative to the ramp. The magnet (20) attracts the parts to the casing (18) and causes the parts (a,a') to rotate about the axis of the casing (18) while the ramps (30) cause the parts (a,a') to advance along the length of the casing (18). The ramps (30) include a multiple part segregating mechanism for segregating parts received and discharged along the length of the casing (18). | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an information retrieval system and information retrieval device which retrieve position data and related data, for example using the Internet, and display them.
[0003] 2. Description of Related Art
[0004] The Internet comprises a service referred to as the WWW (World Wide Web), which performs multimedia data retrieval via the network based on hypertext linking character information, image information and audio information. An enormous amount of information of many kinds can be accessed using the WWW ranging from technical data and economic information to shopping and restaurant information. There are also many types of WWW sites ranging from official bodies such as Governments and local public authorities to small companies, shops and even individuals. It is moreover envisaged that services using the WWW will undergo even further expansion in the future.
[0005] When these WWW services are used, information about shopping and events can easily be obtained. However even if such information is acquired, map information is required to know exactly where a shop is located, or where an event is being held. When the WWW provides shopping or event information, it would be desirable if the location of a shop or event were displayed on a map. The WWW uses hypertext, so if a map of the nearby area is prepared as image data, and the location of the shop or event is marked on the map, the map can be marked at a predetermined position on a predetermined page.
[0006] However, roads and topography are extremely complex, and it is therefore very difficult for persons preparing WWW pages to construct maps near shops or events, and paste them on predetermined pages. Also, the maps drawn by WWW page authors are frequently inaccurate.
[0007] A WWW site providing map data could be envisaged wherein, when position data such as latitude or longitude is input, a map corresponding to the specific position is displayed. If there were such a WWW site, a user who acquired shopping or event information could then open a WWW search page providing this map data, and find the location of a shop or event on a map by inputting its position.
[0008] To retrieve the map data, exact position information such as latitude and longitude are required. However, information regarding a shop or event generally includes only the shop name or event venue, telephone number and address, etc., and absolute position information such as latitude and longitude is almost never given. Therefore, even if map positions of shops or events are searched using a WWW site providing such map data, they are of no use if the absolute position of the shop or event is unknown.
[0009] CD-ROM's are on the market which contain map data, and a map display application which displays a map around a place when the place is specified, so it would seem feasible to use the map data in such a CD-ROM. Using the CD-ROM application, it is possible to retrieve the map data position for a shop or event.
[0010] This CD-ROM could also be used when preparing map data at sites which provide shopping or event information on the WWW. In other words, sites offering shopping or event information on the WWW would extract positions of shops or events from the map data in the CD-ROM. A shopping or event information page would be prepared, and map data from the CD-ROM would be pasted on the page. In this way, persons preparing WWW pages could paste accurate maps on pages without drawing maps themselves.
[0011] However, map data is constantly changing. New buildings are erected, old buildings are demolished, and cities are always in a state of flux. There is also regional development and new roadworks. Hence, if map data in a CD-ROM were used, it would be difficult to cope with these changes in the data. Also the maps used with the WWW would include all kinds, from full coverage maps of the whole world to detailed maps showing shops belonging to private individuals in various world areas and of various scales. CD-ROM have a data storage limit, and cannot satisfy such wide-ranging demands.
[0012] Further, if WWW pages are prepared using the map data in a CD-ROM, the map data would be used without restriction and it would be difficult to protect copyrights.
SUMMARY OF THE INVENTION
[0013] It is therefore an object of the invention to provide a data structure group for offering map and/or related data, and a method for offering map and/or related data.
[0014] It is a further object of the invention to provide a data receiving apparatus.
[0015] According to this invention, there are provided position data such as for example latitude and longitude, and a map data base in which map data corresponding to this position data is stored. A position related data base in which this position data, and data related to position data such as concerning buildings, shops and goods handled by the shops at the position in question, are stored, is also provided. This map data base, position related data base and a user terminal are connected by for example the Internet. On the user terminal, related data is searched using the position related data base, and a map of the corresponding location is displayed using the map data base. In this way, for example, shops meeting required conditions can be searched, and map data for the location can easily be obtained.
[0016] According to this invention, there are provided position data such as for example latitude and longitude, and a map data base in which map data corresponding this position data is stored. Also provided is a data base in which guide data are stored. When a map is required for this data, position data for this position is included. At the user terminal, the data is searched, and when there is a map in the supplementary data, this map data is sent from the map data base and included in the supplementary data. In this way, a map may be included in supplementary data such as guide data, and an accurate map may easily be displayed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a block diagram for the purpose of describing an embodiment of this invention.
[0018] [0018]FIG. 1- 1 is a block diagram for the purpose of describing one embodiment of this invention.
[0019] [0019]FIG. 2 is a rough drawing for the purpose of describing an embodiment of this invention.
[0020] [0020]FIG. 3 is a rough drawing for the purpose of describing an embodiment of this invention.
[0021] [0021]FIG. 4 is a rough drawing for the purpose of describing an embodiment of this invention.
[0022] [0022]FIG. 5 is a rough drawing for the purpose of describing an embodiment of this invention.
[0023] [0023]FIG. 6 is a rough drawing for the purpose of describing an embodiment of this invention.
[0024] [0024]FIG. 7 is a state transition diagram for the purpose of describing the image display according to one embodiment of this invention.
[0025] [0025]FIG. 8 is a state transition diagram for the purpose of describing the image display according to one embodiment of this invention.
[0026] [0026]FIG. 9 is a state transition diagram for the purpose of describing the image display according to one embodiment of this invention.
[0027] [0027]FIG. 10 is a state transition diagram for the purpose of describing the image display according to one embodiment of this invention.
[0028] [0028]FIG. 11 is a state transition diagram for the purpose of describing the image display according to one embodiment of this invention.
[0029] [0029]FIG. 12 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0030] [0030]FIG. 13 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0031] [0031]FIG. 14 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0032] [0032]FIG. 15 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0033] [0033]FIG. 16 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0034] [0034]FIG. 17 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0035] [0035]FIG. 18 is a rough drawing for the purpose of describing drawing data according to an embodiment of this invention.
[0036] [0036]FIG. 19 is a block diagram of this invention.
[0037] FIGS. 20 - 27 are diagrams for the purpose of describing information registration and editing according to this invention.
[0038] [0038]FIG. 28 is a block diagram of this invention.
[0039] [0039]FIGS. 29 and 30 are diagrams for the purpose of describing information registration and editing according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] This invention will be described in the following sequence.
[0041] 1. System overview
[0042] 2. Processing by position retrieval service
[0043] 3. Processing by guide information service with added map data
[0044] 4. Protection of data in map data base
[0045] 5. Modifications
[0046] 6. Map drawing information
[0047] 1. System Overview
[0048] [0048]FIG. 1 shows an outline of a system to which this invention is applied. In FIG. 1, 1 is a map data base center. The map data base center 1 manages a WWW site providing map data. The WWW is a service which performs multimedia data retrieval via a network based on hypertext linking character information, image information and audio information. To use the WWW, an application program referred to as a browser is used. In the WWW, using hypertext, links to other WWW sites, Gopher servers and FTP servers can easily be made.
[0049] The meaning of WWW in the context of this invention is used in the wide sense of a general entity comprising all data structures, such as http/gopher/ftp.
[0050] The map data base center 1 is provided with a server 11 connected to the Internet 10 . The server 11 stores map data corresponding to position data such as latitude and longitude. In other words, 0th dimension information. The map data stored in the server 11 is constantly updated to correspond with constantly changing map data. Desired map data may be obtained by accessing the WWW site of the map data in this map data base center 1 .
[0051] For example, assume that a user who has a user terminal 15 which can be connected to the Internet 10 , wishes to acquire map data. For this purpose, he opens the WWW site managed by the map data base center 1 . When the map data base site is opened, a map data search page is sent to the user terminal 15 from the server 11 of the map data base center 1 , as shown in FIG. 2A. The user enters parameters of the desired map data, e.g. latitude, longitude and scale reduction, in this search page. When the parameters are input, the desired map data is searched from the map data stored in the server 11 . This map data is sent to the user terminal 15 from the server 11 of the map data base center 1 , and the desired map is displayed on the screen of the user terminal 15 as shown in FIG. 2B.
[0052] The amount of data required for map display is enormous. Consequently when map data is sent from the server 11 of the map data base center 1 , if all the data required for the map display is sent, transfer time is long and the network load is high. Therefore, drawing information comprising numbers and character strings for drawing a shape on the map is sent as described hereafter.
[0053] Numeral 2 is a position data base center. The position data base center 2 manages a WWW site for searching the position of a shop or event venue. The position data base 2 has a server 12 . This server 12 stores a data base for searching, for example, latitude/longitude data corresponding to addresses, main building names and shop names, and latitude/longitude data for event venues. The data in the server 12 of the center 2 also comprises information such as shop opening hours, types of business conducted and goods handled. When the WWW site of the center 2 is accessed, and for example addresses are input, latitude/longitude data can be retrieved. Again, when main building names, shop names and event venues are input, latitude/longitude data can be retrieved. Conversely, when latitude/longitude data is input, addresses, main building names or shop names can be searched. Moreover, shops, etc., which meet given conditions such as types of business or opening hours, can be retrieved.
[0054] Searches wherein maps are directly displayed may also be performed by linking the WWW site of the position data base center 2 and the WWW site of the map data base center 1 .
[0055] For example, assume the user wishes to know the location of a shop which meets predetermined conditions. In this case, the user opens the WWW site managed by the position data base center 2 using the browser of the terminal 15 . When the site of the center 2 is opened, data is sent from the site of the center 2 to the terminal 15 , and the position search WWW page is displayed on the screen of the terminal 15 , as shown in FIG. 3A. The user enters the required items on the search page. When the required items are entered, latitude/longitude data for the positions of shops which meet the conditions is searched based on the items entered by the server 12 of the center 2 . Retrieved latitude/longitude data is sent to the map data base center 1 . When latitude/longitude data is sent to the center 1 , map data corresponding to this position is searched from map data stored in the server 11 . This map data is linked to the position search WWW page, and a map of the input shop is thereby displayed on the screen of the terminal 15 as shown in FIG. 3B.
[0056] Conversely, assume that the user wishes to know the address or telephone number of a location shown on the map. In this case, the WWW site managed by the position data base center 2 and the WWW site of the map data base center 1 are linked, and the screen shown in FIG. 4A is displayed on the terminal 15 . Herein, when a point Pmk on the map is specified, the position at this time (latitude/longitude) is sent from the server 11 of the center 1 to the server 12 of the center 2 . Information concerning the place corresponding to this position is then searched by the server 12 of the center 2 , and is displayed as shown in FIG. 4B.
[0057] Numeral 3 is a guide data base center. This center 3 manages a WWW site which provides guide data. The center 3 has a server 13 connected to the Internet 10 . The server 13 stores information about events and shopping, etc.
[0058] When the user wishes to acquire information about events or shopping, he opens a WWW site managed by the center 3 using a browser in the terminal 15 . When the site of the center 3 is opened, data is sent from the server 13 of the center 3 to the terminal 15 , and the guide data WWW page is displayed on the screen of the terminal 15 . Using this guide data WWW page, event or shopping data can be obtained.
[0059] It is sometimes desired to display shops and event venues on a map in the guide data WWW page. Conventionally, when map data was displayed, the map data was prepared by the center 3 , and this had to be pasted on the WWW page. In the system to which this invention is applied, however, this is unnecessary because map data stored in the server 11 of the center 1 can be used as the map data displayed in the guide data.
[0060] Specifically, a map is displayed in a part indicated by MAP in the guide data WWW page shown in FIG. 5. The map in this part MAP is map data extracted from the server 11 of the center 1 . In other words, the guide data read from the server 13 of the center 3 and map data read from the server 11 of the center 1 are combined, and the guide data page comprising the map MAP is displayed as shown in FIG. 5.
[0061] It should be understood that when maps from the center 1 are combined in the guide data WWW page, maps in the WWW page may be combined using the browser of the terminal 15 . Map data may also be prepared and supplementary data superposed by the map data base center 1 . In other words, when the guide data base center 3 is opened by the browser of the terminal 15 , a guide data search page is sent as shown in FIG. 6A. When a MAP button in this page is pressed, corresponding map data is retrieved by the center 1 , and combined by the center 2 . This map is then displayed on the screen of the terminal 15 as shown in FIG. 6B.
[0062] Hence, systems to which this invention is applied comprise a data base center 1 which provides map data via the WWW. When this center 1 which provides map data is accessed, map data comprising a position is extracted from position data such as latitude or longitude. In addition the center 1 , by linking up to the center 2 or the WWW page of the center 3 , provides a service whereby a position of a shop or event is searched from the shop or event name so as to display it on a map, and the map data is simply embedded in the guide data.
[0063] 2. Processing by Position Search Service
[0064] A description will now be given of the processing performed when the WWW of the center 1 and the WWW of the center 2 are linked, a position is searched from the name of a shop or event and displayed on a map, and information about the shop at that location is displayed from the map position.
[0065] [0065]FIG. 7 is a flow chart showing the processing performed at this time. A search page is sent to the user terminal 15 from the server 12 of the position search data base center 2 (step S 1 ). This search page is displayed on the screen of the user terminal 15 (step S 2 ). A search condition is input from the keyboard or mouse, and sent from the user terminal 15 to the server 12 of the center 2 (step S 3 ). Places conforming to this condition are searched by the server 12 of the center 2 (step S 4 ), and the search result is sent to the user terminal 15 (step S 5 ). Also, position data (latitude, longitude) for the searched location is sent to the server 11 of the map data base 1 from the server 12 of the center 2 (step S 6 ). Map data corresponding to this position data is searched by the server 11 of the map data base 1 (step S 7 ). A drawing command for this map data is then sent to the user terminal 15 from the server 11 of the map data base 1 (step S 8 ).
[0066] The search result from the center 2 and the map data from the center 1 are sent to the user terminal 15 . The search data and map data sent to the user terminal are then linked by a browser, and displayed on the screen (step S 9 ).
[0067] [0067]FIG. 8 is a flowchart showing the processing performed when a map is displayed on the search screen, a position on the map is entered, and data corresponding to this position are searched.
[0068] The search screen from the server 12 of the data base 2 is sent to the user terminal 15 (step S 11 ), the map drawing data from the server 11 of the map data base center 1 is sent to the user terminal 15 (step S 12 ), these data are linked by the application software of the browser, and a search screen and map are displayed on the screen (step S 13 ). When a search position is specified on this map, the search position is sent to the server 11 of the center 1 (step S 14 ). Position data corresponding to the search position on the map is searched by the server 11 of the center 1 (step 15 ). This position data is then sent to the server 12 of the position search data base 2 (step S 16 ). Data for a location corresponding to this position information is searched by the server 12 of the data base 2 (step S 17 ). The data for the searched location is sent to the terminal 15 from the server 12 of the center 2 (step S 18 ).
[0069] The map data and data for the searched location are then linked by the browser, and displayed on the screen (step S 19 ).
[0070] 3. Processing of Guide Data Added to Map Data
[0071] [0071]FIG. 9 is a flowchart showing an example of the processing performed when map data is embedded in guide information. In FIG. 9, a search screen is sent to the user terminal 15 from the server 13 of the center 3 (step S 21 ). This search screen is displayed on the screen of the user terminal 15 (step S 22 ). When search data is input to the user terminal 15 via a user keyboard or mouse, this search data is sent to the center 3 (step S 23 ).
[0072] Guide data corresponding to the search data is searched by the server 13 of the center 3 (step S 24 ). This guide data is sent from the server 13 of the center 3 to the user terminal 15 (step S 25 ). In the user terminal 15 , the guide data is decoded (step S 26 ). A command for displaying a map using the map data base and map position data (specifically, latitude and longitude, etc.) is embedded in this guide information. Map data is requested from the center 1 according to this command and map position data (step S 27 ).
[0073] The server 11 of the map data base 1 searches the desired map according to the map position data received (step S 28 ). Drawing data for this map is then sent from the server 11 of the center 1 to the user terminal 15 (step S 29 ).
[0074] Hence, guide data from the center 3 and map drawing data from the center 1 are sent to the user terminal 15 . The search data in the guide data sent to the user terminal 15 and map drawing data from the center 1 are linked by a browser, and displayed on the screen (step S 30 ).
[0075] [0075]FIG. 10 shows another example of processing where map data from the map data base center 1 is added to a page of the center 3 . According to this example, map data was prepared and supplementary data superposed in the center 3 . In FIG. 10, a search screen is sent from the server 13 of the center 3 to the user terminal 15 (step S 41 ). This search screen is displayed on the screen of the user terminal 15 (step S 42 ).
[0076] When search data is input by the user terminal 15 via a user keyboard or mouse, this search data is sent to the center 3 (step S 43 ). Guide data corresponding to the search data is searched by the server 13 of the center 3 (step S 44 ). The searched guide data is sent to the user terminal 15 from the server 13 of the center 3 (step S 45 ). In the user terminal 15 , the searched guide data is decoded (step S 46 ). This guide data comprises a button to display map data.
[0077] When this button is pressed (step S 47 ), a map image display request is sent from the user terminal to the server 11 of the center 1 (step S 48 ). The server 11 of the center 1 searches the requested map according to received map position data (step S 49 ). Supplementary data is drawn on the map image (step S 50 ). Hence, supplementary data is superposed, and drawing data is sent from the server 11 of the map data base 1 to the user terminal 15 (step S 51 ). The received image is displayed by the user terminal 15 (step S 52 ).
[0078] According to this example, map data and supplementary data are combined in the center 1 , and then sent to the user terminal 15 , so there is no need for the browser to have a special command to link the map data.
[0079] 4. Data Protection for Map Data Base
[0080] By providing a map data base center 1 as described, a WWW page with map data can easily be made even when map data is not prepared by the guide data base center 3 . However, there is a risk that if map data can be easily accessed, it might be impossible to protect copyrights of maps prepared by the map data base center 1 .
[0081] This problem might be resolved by the processing shown in FIG. 11.
[0082] In FIG. 11, when search data is input to? the center 3 from the user terminal 15 (step S 61 ), a search is conducted by the server 13 of the center 3 (step S 62 ). An order number is transmitted to the user terminal 15 from the server 13 of the center 3 (step S 63 ). A similar order number is then sent to the server 11 of the center 1 from the server 13 of the center 3 (step S 64 ), and this order number is accepted by the center 1 (step S 65 ).
[0083] This order number comprises a code A issued by the center 1 , and an order serial number generated by the center 3 , and the two codes are also encoded. The code A is updated by the center 1 at regular intervals (e.g. every hour), and is sent to a data base center which has a contract with the center 1 . After this code is issued, order numbers containing codes other than the code A are not accepted.
[0084] The user terminal 15 displays the search result sent from the center 3 (step S 66 ), and a map request corresponding to search data and the order number from the center 2 are sent to the center 1 (step S 67 ).
[0085] In the map data base center 1 , order numbers are accepted via two routes, i.e. from the center 3 and the user terminal 15 . In the map data base center 3 ( 1 ?), the order number from the center 3 and the order number from the terminal 15 are compared (step S 68 ). As the same order number is sent to the user terminal 15 and the center 1 from the center 2 ?, the order numbers should be identical in the case of legitimate use. It is determined whether or not the order numbers coincide (step S 69 ), and when it is determined that they are identical, map data is searched (step S 70 ), and this map data is sent to the user terminal 15 (step S 71 ). This map data and supplementary data are displayed on the user terminal 15 (step S 72 ). When the order numbers do not coincide, a reject code is sent to the user terminal 15 from the server 11 of the center 1 (step S 73 ). It is determined whether or not this reject code was accepted (step S 74 ), and if the reject code was accepted, display of map data is refused (step S 74 ).
[0086] 5. Modification
[0087] In the above examples, the data base center have been described as being connected to the INTERNET, however data base centers may be connected in other ways. This is shown in FIG. 1- 1 . In FIG. 1- 1 , a user terminal is connected to a data base server via the INTERNET, and the server is connected to a computer in a data base center. The computer has a map search engine, position search engine and guide information service engine which are firmware, and they each have their respective functions. In this case, the only hardware is the computer, each engine exists only as software, and it is unnecessary to clearly specify the positions of all the commands in the program for each engine. Therefore, the same effect as that of FIG. 1 may be obtained if objects that start each engine function according to the state transition diagrams in FIG. 7-FIG. 11 even when each engine is not distinguished physically or in the program arrangement.
[0088] It will be understood that the intermediate states of FIG. 1 and FIG. 1- 1 , i.e. the map search engine and position search engine, may be located in the same computer, only the guide information service engine being located in another data base center.
[0089] It will further be understood that apart from the INTERNET, this invention may be applied also to general computer communications services and leased circuit connections.
[0090] 6. Map Drawing Data
[0091] As described hereinabove, map drawing data is sent to increase transfer rates and reduce the load on the network when map data is sent from the map data base center 1 . This drawing data will now be described in more detail.
[0092] A. (Latitude/Longitude Format)
[0093] Latitude and longitude are expressed as follows:
Latitude: 4 byte integer with code Longitude: 4 byte integer with code
[0094] Northern latitude and eastern longitude are expressed as positive, southern latitude and western longitude are expressed as negative.
[0095] When the angle is expressed in {fraction (1/2000)} second units, the maximum value=
+180×60×60×2000=4 D 3 F 6400 hex,
[0096] the minimum value=
−+180×60×60×2000= B 2 C 09 C 00 hex , and
[0097] maximum value−minimum value=
360×60×60×2000=9 A 7 EC 800 hex.
[0098] This value is used effectively up to the uppermost bit of the 4 bytes. The number of bytes is a square, and as they are the same as the integer processing units of a computer, it is suited for use with a computer.
[0099] Making the above value correspond with the circumference of the equator (6378167 m), we obtain:
2π×6378167/360×60×60×2000=0.01546( m ).
[0100] At this resolution, when the map is displayed on the screen of a personal computer having 640 dots×480 dots (1 dot=1 pel), the length of the display in the horizontal direction is:
640×0.01546=9.8944 ( m )
[0101] which is adequate for displaying the form of buildings, etc.
[0102] To represent latitude and longitude, coded numbers and character strings may be used with other methods, and error correction codes may also be applied in the coding.
[0103] B. Communication Commands
[0104] There are the following 4 types of commands:
[0105] (1) Environment setting group
[0106] (2) Drawing command group
[0107] (3) Property specifying group
[0108] (4) Point indicating group
[0109] Most drawing commands have a property number specifying argument. Commands are either pure commands or commands associated with an argument. The commands in each group are described below.
[0110] (1) Environment Setting Group
[0111] a. Scale Reduction
[0112] (Argument)
[0113] Scale reduction: 4 byte integer with code
[0114] Shows the actual distance on the earth per 100 dots in a horizontal direction on the map display as a longitude interval.
[0115] The format is the same as that of latitude/longitude.
[0116] (Function)
[0117] When the map display application has the scale reduction data which was actually specified, it follows this data. When it does not have this data, it either displays data having an approximate scale reduction close to this value or converts this approximate data to data having the specified scale reduction.
[0118] b. Display Center Position
[0119] (Argument)
[0120] Latitude: 4 byte integer with code
[0121] Longitude: 4 byte integer with code
[0122] Displays the position of the map center.
[0123] (Function)
[0124] As shown in FIG. 12, the map display application prepares and displays map data such that the display center position Xc, Yc is in the center in the directions of latitude and longitude.
[0125] c. Display Frame Size
[0126] (Argument)
[0127] Horizontal direction size: 2 byte integer without code
[0128] Vertical direction size: 2 byte integer without code
[0129] The display frame size Xw, Yh (FIG. 12) is expressed as a number of dots.
[0130] (Function)
[0131] When the map display application displays a map in a window of another application, it shows the size of the display area (FIG. 12).
[0132] (2) Drawing Command Group
[0133] a. Graphic Drawing Point Displacement
[0134] (Argument)
[0135] Latitude; 4 byte integer with code
[0136] Longitude: 4 byte integer with code
[0137] (Function)
[0138] Specifies the start point of the next drawing command (pointer, location mark, straight line, circle, polygon). For a circle, specifies the center position.
[0139] b. Pointer
[0140] (Argument) None
[0141] (Function)
[0142] Draws a pointer mark to indicate a place in which the user is presently interested. When the image to be drawn at the point display position is not specified, this a black circle () of 16 dots×16 dots. Only one pointer can be displayed at one time by the map display application. When a pointer drawing command is issued, the map display application cancels the mark which was drawn by the immediately preceding command.
[0143] C. Location Mark
[0144] (Argument)
[0145] Property no.: Property no. without code
[0146] This is a property no. specified by 0-31.
[0147] (Function)
[0148] Draws a mark showing buildings or facilities on a map. For example, to show the location of a shop, the latitude/longitude may be given to indicate the center of the premises or the center of the part facing the road in front of the shop. When the image drawn in the mark display position is not specified, it is a black circle () of 16 dots×16 dots.
[0149] d. Straight Line
[0150] (Argument)
[0151] Property no.: Property no. without code
[0152] This is a property no. specified by 0-31.
[0153] Latitude: 4 byte integer with code
[0154] Longitude: 4 byte integer with code
[0155] Displays the position of the end of the straight line to be drawn.
[0156] (Function)
[0157] Draws a straight line from a location to? which a graphic drawing point is to be moved, or an end point of a linear part of a drawing, to a specified latitude/longitude position.
[0158] e. Circle
[0159] (Argument)
[0160] Line drawing property no.: Property no. without code
[0161] This is a line drawing property no. specified by 0-31.
[0162] Shading property no.: Property no. without code
[0163] This is a shading property no. specified by 0-31.
[0164] Radius; 1 byte integer without code
[0165] Expresses the size of a circle in the longitude direction on the screen as a number of dots.
[0166] (Function)
[0167] Draws a circle of the given radius around a location to which a graphic drawing point is to be moved.
[0168] f. Polygon
[0169] (Argument)
[0170] Line drawing property no.: Property no. without code
[0171] This is a line drawing property no. specified by 0-31.
[0172] Shading property no.: Property no. without code
[0173] This is a shading property no. specified by 0-31.
[0174] No. of points: 1 byte integer without code
[0175] Expresses the no. of points comprising the polygon.
[0176] The origin and end point are treated as separate points.
[0177] Point coordinate data:
[0178] Latitude: 4 byte integer with code
[0179] Longitude: 4 byte integer with code
[0180] The latitude/longitude pair continues for the number of points?
[0181] The coordinates of the points of the polygon are expressed by latitude/longitude.
[0182] (Function)
[0183] Draws a polygon linking each point. The start point and end point specified by the argument are treated as separate points, and the start point and end point are linked without closing the polygon when the drawing is made.
[0184] Character displays in map data may be superposed on the polygon by the map display application, and the characters may be made unerasable by shading in the polygon.
[0185] g. Character String
[0186] (Argument)
[0187] Property no.: Property no. without code
[0188] This is a property no. specified by 0-31.
[0189] Length of character strings: 1 byte integer without code
[0190] This is the no. of bytes in the character string.
[0191] Character data: 1 byte or 2 byte character×character string length.
[0192] (Function)
[0193] Displays the character string. As shown in FIG. 13, the coordinate Ps specified by displacement of the graphic drawing point is situated at the lower left corner.
[0194] h. Drawing Content Erasure
[0195] (Argument) None
[0196] (Function)
[0197] All supplementary data drawn on the map so far is erased excepting for the pointer display.
[0198] The drawing contents of the supplementary data are stored internally, and even when scroll is performed or the magnification is changed, the supplementary data is again drawn in corresponding position on the map. When a command is received to erase the drawing contents, the supplementary data contents are erased from the display, and the drawing data for re-drawing stored internally is also erased. This prevents losing the map when various supplementary data are displayed in succession.
[0199] i. Pointer Erasure
[0200] (Argument) None
[0201] (Function)
[0202] Erases the pointer display. The drawing contents apart from the pointer do not change.
[0203] (3) Property Specifying Group
[0204] a. Display Properties of Pointer Drawing
[0205] (Argument)
[0206] Display color/foreground: RGB. Each is a 1 byte integer without code
[0207] Display color/background: RGB. Each is a 1 byte integer without code
[0208] Specifies the color of the pointer display as levels of red, green and blue
[0209] Blink interval: 1 byte without code (specified in units of {fraction (1/10)} second)
[0210] Specifies the blink interval of the pointer display.
[0211] When the blink interval is not an integer/size 0, a point mark is displayed or erased. When it is erased, the display is returned to the state before drawing the point.
[0212] Alternate color flag: Integer/size 1 byte without code The following alternate colors are valid when the flag is “1”.
[0213] They are invalid when the flag is “0”.
[0214] Alternate colors/foreground: Red (R), Green (G) and Blue
[0215] (B). Each is a 1 byte integer without code
[0216] Alternate colors/background: R, G, B. Each is a 1 byte integer without code
[0217] Symbol bit data: 16 bytes
[0218] Expresses 16×16 dot symbols. The data sequence is as shown in FIG. 14.
[0219] A “1” bit draws dots in the foreground, and a “0” bit draws dots in the background.
[0220] Only dots for which the following mask bit pattern is “1” are drawn (FIG. 16)
[0221] Mask bit pattern: 16 bytes
[0222] Expresses 16×16 dot patterns. The data sequence is as shown in FIG. 14.
[0223] Only positions denoted by “1” bits are drawn according to the aforesaid symbol bit pattern (FIG. 16).
[0224] Nothing is drawn in “0” bit positions, and they therefore appear to be transparent as shown in FIG. 16C.
[0225] Hot point command: 1 byte integer without code
[0226] Positions denoted for the purpose of explanation indicate the locations of symbols.
[0227] The correspondence between values of the point indication (0 8) and positions on symbols is shown in FIG. 15.
[0228] (Function)
[0229] The color of the point display can be varied between “display color” and “alternate colors”.
[0230] When the time indicated by “blink interval” elapses starting from when display begins in either the “display color” or “alternate color”, there is a change-over to the other color, and this operation is successively repeated.
[0231] However blinking and alternate colors are used when a plurality of points are displayed, and only for the point which is finally drawn?.
[0232] b. Location Mark Symbol Specification
[0233] (Argument)
[0234] Property no.: Property no. without coding
[0235] This is a property no. specified by 0-31.
[0236] Symbol bit pattern: 16 bytes
[0237] Expresses 16×16 dot symbols. The data sequence is as shown in FIG. 14.
[0238] A “1” bit draws a dot in the foreground, and a “0” bit draws a dot in the background. Only pels for which the mask bit pattern is “1” are drawn (FIG. 16).
[0239] Mask bit pattern: 16 bytes
[0240] Expresses 16×16 dot patterns. The data sequence is as shown in FIG. 14.
[0241] Only positions denoted by “1” bits are drawn according to the symbol bit pattern (FIG. 16).
[0242] Nothing is drawn in “0” bit positions, and they therefore appear to be transparent as shown in FIG. 14C.
[0243] Point indication: 1 byte integer without code
[0244] Selects the part of a symbol indicated by the latitude and longitude position denoted by the location mark.
[0245] The correspondence between the value of the point indication and position on the symbol is shown in FIG. 15.
[0246] c. Line Display Property
[0247] (Argument)
[0248] Property no.: Property no. without code
[0249] Property no. specified by 0-31
[0250] Line width: 1 byte without code
[0251] Expresses number of dots.
[0252] Colors: Red (R), Green (G), Blue (B). Each is a 1 byte integer without code. Specifies colors as levels of red, green and blue.
[0253] Line pattern: 2 bytes without code
[0254] Only positions of “1” bits are drawn. Nothing is drawn in positions corresponding to “0” bits, and they therefore appear to be transparent.
[0255] The bit sequence and pattern for dotted lines is shown in FIG. 17.
[0256] (Function)
[0257] Specifies the width, color and pattern of straight lines, circles or polygons.
[0258] Draws a solid line when the drawing is not specified.
[0259] d. Shading Property
[0260] Property no. specified by 0-31.
[0261] Pattern: 1 byte integer×8 rows without code
[0262] Bit sequences and patterns for parallel slanting lines are shown in FIG. 18.
[0263] Display color/foreground: R, G, B, each 1 byte integers without code
[0264] Display color/background: R, G, B, each 1 byte integers without code
[0265] Specifies colors as levels of red, green and blue
[0266] (Function)
[0267] Specifies property when circles and polygons are shaded.
[0268] Display color/foreground specifies the color of positions corresponding to “1” bits in the shaded pattern.
[0269] Display color/background specifies the color of positions corresponding to “0” bits in the shaded pattern.
[0270] e. Character String Display Properties
[0271] (Argument)
[0272] This is a property no. specified by 0-31.
[0273] Font size: 1 byte integer without code
[0274] The height of a rectangle containing the character is expressed as a no. of dots.
[0275] The map display application selects and displays the font size closest to this specification.
[0276] Display direction: 1 byte integer without code Specifies the alignment direction of the character string.
[0277] 0: right direction (left to right)
[0278] 1: left direction (right to left)
[0279] 2: vertical direction (top to bottom)
[0280] Display color/foreground: R, G, B, each 1 byte integers without code
[0281] Specifies colors of characters as levels of red, green, blue.
[0282] Display color/background: R, G, B, each 1 byte integers without code
[0283] Specifies colors of character backgrounds as levels of red, green and blue.
[0284] 4. Point Specifying Group
[0285] a. Point Specification
[0286] (Argument)
[0287] Latitude: 4 byte integer with code
[0288] Longitude: 4 byte integer with code
[0289] (Function)
[0290] Issued when the specifies a map in the map drawing application using a pointing device.
[0291] C. Limitations of Drawing
[0292] ( 1 ) Upper/Lower Relation on Display
[0293] When a plurality of display elements are superposed, the elements drawn by the latest command will be on top, and elements already drawn will be hidden. For example when a shaded polygon is superposed on a character display, the characters will be no longer be visible, so the sender of additional drawing information must control which of the two appears on top. However pointers are always uppermost and are never hidden by other drawing elements.
[0294] (2) Storage of Display Contents
[0295] The map display application must store received drawing group commands so that additional drawing information can be redrawn when the user performs scrolling or zoom-in.
[0296] There is however generally no need to store drawing group commands before receiving drawing content erasure commands.
[0297] (3) Types of Display Properties
[0298] To facilitate creation of applications, up to 32 types of display properties may be used on one occasion.
[0299] Next, the registration of additional information in the map information system according to this invention will be described with reference to FIG. 19 and FIG. 20.
[0300] First, describing the general registration procedure, the home page designer accesses a map information data base 23 via the INTERNET 25 , and acquires an additional drawing/editing application for registration. This uses applets which distribute applications via networks that are already commercialized such as JAVA and Active X. Alternatively, the home page designer may start an application already in the home page designer's terminal. Next, the display position is moved using a map shift button 38 , and a desired map is displayed by operating an enlargement button 36 or reduction button 37 . Additional elements are drawn on this map using the additional drawing tools 28 to 35 and 39 to 41 . After editing of the additional drawing elements is complete, the elements are registered in the additional information data base.
[0301] The details of the method of editing this additional information will be described with reference to FIG. 21A- 21 H. FIG. 21A- 21 H describe the registration application operating screen. First, in FIG. 21( a ), an area specifying tool 28 is selected. The selection of tools is made by clicking a button corresponding to the tool with the mouse. When the tools 28 to 35 are selected, the selection is shown by a change in the display such as the background color. When a cursor 43 is brought over an additional drawing element which has already been written on the map, in this case the character string “ABC Shop”, and the mouse button is clicked, the character string is selected. Four small squares are displayed at the four corners of the character string to show the selection. When the mouse is moved while the mouse button is depressed, the character string is dragged with the cursor 43 , and when the mouse button is released, the character string is moved to the new position. When an erase button 39 is pressed, the character string is erased.
[0302] In FIG. 21B, the line tool 10 is described. When the line tool is selected, a cursor 44 becomes a cross as shown in the diagram. When the mouse button is pressed at a point A and moved to a point B while it is still depressed, a line is drawn from the point A to the point B as shown in the figure. When the mouse button is released, this line is registered as one dimensional information.
[0303] In FIG. 21C, the square tool 32 is described. When the square tool is selected, a cursor 45 becomes a cross as shown in the diagram. When the mouse button is pressed at a point C and moved to a point D while it is still depressed, a square is drawn having a diagonal between the points C and D as shown in the figure. When the mouse button is released, this line is registered as two dimensional information.
[0304] In FIG. 21D, the shift tool 34 is described. When the shift tool is selected, a cursor 46 assumes the shape of a hand. When the mouse button is pressed at a point E and moved to a point F while it is still depressed, the map display is scrolled by an amount corresponding to a vector EF.
[0305] In FIG. 21E, the character input tool is described. When the character input tool is selected, a cursor 47 becomes the shape of a letter I. When characters are then input from the keyboard, the input characters are drawn on the map.
[0306] In FIG. 21F, a circle tool 30 is described. When the circle tool is selected, a cursor 48 becomes a cross. When the mouse button is pressed at a point G and moved to a point H while it is still depressed, a circle is drawn inside a square having a diagonal from the point G to the point H, as shown in the figure. When the mouse button is released, this circle is registered.
[0307] In FIGS. 21G and 21H, a polygon tool 33 is described. When the polygon tool is selected, a cursor 49 becomes a cross. When the mouse button is pressed at a point I, released, then pressed at a point J, released, and the same procedure is repeated at points K,L, lines IJ, JK and KL are drawn as shown in FIG. 21G. When the mouse button is quickly pressed twice, a polygon is drawn having apices I,J,K,L as shown in FIG. 21H, and this polygon is registered.
[0308] In FIG. 22, a color specifying method is described. When a color specifying button 35 is pressed, a window shown in FIG. 22 is displayed. Small color specifying squares are arranged in rows in the window, and when the mouse is clicked on one of the squares, the color of that square is selected and the window closes. Characters, lines, circles, polygons and squares which are specified subsequently are drawn in the specified color.
[0309] In FIG. 23A and FIG. 23B, a method of selecting line types is described. When the cursor is brought over the broken line selection button 40 , and the mouse button is pressed, a pop-up menu is displayed as shown in FIG. 23A, and the line corresponding to the broken line type selected, is displayed with black and white reversed. In this example, the uppermost solid line is selected.
[0310] Next, the cursor is brought over a line type different from the type which was first inverted with the mouse button still depressed. Only the line beneath the cursor is then displayed with black and white reversed, as shown in FIG. 23B. When the mouse button is released, the line type with which the cursor was aligned is selected, and all lines drawn subsequently are drawn with this line type.
[0311] In FIG. 24A and 24B, a method of selecting line thickness is described. When the cursor is brought over a line thickness selecting button 41 , a pop-up menu is displayed as shown in FIG. 24A, and the line type corresponding to the selected line thickness is displayed with black and white reversed. This line thickness is then selected by the same procedure as in the pop-up menus of FIG. 23A and 23B.
[0312] When all the elements have been drawn, they are then registered in the additional information center. The registration procedure is performed for example using a pull-down menu 50 from a menu bar 51 , as shown in FIG. 25. When registration is selected from the pull-down menu, the following details are registered in the additional information data base 24 from the home page designer terminal 26 shown in FIG. 19.
[0313] Map center latitude and longitude
[0314] Map scale
[0315] Map height and width
[0316] Edited additional drawing elements
[0317] When registration in the additional information data base is complete, a window shown in FIG. 28 is displayed, and a registration number for the information automatically assigned by the additional information data base is displayed.
[0318] When the home page designer presses a button linking to a map, this number is used to call the map information data base center. An example in HTML (HyperText Markup Language) is shown below.
[0319] <A href=“http://www.mapserver.com/cgi-bin/displaymap?1234567890”><IMG src=“button.gif”></A>
[0320] When this example is displayed on a home page, it appears as shown in FIG. 29.
[0321] The above is a description using the additional information data base. FIG. 28 shows an example where the additional information data base is not used. In this case, the details superposed on the map are stored by the home page server, and are written in a text file using the HTML which describes the home page. A function is therefore provided to display the editing results as a character string instead of the registration function in the additional drawing editing application.
[0322] This will be described with reference to FIG. 29 and FIG. 30. The pull-down menu 50 is displayed from the menu bar 51 , and data edit is selected. This causes a window 53 shown in FIG. 30 to be displayed, and the editing results are displayed as a character string in a text display 52 .
[0323] To represent the editing results as a character string, they are joined to a statement having a unique function. An example of the statement format will be described.
[0324] (1) Map: Scale Level, Latitude, Longitude, Width, Height
[0325] Specifies the map display method.
[0326] Scale level: shows the map scale level, e.g. 0 is the widest level and 10 is the most detailed Latitude, longitude: latitude and longitude of map center (0.1 degree units)
[0327] Width, height: shows width and height of map image in pixel units
[0328] (2) Color: R,G,B
[0329] Colors are specified in terms of red, green and blue components. All drawing specification statements written subsequently are drawn in the colors specified here.
[0330] R: red (0 to 255)
[0331] G: green (0 to 255)
[0332] B: blue (0 to 255)
[0333] (3) Line Type: n
[0334] Specifies the line type. Line types in line drawing statements written after this statement, follow the specified line type.
[0335] n: 0=solid line, 1=fine dotted line, 2=dot-dash line, 3=rough dotted line
[0336] (4) Width: n
[0337] Specifies the line width. Line widths of line drawing statements written after this statement, and line widths of outlines drawn by rectangle, ellipse and polygon drawing statements, follow the line width specified here.
[0338] n: shows line width in number of pixels
[0339] (5) Line: x1,y1,x2,y2
[0340] Specifies a line drawing:
[0341] x1: Latitude of line start latitude (0.1 degree units)
[0342] y1: Longitude of line start point (0.1 degree units)
[0343] x2: Latitude of line end point (0.1 degree units)
[0344] y2: Longitude of line end point (0.1 degree units)
[0345] (5) Oval: x1,y1,x2,y2
[0346] Specifies ellipse drawing. Draws an ellipse touching the sides of a rectangle of which one diagonal is a line connecting a position coordinate 1 represented by (x1,y1) and a position coordinate 2 represented by (x2,y2).
[0347] x1: Latitude of position coordinate 1 (0.1 degree units)
[0348] y1: Longitude of position coordinate 1 (0.1 degree units)
[0349] x2: Latitude of position coordinate 2 (0.1 degree units)
[0350] y2: Longitude of position coordinate 2 (0.1 degree units)
[0351] (6) Rect: x1,y1,x2,y2
[0352] Specifies rectangle drawing. Draws a rectangle of which one diagonal is a line connecting a position coordinate 1 represented by (x1,y1) and a position coordinate 2 represented by (x2,y2).
[0353] x1: Latitude of position coordinate 1 (0.1 degree units)
[0354] y1: Longitude of position coordinate 1 (0.1 degree units)
[0355] x2: Latitude of position coordinate 2 (0.1 degree units)
[0356] y2: Longitude of position coordinate 2 (0.1 degree units)
[0357] (7) Poly: c1,y1,dx2,dy2,dx3,dy3 . . .
[0358] Specifies a polygon drawing. A position coordinate represented by (x1,y1) is the start point, and the following dx2,dy2,dx3,dy3 . . . form pairs which represent the coordinates of the apices of the polygon. It should be noted that these pairs do not correspond to latitude and longitude, but to differences from the coordinates represented by the immediately preceding pair. For example, dx2,dy2 represents the preceding start point, and the difference in latitude and longitude from the following apices of the polygon. Expressed as an equation, when the coordinates of the polygon apices (latitude, longitude) are
[0359] (x1,y1),(x2,y2),(x3,y3) . . .
[0360] dx2=x2−x1
[0361] dy2=y2−y1
[0362] dx3=x3−x2
[0363] dy3=y3−y2
[0364] Here, all coordinate values are expressed in 0.1 degree units.
[0365] For example, writing a map link in the HTML format using the editing results shown in FIG. 30:
[0366] <FORM METHOD=“POST”
[0367] ACTION=“http://www.mapserver.or.jp/cgi-bin/showmap”>
[0368] <INPUT TYPE=HIDDEN” NAME=“DISP_PARAM”
[0369] VALUE=“map;7,135020459,3404301,400,300;poly:135023493,34 05320,233,0,3-30,-43,3;”>
[0370] <INPUT type=“IMAGE” name=“map” src=“button.gif”>
[0371] </FORM>
[0372] The information displayed by the web browser according to this statement is the same as that of FIG. 27. When the button shown is pressed, information to the effect that the parameter having the name
[0373] “DISP_PARAM” is the character string:
[0374] “map:7,135020459,3404301,400,300;poly:135023493,3405320, 233,0,3-30,-43,3;” is sent to the map information data base using the format “FORM”. In accordance with the value of the parameter received, a map is drawn with additional information superposed, and map image data is sent to the user's web browser. | To provide a method and device for displaying map data and related data permitting easy enlargement of the scope of application of map-based data services.
Additional drawing data for superposing on a map displayed on a screen, and setting data for specifying a map display, are sent and received between different application programs using inter-application exchange in a standard data format. Required map data and related data are displayed on the screen using a first application program having a function for converting received additional drawing data and setting data to the aforesaid data format and transmitting it by inter-application exchange, then using a second application program MPapln which displays a map on the display screen according to the setting data transmitted by the first application program and displays additional data on the screen map corresponding to the additional drawing data. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
U.S. patent application Ser. No. 208,784, filed Nov. 20, 1980, entitled "Text Keyboard Mismatch Operation", and having John A. Aiken, Jr. as inventor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the correction of keyboard input text as stored for display or hard copy printing, and more particularly, to the selection from among multiple keyboard character sets for correct matching.
2. Description of Prior Art
Prior art relating to the present invention includes:
(a) Key-to-display systems such as IBM OS/6 System in which an 8-bit extension of the 7-bit magnetic card code was utilized wherein a keyboard number for a document was saved in a document master format and was made operator-selectable. For multi-line portions of the document, where another keyboard character set was required, provision was made for a change of the keyboard and a format change. One problem with the OS/6 System was that an operator had to either find and inspect the prior format or had to remember the identification of the active input keyboard in order to know what key to press for inclusion in the text of a given desired graphic.
Further, the 6-byte sequences utilized in the OS/6 made for an inefficient use of storage for words or phrases, especially in limited areas such as margin text.
Further, if the operator changed the keyboard specified in the master format or in a format change, the printed/displayed text would also change, since the internal code points were not retranslated. The same result would take place if a block of text were moved to a section of the document keyed under a different format.
(b) The IBM 5520 System eliminated some of the above problems attendant the OS/6 System by adopting specific EBCDIC codes as its internal text representation. This required each point to be self-defining. Thus, keyboarding was strictly an input function and the data steam was independent of the active input keyboard. At any time, the operator could change the input keyboard without affecting the existing text. However, the IBM 5520 approach involved difficulty in communicating with other devices such as the OS/6 System.
OBJECTS OF THE INVENTION
It is accordingly an object of the present invention to further facilitate the correction of texts that have been input by way of keyboard to storage preparatory to hard copy printout or other display.
It is a further object of this invention to provide for keyboard mismatch correction to facilitate the insertion of text or other graphics into a data system previously entered into storage by way of keyboard input.
SUMMARY OF THE INVENTION
These and other objects and advantages are achieved with the present method and apparatus. Briefly, there is provided a word processor wherein a text stream, input by way of a keyboard, is stored and is displayed to an operator. Different keyboard character sets are identified as available for use upon keyboard select commands. In accordance with the invention, means are provided for signalling the location at which an insert of one or more characters is to be added to the data stream. Means are provided to compare (a) the active document keyboard character set with (b) the unique input keyboard character set to produce a first output if the compared sets are the same and to produce a second output if the compared sets are different. Means are provided responsive to the first output to direct the insert into the text stream without the addition of character set change codes. Means responsive to the second output enter a character set change code immediately upstream of said location to indicate the keyboard character set of said insert, then the insert is entered and a further character set change code is entered, if necessary, immediately downstream of said insert to indicate the keyboard character set for the downstream text.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and advantages of the invention will become apparent from the following, more particular description of a preferred embodiment, as illustrated in the accompanying drawings wherein:
FIG. 1 is a block diagram of the system embodying the present invention.
FIG. 2 is a block diagram of the processor shown in FIG. 1.
FIG. 3 is a flow diagram indicating the sequence of operations in the system of FIG. 1.
FIG. 4 illustrates a series of steps involved in the operations depicted in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a portion of the text processing system is shown, including a processor 10 to which is connected a bus 12 leading from a keyboard 14. Character data generated by manual actuation of keyboard 14 applies character-related signals to processor 10 which provides on an output memory bus 16 a data stream which the characters selected by actuation of keyboard 14 appear suitably encoded.
Memory bus 16 extends to a memory unit 20, to a display unit 22, to a diskette unit 24 and to a printer 25.
Memory 20 includes a text storage buffer 26 which serves to store the coded data stream comprising the text input through the keyboard 14. Included in the text storage buffer 26 is a storage section for the identity of the active document format which contains the active document keyboard character set namely, in portion 28.
A text storage buffer control block 30 is linked to buffer 26 and includes a cursor control section 32.
A text storage buffer manager 34 is linked by channel 36 to the control block 30, by channels 38 to the buffer 26 and by channels 40 and 42 to a keystroke service routine section 44.
A keystroke control routine block 46 is provided for the keystroke service routine section 44 to select the appropriate routine for the entered keystroke. The control block 30 is connected to section 44 by channel 48. Buffer 26 is coupled by channel 50 to a display access method block 52 which is coupled by way of channel 54 to a display refresh buffer 56. A display control block 58 is coupled by channel 60 to the display access method block 52.
In accordance with the present invention, a channel 62 is connected from the active document format storage 28 of buffer 26 to the keystroke service routine section 44. Further, an input keyboard character set (KB/CS) block 64 stores the identity of any desired input keyboard character set of keyboard 14 and is connected by way of channel 66 to the keystroke service section 44.
The display access method block has corresponding access method blocks for the diskette 24 and printer 25. Each of the blocks serves as an interface to the corresponding unit.
The display refresh buffer 56 contains the actual text which is shown on display 22 while the buffer 26 contains all of the display text plus control data.
In operation of the system of FIG. 1, the encoded data stream on memory bus 16 is stored in the text storage buffer 26. In the process of correction and editing, the contents of the text storage buffer 26 i.e., selected portions or lines of a page, are presented on display unit 22. Stored in active document format section 28 is the code designating the keyboard character set that was employed in the production of the coded data stream appearing on memory bus 16 leading from processor 10 and applied from text storage buffer 26 to display unit 22 for edit.
If it is necessary, for example, to insert a graphic item into the text displayed on unit 22, then the present invention is employed. A cursor, conventionally available on such display systems, is placed below the character on display 22 at the location immediately preceding which an insert is to be made. The input keyboard character set identification of which the graphic item to be inserted forms a part, is applied by way of channel 66 to the keystroke service routine section 44 then which causes a comparison between the identification of the input keyboard character set stored in block 64 and the active document format keyboard character set in storage 28.
If, as a result of the comparison, it is found that the keyboard character sets are the same, then the desired insert graphics are input through keyboard 14. The insert will appear at the selected location without the need for inserted character set change codes.
If, as a result of the comparison, it is found that the input keyboard character set stored by block 64 differs from the active document format keyboard character set in storage 28, then a character set change code for the input keyboard character set is inserted by the keystroke service routine into the data stream immediately ahead of the location of the cursor and a second character set change code following the first code is inserted in the data stream designating the active document format keyboard character set as stored in storage 28. The graphics desired are then inserted between the character set change codes.
Referring to FIG. 2, the processor 10 is further detailed to show typical logic hardware elements as found in such processors. The processor may be a commercially available unit, such as from Intel Corporation and identified by the number 8086. Typically the processor includes a control logic unit 70 which responds to interrupts on a device buss 71 from the keyboard 14. The control logic unit 70 is also connected to a data and address bus 82 interconnected to various other logic units of the processor 10.
In response to a fetch instruction from the random access memory 20, the control logic unit 70 generates control signals to other logic elements of the processor. These control signals are interconnected to the various elements by means of a control line 72 which is illustrated directly connected to an arithmatic logic unit 73 and identified as a "control" line 72 to other elements of the processor. Synchronous operation of a control unit 70 with other logic elements of the processor 10 is achieved by means of clock pulses input to the processor from an external clock source on a clock line 74. Line 74 is also known interconnected to other logic elements of the processor 10 detailed in FIG. 2.
Data and instructions to be processed in the processor 10 are input through a bus control logic unit 76. Data to be processed may also come from program input/output control logic unit 77. The bus control logic 76 connects storage elements of the random access memory 20 and receives instructions for processing data received from the input/output control 77 or received from the random access memory 20. Thus, the input/output control 77 receives data from the keyboard 14 or the random access memory 20 while the bus control logic 76 receives instructions and/or data from the same memory. Note the different storage sections of the random access memory 20 identifiable for instruction storage and data storage.
Device control information from the processor 10 is output through the program input/output controller 77 over a data bus 80. Input data on the data bus 80 from the keyboard 14 is processed internally through the processor by instructions on the bus 82 to temporary scratch registers 83. The arithmetic logic unit 73, in response to a control signal on line 72 and in accordance with instructions received on input/output data bus 80, performs computations and the results can be stored in the temporary scratch registers 83. Various other tranfers of data between the arithmetic logic unit 73 and other logic elements of the processor are of course possible. Such additional transfers may be to a status register 85, data pointer register 86 or a stack pointer register 87. A program counter 88 is also connected through the data stream bus 82 to various other logic elements in the processor 10.
A particular operating sequence for the processor 10 is determined by instructions and data on the memory bus 16 and input data on the bi-directional bus 80. As an example, in response to received instructions, the processor 10 transfers data stored in the scratch registers 83 to one of the registers 85, 86 or 87. Such operations of processors as detailed in FIG. 2 are considered to be well known and understood by one or ordinary skill in data processing field. A detailed description of each operation of the processor in FIG. 2 is not deemed necessary for a full understanding of the present invention as claimed.
In FIG. 3, a flow chart illustrates the steps followed in the keystroke service routine (KSR) section 44 of FIG. 1 for graphic insertion operations.
The keystroke service routine desired for graphic insertion utilizes service routines stored in the text storage buffer manager 34. The KSR routine 100 involves a first step 102 in which the code for the input keyboard character set is fetched from storage block 64. Next, the active document format keyboard character set is fetched from storage block 28. The two sets are then compared in step 106. If they are the same, then, as indicated by a first output link 108, the graphic character is merely inserted ahead of the cursor location as indicated in step 110. This updates the display, following which the system returns to the start condition, as indicated by step 112.
If, in the comparison step 106, it is found that the input keyboard character set and the active document format keyboard character set differ, then a second output link is taken to step 114 where a character set code (SCG) is inserted in the data stream for the input keyboard character set. Next, a check is made to see if the cursor is at the location in the data stream at which the active document format keyboard character set change code had previously been inserted as indicated by step 116. If the cursor is at the code location, then the graphic is inserted as indicated by link 118.
If a comparison in step 116 is negative, then a code for the active document format keyboard character set is inserted after the code previously inserted for the input keyboard character set as indicated in step 120. The cursor is then placed on the last inserted keyboard character set change code SCG, namely, the active document keyboard format character set as indicated in step 122. Thereupon, the desired graphics are inserted, as indicated in step 110, to update the display. The system is then returned to its normal state.
As the process described in reference to FIG. 3 is repeated there may be the occurrence of contiguous character set change codes in the text stream. Should this occur, the upstream character set change codes are deleted leaving the last downstream code.
The system and examples of its operation are further illustrated by the steps depicted in FIGS. 4A-J. Step 4A indicates that the input keyboard 14 is to be used to insert a graphic character based upon a keyboard character set Y.
Step 4B illustrates a portion of the data stream that has been input in the document format keyboard character set X. By way of example only, keyboard character set X may include standard alphanumeric symbols while keyboard character set Y may contain "greek" alphabet symbols. The insert location in the data stream appearing on display 22 is at a point between the characters A and B, between the document text segments 130 and 132. Preparatory to such insertion, the cursor 134 is manipulated by the operator to a location under the character B. In step 4C the operator depresses an input key for a graphic symbol, for example, Δ, which is one of the symbols in set Y and not in set X.
Step 4D indicates that the symbol Δ has been inserted into the data stream between the SCG code for the keyboard character set Y and the SCG code for the keyboard character set X. In step 4E, manual depression of, for example, the key D in the input keyboard character set Y results in step 3F, wherein the symbol D is inserted into the document stream after the symbol Δ.
It will be noted that the data stream signal 132 is shifted from one step to the right from the locations in step 4B to the locations in steps 4D and 4F. That is, the codes and desired graphics are inserted into the stream and the rest of the stream is shifted downward.
Step 4G indicates that the input keyboard is changed to keyboard character set Z, which by way of example only, may include text processing symbols.
As indicated in step 4H, no codes are inserted into the data stream at this point since no graphic is inserted when changing the input keyboard character set from Y to Z.
However, as indicated in step 4I, if the input key is depressed to insert, for example, , as found only in keyboard character set Z, then, as indicated in step 4J, the symbol is inserted into the data stream, along with the code for the keyboard character set Z immediately preceding the symbol . Again, the cursor is shifted downstream, along with the rest of the data stream. Two more symbol slots accommodate the keyboard character set SCG code Z and the desired graphic symbol . Note that another SCG code was not inserted after the symbol since the cursor was already on an SCG code.
When the keyboard character set change code is encountered and one of the following characters is not on the print head during a print operation, the printer is stopped and the operator is alerted to change the print head for the new character set. The operator must make such a change whenever there is a character in the data storage set not included on the installed print head.
Although one embodiment of the invention has been illustrated in the accompanying drawings and described in the foregoing Description of the Preferred Embodiment it will be understood that the invention is not limited to the embodiment disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention. | In a word processor where a text stream is input by way of a keyboard for storage and is displayed to an operator and wherein different keyboard character sets are available, means are provided for signalling the location at which an insert of one or more characters is to be added to the text stream. Means are provided for comparing the active keyboard character set in the text stream immediately preceding the location to the keyboard character set of the insert to produce a first output when the keyboard character sets compare and a second output when the keyboard character sets do not compare. The insert is entered into the text stream at the location upon generation of the first output. Upon generation of the second output a character set change code is added immediately upstream of said location to indicate the keyboard character set for the insert. Immediately following the insert a character set change code is added to indicate the keyboard character set for the text shown immediately following the insert. | 6 |
BACKGROUND
The present invention relates generally to semiconductor device manufacturing and, more particularly, to a niobium thin-film stress relieving layer for thin-film solar cells.
Solar cells are photovoltaic devices that convert sunlight directly into electrical power. Generally, p-n junction based photovoltaic cells include a layer of an n-type semiconductor in direct contact with a layer of a p-type semiconductor. When a p-type semiconductor is positioned in intimate contact with an n-type semiconductor, a diffusion of electrons occurs from the region of high electron concentration (the n-type side of the junction) into the region of low electron concentration (the p-type side of the junction). However, the diffusion of charge carriers (electrons) does not happen indefinitely, as an opposing electric field is created by this charge imbalance. The electric field established across the p-n junction induces a separation of charge carriers that are created as result of photon absorption.
The most common type of solar cell material is silicon, which is in the form of single or polycrystalline wafers. However, the cost of electricity generated using silicon-based solar cells is still higher than the cost of electricity generated by the more traditional methods. Since the early 1970's there has been an effort to reduce cost of solar cells for terrestrial use. One way of reducing the cost of solar cells is to develop low-cost, thin-film growth techniques that can deposit solar cell quality absorber materials on large area substrates and to fabricate these devices using high-throughput, low-cost methods.
The increased interest in thin-film photovoltaics has been due primarily to improvements in conversion efficiency of cells made at the laboratory scale, with the anticipation that manufacturing costs can be significantly reduced compared to the older and more expensive crystalline and polycrystalline silicon technology. The term “thin-film” is thus used to distinguish this type of solar cell from the more common silicon based cell, which uses a relatively thick silicon wafer. While single crystal silicon cells still demonstrate the best conversion efficiency to date at over 20%, thin-film cells have been produced which can perform close to this level. As such, performance of the thin-film cells is no longer the major issue that limits their commercial use. Instead, primary factors now driving the commercialization of thin-film solar cells include cost, manufacturability, reliability and throughput, for example.
SUMMARY
In one aspect, a method of forming a photovoltaic device includes forming a thermal stress relieving layer on top of a substrate; forming a sacrificial back electrode metal layer on the thermal stress relieving layer; forming a semiconductor photon absorber layer on the sacrificial back electrode metal layer; and reacting the absorber layer with substantially an entire thickness of the sacrificial back electrode metal layer, thereby forming a back ohmic contact comprising a metallic compound of the sacrificial back electrode metal layer and the absorber layer, in combination with the thermal stress relieving layer.
In another aspect, a method of forming a photovoltaic device includes forming a thermal stress relieving layer on top of a substrate; forming a sacrificial back electrode metal layer on the thermal stress relieving layer; forming a solution-based, p-type semiconductor photon absorber layer on the sacrificial back electrode metal layer; annealing the absorber layer so as to react substantially an entire thickness of the sacrificial back electrode metal layer with the absorber layer, thereby recrystallizing the absorber layer and forming a back ohmic contact comprising a metallic compound of the sacrificial back electrode metal layer and the absorber layer, in combination with the thermal stress relieving layer; forming a transparent, n-type semiconductor layer over the absorber layer so as to define a p-n junction therebetween; and forming a transparent top electrode on the n-type semiconductor layer.
In another aspect a photovoltaic device includes a thermal stress relieving layer on top of a substrate; a back ohmic contact on the thermal stress relieving layer; and a p-type semiconductor photon absorber layer on the back ohmic contact; wherein the back ohmic contact comprises a metallic compound of the sacrificial back electrode metal layer and the absorber layer, in combination with the thermal stress relieving layer, and wherein the thermal stress relieving layer has a substantially similar thermal expansion coefficient with respect to the substrate and the absorber layer and a lower Young's modulus with respect to the sacrificial back electrode metal layer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a cross sectional schematic view of a thin-film photovoltaic cell;
FIG. 2 is a cross sectional view of various photovoltaic cell layers, such as the cell schematically depicted in FIG. 1 ;
FIG. 3 is a scanning electron micrograph (SEM) image of a molybdenum back electrical contact layer and a CIGS absorber layer formed thereon;
FIG. 4 is another scanning electron micrograph (SEM) image of a molybdenum back electrical contact layer and a CIGS absorber layer formed thereon;
FIG. 5 is a flow diagram illustrating a method of forming a solar cell having a thin-film stress relieving layer, in accordance with an exemplary embodiment; and
FIG. 6 is a cross sectional schematic view of a thin-film photovoltaic cell, such as formed in accordance with the processing illustrated in FIG. 5 .
DETAILED DESCRIPTION
With respect to thin-film photovoltaic cells as discussed above, FIG. 1 is a cross sectional schematic view of one exemplary type of cell 100 . The thin-film cell 100 is fabricated on a substrate 102 , such as a sheet of glass, a sheet of metal, an insulating foil or web, or a conductive foil or web, for example. A back electrical contact layer 104 is deposited on the substrate 102 , and serves as an ohmic contact for the cell 102 . One example of such a back contact material layer is molybdenum (Mo), which is currently perhaps the most commonly used material, having a thickness of about 0.5 microns (μm) to about 2.0 μm. A photon absorber layer 106 is formed on the back contact layer 104 . In such a thin-film structure, the absorber layer 106 may be a copper-indium-gallium-sulfide/selenide (CIGS) or copper-zinc-tin-sulfide/selenide (CZTS), p-type semiconductor absorber layer, having an exemplary thickness of about 0.5 μm to 3 μm thick.
As further illustrated in FIG. 1 , an n-type semiconductor layer 108 is formed over the absorber layer 106 so as to define a p-n junction therebetween. Relatively speaking, the n-type layer 108 is much thinner than the absorber layer (e.g., about 60 nanometers (nm)), and is desirably highly transparent to solar radiation. An exemplary material for the n-type layer 108 is cadmium sulfide (CdS). Formed upon the n-type layer 108 is a thin, (e.g., about 0.2 μm to about 0.6 μm) transparent top electrode 110 , which completes a functioning cell. The top electrode 110 is both highly conductive and as transparent as possible to solar radiation. Exemplary top electrode materials in this regard include transparent conductive oxides (TCO) such as, for example, zinc oxide (ZnO), indium tin oxide (ITO), aluminum doped ZnO, etc. An optional antireflection (AR) coating 112 is also depicted on the solar cell structure 100 of FIG. 1 , which can allow a significant amount of extra light into the cell 100 . Depending on the intended use of the cell 110 , the AR coating 112 may be deposited directly on the top electrode 110 (as illustrated), or on a separate cover glass, or both.
In operation, some photons 114 in sunlight pass through the AR coating 112 , top electrode 110 and n-type layer 108 , and are absorbed by the p-type semiconductor absorber layer 106 . Other photons, depending on the photon energy, may reflect off the cell surface or pass completely through absorber layer 106 . In the latter case, it is possible that photos may be reflected back from the back electrical contact layer 104 and then absorbed by the absorber layer 106 . In any case, photons that are absorbed by the absorber layer 106 give their energy to the crystal lattice of the absorber layer 106 , in turn knocking electrons loose from their atoms. Due to the composition of the cell 100 , the electrons flow in a single direction, and therefore are capable of providing direct current (DC) electricity to an exemplary load 116 .
In more structural detail, FIG. 2 is a cross sectional view of various photovoltaic cell layers, such as the cell 100 schematically depicted in FIG. 1 . For ease of illustration, similar layers in FIGS. 1 and 2 are designated with the same reference numeral. The exemplary substrate 102 shown in FIG. 2 may be formed from a material such as glass, metal foil or plastic. In the case of glass, the substrate 102 has a thermal expansion coefficient (TEC) of about 9×10 −6 /K and a Young's modulus of about 80 gigapascals (GPa). The molybdenum back electrical contact layer 104 has a TEC of about 4.8×10 −6 /K, a Young's modulus of about 329 GPa, and an electrical resistivity of about 5×10 −8 /Ω·m (ohm-meters). In addition, the relatively thick CIGS/CZTS absorber layer 106 has a TEC of about 9×10 −6 /K, a Young's modulus of about 60 GPa.
Physical vapor deposition (PVD) based processes, and particularly sputter based deposition processes, have conventionally been utilized for high volume manufacturing of such thin film layers with high throughput and yield. More recently, techniques for depositing the CIGS/CZTS absorber layer 106 via solution (instead of by traditional vacuum based co-sputtering and co-evaporation deposition processes) have attracted increasing attention. Advantages associated with such solution-based deposition techniques include lower-initial capital cost, higher throughput, and higher material utilization rate.
For the traditional vacuum based deposition processes, the deposition takes place at an elevated temperature, e.g., about 400° C. to about 600° C., to form polycrystalline semiconductors with large grain size. The cooling process after deposition could lead to high thermal stress at CIGS/CZTS-Mo interface, which in turn can lead to severe film cracking issues. For low-temperature, solution-based processes, a rapid high temperature annealing step after deposition is necessary to transform initially deposited amorphous or nanocrystalline films into high quality, polycrystalline films for solar cell applications. However, such a rapid heating/cooling process may also lead to very high thermal stress at CIGS/CZTS-Mo interface, which in turn can lead to severe film cracking issues. For example, FIG. 3 is a scanning electron micrograph (SEM) image of a molybdenum back electrical contact layer 302 and a CIGS absorber layer 304 formed thereon. However, due to the thermal stress from annealing, the CIGS absorber layer 304 suffers from cracking and delamination, as indicated at the arrow.
Other issues associated with rapid high temperature annealing of solution deposited semiconductor films are illustrated in FIG. 4 . As shown in the SEM image of FIG. 4 , a molybdenum back electrical contact layer 402 has a CIGS absorber layer 404 formed thereon. FIG. 4 also depicts a CdS n-type layer 406 on the CIGS layer 404 , and a ZnO/TCO top electrode 408 on the CdS n-type layer 406 . Although the CIGS layer 404 is not cracked in this particular image, multiple voids/defects 410 between the CIGS layer 404 and the molybdenum back electrical contact layer 402 are evident. These voids and defects could adversely affect both the power conversion efficiency of associated solar cells and the yield of integrated solar modules.
In terms of surface delamination energy, which is a function of material hardness, thickness, and thermal expansion coefficient, a molybdenum back electrical contact layer is not well matched with, for example, a glass substrate and a semiconductor CIGS/CZTS absorber layer. Relatively speaking, molybdenum has a lower CTE with respect to glass and CIGS/CZTS and a high modulus. On the other hand, molybdenum works well as a back contact metal since the reaction between molybdenum and (for example) selenium in CIGS produces a layer of MoSe 2 , which forms an ohmic contact.
Accordingly, the exemplary embodiments disclosed herein address the above described problems by introducing a thermal stress relieving layer between the solar cell substrate and a molybdenum-based compound. Initially, several materials for the stress relieving layer were considered based on the following desired characteristics: (1) a TEC of about 9×10 −6 /K to match up with glass and CIGS/CZTS; (2) a relatively low modulus; (3) low resistivity; (4) high melting temperature; (5) low reactivity with selenium/sulfur; and (6) low cost, high abundance.
Based on these criteria, titanium (Ti), while having desirable TEC, modulus and resistivity values, is hard to form a low-stress, thick film, has high reactivity with Se, and is expensive. Titanium nitride (TiN) also has a matching TEC but has a high modulus and is a difficult material for forming a thick film. Platinum (Pt), while having a suitable TEC, is an expensive material for photovoltaic applications. Vanadium (V) has compatible TEC, modulus and resistivity values, but like titanium, has high reactivity with Se.
In contrast, niobium (Nb), has a compatible TEC (about 7.4×10 −6 /K), low modulus (about 105 GPa), and resistivity (about 15×10 −8 /Ω·m). In addition, niobium has a melting temperature of 2468K, has low reactivity with selenium, is easy to form a low-stress thick film, and has a cost comparable with that of molybdenum.
Referring now to both FIGS. 5 and 6 , FIG. 5 is a flow diagram illustrating a method 500 of forming a solar cell having a thin-film stress relieving layer, in accordance with an exemplary embodiment. FIG. 6 is a cross sectional schematic view of a thin-film photovoltaic cell 600 , such as formed in accordance with the processing illustrated in FIG. 5 .
As illustrated in block 502 of FIG. 5 , a conductive thermal stress relieving layer is deposited on a substrate. In the exemplary embodiment of FIG. 6 , the substrate 602 a material such as glass, metal foil or plastic. In the case of glass, the substrate 602 has a TEC of about 9×10 −6 /K and a Young's modulus of about 80 GPa. In contrast to a thick molybdenum layer formed directly on the substrate, the cell 600 has a niobium thermal stress relieving layer 604 formed on the substrate 602 , which is thick enough to provide low resistance for electron transport. In an exemplary embodiment, the Nb thermal stress relieving layer 604 may have a thickness of about 0.5 μm to about 2.0 μm. After deposition of the Nb thermal stress relieving layer, a thin back electrode metal layer is formed directly on the thermal stress relieving layer as indicated in block 504 of FIG. 5 . As indicated above, molybdenum is still a desirable metal for this purpose. However, in contrast to conventional solar cell designs, the sacrificial back electrode metal layer is composed of a thin layer of molybdenum (e.g., on the order of about 60 nm) for better contact and a conductive stress relieving layer. This decreased thickness of a hard molybdenum layer and the adoption of a thick but soft stress relieving layer with better matched TEC minimize thermal stresses at the interfaces between the back electrode metal layer and a subsequently formed absorber layer, without affecting the resistance of the back electrode.
In block 506 of FIG. 5 , a semiconductor absorber layer is formed on the back electrode metal layer. The absorber layer may be, for example, CIGS, CZTS, or combinations thereof. Embodiments described herein are applicable to either vacuum-based semiconductor deposition techniques at elevated temperatures or, alternatively to a low temperature (e.g., room temperature) solution-based spin-on technique, followed by a recrystallizing anneal process.
In either approach, as depicted in block 508 , the device is at some point subjected to an elevated temperature process (either during or after semiconductor absorber layer deposition) to transform the semiconductor film into a high quality, polycrystalline for solar cell applications. For a low temperature, liquid depositon of semiconductor material, this may be followed by a rapid thermal anneal (RTA) or a laser spike anneal. As a result of the elevated temperature process, the molybdenum back electrode metal layer reacts with the absorber to form a compound of, for example, molybdenum selenide (MoSe 2 ) or molybdenum disulfide (MoS 2 ). The molybdenum back electrode may or may not completely react with the absorber, but in any case forms part of an ohmic contact. With respect to FIG. 6 , the thin, reacted molybdenum-based compound is indicated by a back interface contact layer 605 atop the niobium thermal stress relieving layer 604 , which together define a back electrode.
As further illustrated in FIG. 6 , the CIGS/CZTS absorber layer 606 is formed atop the thin, back interface contact layer 605 . Once the CIGS/CZTS absorber layer 606 is formed, the remaining solar cell layers may be formed as indicated in block 510 of FIG. 5 . These layers include, as shown in FIG. 6 for example, a thin n-type layer 608 (e.g., about 60 nanometers (nm)) transparent to solar radiation such as CdS), a thin (e.g., about 0.2 μm to about 0.6 μm) top transparent electrode 610 , such as ZnO, ITO, aluminum doped ZnO, etc., and an optional AR coating 612 .
While the invention has been described with reference to a preferred embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A method of forming a photovoltaic device includes forming a thermal stress relieving layer on top of a substrate and forming a sacrificial back electrode metal layer on the thermal stress relieving layer. A semiconductor photon absorber layer is formed on the sacrificial back electrode metal layer, and the absorber layer is reacted with substantially an entire thickness of the sacrificial back electrode metal layer, thereby forming a back ohmic contact comprising a metallic compound of the sacrificial back electrode metal layer and the absorber layer, in combination with the thermal stress relieving layer. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority of DE 10 2014 206 012.5, filed Mar. 31, 2014, the priority of this application is hereby claimed and this application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention pertains to a method for automatically controlling a vapor content of a working medium heated in a evaporator of a system for carrying out a thermodynamic cycle, to a control unit for a corresponding system, to a system for a thermodynamic cycle, and to an arrangement with an internal combustion engine and a system.
[0003] Thermodynamic cycles of the type in question here are known. A working medium is conveyed through a circuit by a conveying device, wherein the medium is vaporized in a evaporator and sent to an expansion device, wherein it performs mechanical work. The expanded working medium is cooled in a condenser and thus condensed, after which it is sent back to the evaporator by the conveying device. A typical example of a thermodynamic cycle of this type is the Clausius-Rankine cycle. Very similar to it is the organic Rankine cycle (ORC), which, because of the lower temperature level in the evaporator thanks to the use of an organic working medium, is especially adapted to the use of waste heat in stationary applications such as geothermal power plants or to the use of the waste heat of an internal combustion engine. Whereas, in classical steam-powered machines and/or steam power plants, the steam is usually superheated after the vaporization of the working medium, so that dry steam can be expanded in the expansion device, it has been found, especially in conjunction with the use of waste heat and with the ORC process, that it can be advantageous to operate in the wet steam region. To ensure that the process can be carried out in stable fashion, however, it is necessary to work with a defined steam content, which means in particular that this content must be automatically controlled. The working medium is typically vaporized at a constant pressure and a constant temperature. There is thus no clear correlation between these variables on the one hand and the steam content on the other. It is therefore impossible to determine the quality of the steam directly by means of the rudimentary measuring techniques which would normally be present in any case. It is possible to make use of capacitive moisture measurements to determine the steam content, but this approach is complicated and expensive.
SUMMARY OF THE INVENTION
[0004] The invention is based on the goal of creating a method for automatically controlling a steam content, namely, a method which is easy to carry out and at the same time allows stable and accurate control. The invention is also based on the goal of creating a control unit for carrying out a process of this type, a system for a thermodynamic cycle which can be automatically controlled by means of such a method, and an arrangement consisting of an internal combustion engine and a system of this type.
[0005] The goal is achieved in a method in which a phase separation is carried out for the working medium downstream from the evaporator. Liquid components are therefore separated from the vapor components of the working medium. The separated liquid components of the working medium are conducted to a reservoir, and the level reached in the reservoir is determined. As a function of this level, a control variable is adjusted to control the steam content. This means that the level of the separated liquid working medium is used as the measurement value for the automatic control process, which ultimately represents the indirect control of the wet steam content. Because the amount of liquid separated during the phase separation step will be larger or smaller as a function of the steam content of the wet steam generated in the evaporator, it is possible, by determining the level in the reservoir, to infer the steam content. This content can thus be determined very easily and without complicated and expensive measuring devices. The automatic control method makes it possible to achieve robust control behavior especially in the face of changes in the boundary conditions and/or disturbances, wherein the reaction of the thermodynamic state of the process always occurs reliably within the wet steam region. This applies above all to load changes in the system, which will therefore never lead outside the wet steam region, which means that the process as a whole remains stable. This also makes partial load control easier to implement, and the behavior of the system when the load increases quickly is improved. This is especially important in conjunction with the use of waste heat of an internal combustion engine, where the operating state of the system changes as a function of the operating state of the engine, because the exhaust gas temperature and thus the amount of heat available depend on the operating state of the internal combustion engine. Depending on the manner in which the internal combustion engine is being used, load changes occur more or less frequently and at more or less regular intervals. Against this background, stable automatic control of the steam content makes it possible for the first time to operate the process in the wet steam region, which in turn makes it possible to increase the power yield of the system, especially when this is configured as an ORC system.
[0006] The possibility of operating the system, i.e., the cycle, in the wet steam region offers additional advantages with respect to long-term service life and/or component stress: Larger wetted surfaces in the evaporator prevent inhomogeneous temperature distributions in the area of the evaporator wall, which considerably reduces the thermal load on the material of the evaporator. At the same time, the wetting prevents oil from being coked in the evaporator. In addition, the fluid-dynamic stability of the process is increased: As a result of operation in the wet steam region, the phase discontinuity in the evaporator occurs at a later point, which means a smaller gas volume and a slower flow rate in the evaporator. Associated with this is a reduced pressure loss, as a result of which ultimately the tendency to develop fluid-dynamic instabilities, especially a tendency to develop the Ledinegg instability, is decreased. Finally, the amount of circulating lubricant provided to lubricate the expansion device can be reduced, because the circulating lubricant has less of a tendency to form deposits in dead volumes and on the walls of the system. The lubricant is washed away by the liquid components of the working medium and transported further along the circuit. The liquid components therefore have an advantageous washing effect, so that ultimately a greater amount of lubricant can be circulated permanently through the system while at the same time the total amount of lubricant can be reduced.
[0007] The advantageous effects of automatic wet steam control with respect to the service life of the system components are important criteria in particular for so-called off-road applications, that is, couplings of the system with an internal combustion engine for use of its waste heat in areas separate from conventional highway traffic such as in stationary systems or in special types of vehicles, so that the acceptance of this type of waste heat use is considerably increased by the method proposed here.
[0008] The phase separation for the working medium is preferably carried out directly downstream from the evaporator, especially upstream of the expansion device. Thus it is possible to control the fresh steam content at the evaporator outlet very precisely, wherein at the same time saturated steam as free as possible of liquid components is sent to the expansion device.
[0009] An embodiment of the method is especially preferred in which an ORC process is carried out. In this type of process, the advantages of the method are realized in a special way, wherein the process at the same time is especially adapted to the use of waste heat, especially to the use of the waste heat of an internal combustion engine. In a preferred embodiment of the method, ethanol is used as the working medium. Other organic working media are also possible, of course.
[0010] It is possible for the level in the reservoir to be determined intermittently, that is, at certain times. Under certain conditions this can be sufficient for the stable automatic control of the steam content. As an alternative, it is preferable, however, for the level in the reservoir to be determined, especially monitored, at all times. In this way, the automatic control of the steam gas can be carried out with particular precision. Intermittent determination, however, leads to a less complicated method and therefore offers certain cost advantages.
[0011] A preferred embodiment of the method is characterized in that a mass flow of the working medium in the system is varied as a function of the level. The mass flow of the working medium in the system is, to this extent, used as a control variable. This makes it possible to regulate the steam content very efficiently and precisely. It has been found that the pressure at the evaporator outlet is essentially dependent on the mass flow on the one hand and on the rotational speed of the expansion device on the other. When the amount of heat entering the system increases because, for example, an internal combustion engine coupled to the system comes under load and its exhaust gas temperature increases, there is a tendency for the fresh steam to become a superheated, wherein the temperature at the evaporator outlet increases at the same time. The pressure and/or the volume flow rate in front of the expansion device also increases. Simultaneously, the level in the reservoir either falls, increases with at least a reduced separation rate, or remains constant. The level falls especially when working medium is being withdrawn continuously from the reservoir. In any case, the level changes, or the change in level is different, which means that the change in the steam content can be determined. The mass flow in the system is then increased so that the increased amount of heat can be absorbed while keeping the steam content as constant as possible. If, conversely, the amount heat being supplied to the evaporator falls, because, for example, the load on the internal combustion engine decreases significantly, thus leading to a drop in the exhaust gas temperature, the steam content falls simultaneously. As a result, more liquid is separated, and the level in the reservoir rises. In this case, the mass flow in the system is reduced and thus adapted to the smaller amount of available heat.
[0012] Within the scope of the method, preferably the steam content at the evaporator outlet is regulated. In particular, this corresponds to a regulation of the wet steam at the evaporator outlet. The steam content is preferably regulated automatically to match a constant, previously determined value. What this regulation preferably does, therefore, is to maintain a constant steam content.
[0013] Another embodiment of the method is characterized in that a change in the level in the reservoir is determined, wherein the mass flow is varied as a function of the change in level. This takes into account the knowledge that the absolute level of the reservoir, in and of itself, typically says little about the steam content. In contrast, an increase in the level in the reservoir indicates an increase in the separation of liquid components and thus a decrease in the steam content, whereas a decrease in the level—as working medium is being withdrawn continuously from the reservoir—or a reduction in the separation rate and possibly even a constant level indicates an increase in the steam content. To this extent, a method is also preferred in which the rate at which the level changes is determined and evaluated with respect to the steam content or a change in the steam content. On this basis, it is possible to achieve an especially precise automatic control of the steam content.
[0014] Another embodiment of the method is characterized in that the mass flow is varied by variation of an output of a conveying device, wherein the conveying device is used to convey the working medium in the system. In this way, the mass flow can be varied directly, very precisely, and easily. A pump is preferably used as the conveying device, especially a feed pump. To vary the mass flow, preferably the rotational speed of the pump, especially of the feed pump, is varied. A further embodiment of the method is characterized in that a pressure and/or a temperature of the working medium is determined downstream from the evaporator and used as input for the automatic control of the steam content. According to one embodiment of the method, therefore, it is provided that the pressure of the working medium is determined downstream from the evaporator, preferably directly downstream from the evaporator, in particular at the evaporator outlet, and used as input for the automatic control. Alternatively or in addition, it is provided that a temperature of the working medium downstream from the evaporator, especially directly downstream from the evaporator, preferably at the evaporator outlet, is determined and used as input for the automatic control. By determining or acquiring at least one of these measurement variables, the thermodynamic state of the working medium downstream from the evaporator and upstream of the expansion device, especially at the evaporator outlet, can be determined.
[0015] Under certain circumstances, this allows, in and of itself, conclusions to be drawn concerning the steam content. In particular, it is thus possible under certain conditions to determine a superheating of the working medium at the evaporator outlet. In any case, the accuracy of the automatic control can be increased by combining the determination of the level, especially the determination of a change in the level, with the evaluation of the pressure and/or the temperature of the working medium downstream from the evaporator.
[0016] Alternatively or in addition, it is possible to determine the pressure and/or the temperature of the working medium upstream of a separation device, which is provided to separate liquid components of the working medium from the vapor components. The pressure and/or the temperature is preferably determined directly in front of the separation device. Alternatively or in addition, it is possible for the pressure and/or the temperature of the working medium to be determined upstream of an expansion device of the system, especially directly in front of the expansion device.
[0017] Another embodiment of the method is characterized in that the automatic control of the steam content is calibrated by operating the system on or beyond the saturated steam curve of the medium and by intentional deviation from the saturated steam curve into the wet steam region. The phrase “beyond the saturated steam curve” means that the working medium is superheated, so that dry fresh steam is produced. The reservoir is preferably completely emptied prior to the calibration, so that no liquid is present in the reservoir. For the calibration, preferably pure working medium without any lubricant components in the circuit of the system is used. The system is then operated initially on or beyond the saturated steam curve, wherein no liquid components of the working medium separate in the reservoir. By intentional deviation of the operating state of the system from the saturated steam curve into the wet steam region, it is then possible to determine how the level in the reservoir changes when the steam content changes in a defined manner. The data on the level and/or on the change in level in the reservoir as a function of the absolute and/or changing steam content thus acquired are preferably used as input for drawing up a characteristic diagram, which is then used later for automatic control during operation of the system.
[0018] Alternatively it is also possible for the calibration to be carried out when the system is operating with a mixture of working medium and lubricant. It is possible to include the lubricant separating in the reservoir during the operation of the system in the data used to draw up the characteristic diagram. This can increase the accuracy of the calibration and ultimately also the accuracy of the automatic control.
[0019] In another embodiment of the method a withdrawal of liquid from the reservoir is used as input for the automatic control of the steam content. Liquid is withdrawn from the reservoir, first, to prevent the reservoir from overflowing. Liquid is therefore sent back, preferably continuously, from the reservoir to the circuit of the working medium. Exact knowledge of the amount of liquid withdrawn makes possible the precise automatic control of the steam content as a function of the level or change in level.
[0020] It has also been found that at least some of the lubricant used to lubricate the expansion device is typically conveyed around the circuit together with the working medium. The lubricant is not vaporized in the evaporator and is thus separated together with the liquid components of the lubricant as part of the phase separation process in the reservoir. These amounts of separated lubricant are preferably also used as input for the automatic control of the steam content. Lubricant or a mixture of working medium and lubricant is withdrawn from the reservoir—preferably by means of a metering pump; this is then sent to the expansion device by way of lubricant pathways separate from the circuit. The lubricant demand depends on the operating point of the expansion device, especially on its rotational speed, and thus also on the operating point of the system. This operating point-dependent withdrawal of liquid from the reservoir is preferably stored in a characteristic diagram and can thus be used for the automatic control of the steam content as a function of the level. Under steady-state operating conditions, i.e., a constant withdrawal of lubricant or mixture from the reservoir, it is possible to detect a change in the steam content quickly and easily by detecting a change in the level in the reservoir.
[0021] The goal of the invention is also achieved in that a control unit for a system for a thermodynamic cycle is created. This is set up to carry out a method for automatically controlling a steam content of a working medium heated in a evaporator of the system, wherein the control unit is set up to determine a level in a reservoir, which is located downstream from a evaporator and is connected to a separation device for separating liquid components of the working medium, wherein the control unit is also set up to vary a control variable for automatically controlling the steam content as a function of the level. The control unit is preferably set up to carry out a method according to one of the previously described embodiments. Thus, in conjunction with the control unit, the advantages already explained in connection with the method are realized.
[0022] The method can be permanently implemented in an electronic structure, i.e., in the hardware, of the control unit. Alternatively, it is preferred that a computer program product be loaded into the control unit, namely, a program which contains instructions on the basis of which the method is carried out when the computer program product is running on the control unit.
[0023] The control unit is preferably set up to vary a mass flow of the working medium in the system as a function of the level, especially to vary an output of a conveying device in the system.
[0024] The control unit is preferably set up to acquire a change in the level, wherein it is also set up to vary the mass flow as a function of the change in level.
[0025] The control unit is also preferably set up to acquire a pressure and/or a temperature of the working medium downstream from the evaporator, in particular upstream of an expansion device, and especially preferably at the evaporator outlet.
[0026] The control unit is set up to use at least one of these measurement values for the automatic control of the steam content.
[0027] The control unit is also preferably set up to use the withdrawal of liquid from the reservoir as input for the automatic control of the steam content.
[0028] The control unit comprises appropriate interfaces to appropriate sensors and actuators.
[0029] The goal of the invention is also achieved in that a system for a thermodynamic cycle is created. This is characterized by a control unit according to one of the previously described exemplary embodiments. Thus, in conjunction with the system, the advantages previously explained in connection with the control unit and especially the advantages already explained in connection with the method are realized.
[0030] The system preferably comprises a evaporator; a separating device, set up to separate liquid components of the working medium from the vapor components of the working medium; an expansion device; a condenser; and a conveying device for the conveying the working medium in the circuit—arranged in series in the flow direction of the working medium through the circuit of the system. The system is preferably set up to carry out an organic Rankine cycle (ORC), especially with ethanol as the working medium. This makes it possible to employ the system especially effectively as a means of using waste heat.
[0031] A reservoir is preferably connected to the separating device, so that the liquid components separated in the separating device can be conducted to it. The system preferably comprises a level sensor, by means of which the level or the change in level in the reservoir can be detected. The control unit of the system is preferably functionally connected to the level sensor for determining, preferably for monitoring, the level in the reservoir. The control unit is also preferably functionally connected to the conveying device for varying its output and thus in particular for varying a mass flow in the system.
[0032] The system also preferably comprises a pressure sensor and/or a temperature sensor downstream from the evaporator, especially at an evaporator outlet. The control unit is preferably functionally connected to at least one of these sensors and is set up to determine a thermodynamic state of the working medium downstream from the evaporator, especially at the evaporator outlet. The control unit is also preferably set up to use at least one of these measurement values for the automatic control of the steam content.
[0033] Another exemplary embodiment of the system is characterized in that the separating device is configured as a cyclone separator. Baffles cause the working medium to flow in circles in the cyclone separator, as a result of which liquid components strike the baffles and run down them. The cyclone separator makes highly efficient phase separation possible while simultaneously having an extremely low pressure loss.
[0034] Another exemplary embodiment of the system is characterized in that the expansion device is configured as a helical screw expander. A helical screw expander has been found to be especially favorable in terms of power yield especially in the case of an ORC process. This is especially true for ORC systems which operate without superheating, i.e., which operate in the wet steam region. A helical screw expander is a displacement machine free of dead spaces, the working chambers of which are formed by the spaces between the teeth of two helical gear wheels, also called rotors. The teeth of one rotor, which preferably extend in spiral fashion over the rotor's circumferential surface, which is elongated in the axial direction, engage in the tooth spaces of the other rotor. When the two rotors are in relative rotation, working chambers of variable volume are thus formed, in which the working medium expands as it passes through the helical screw expander from the inlet to the outlet.
[0035] Alternatively, it is also possible for the expansion device to be configured as a continuous-flow machine, especially as a turbine, as a displacement machine of some other type, or as a volumetric expansion device, in particular as a reciprocating piston machine, a scroll expander, a rotary vane machine, or a Roots expander.
[0036] Finally, an exemplary embodiment of the system is characterized in that it is set up to use the waste heat of an internal combustion engine. This makes it possible to employ the system advantageously for the mobile or stationary use of waste heat and to increase the efficiency of the internal combustion engine.
[0037] The goal of the invention, finally, is also achieved by an arrangement that comprises an internal combustion engine and a system according to one of the previously described exemplary embodiments. The system is functionally connected to the internal combustion engine for the use of its waste heat. It is possible for the exhaust gas of the internal combustion engine to be conducted to the system so that use can be made of the waste contained in that gas. Alternatively or in addition, coolant of the internal combustion engine can be conducted to the system so that use can be made of the waste heat contained in the coolant. In this way, the overall efficiency of the internal combustion engine can be increased, and beneficial use can be made of its waste heat. It is possible for the mechanical work performed in the system to be returned directly to a crankshaft of the internal combustion engine to support the work of the engine. Alternatively or in addition, the mechanical work can be used elsewhere in directly mechanical fashion. It is also possible for a generator to be functionally connected to the expansion device, so that the mechanical work is converted to electrical energy. This can be sent, by means of an electric motor, for example, back to the crankshaft of the internal combustion engine to support it. Alternatively or in addition, the electrical energy thus generated can be used elsewhere such as in an on-board power supply system, or it can be fed into a power grid.
[0038] The internal combustion engine of the arrangement is preferably configured as a reciprocating piston engine. In a preferred exemplary embodiment, the internal combustion engine serves in particular to drive heavy land vehicles such as mining vehicles and trains or water craft, wherein the internal combustion engine is used in a locomotive or motor coach or in a ship. The use of the internal combustion engine to drive a vehicle serving defensive purposes such as a tank is also possible. In another exemplary embodiment of the internal combustion engine, it is stationary and used for stationary power generation to generate emergency power or to cover continuous-load or peak-load demands, wherein the internal combustion engine in this case preferably drives a generator. The stationary use of the internal combustion engine to drive auxiliary units such as fire-fighting pumps on offshore drilling rigs is also possible. An application of the internal combustion engine in the area of the recovery of fossil materials and especially fossil fuels such as oil and/or gas is also possible. The internal combustion engine can also be used in industry or in the construction field for the production of construction vehicles such as cranes and bulldozers. The internal combustion engine is preferably configured as a diesel engine; as a gasoline engine; or as a gas engine for operation with natural gas, biogas, customized gas, or some other suitable gas. Especially when the internal combustion engine is configured as a gas engine, it is suitable for use in block-type thermal power stations for stationary power generation.
[0039] An especially preferred exemplary embodiment of the arrangement is provided for marine applications, especially for use on board a ferry, wherein the internal combustion engine is provided preferably to drive the ship. Electrical energy for an on-board power system of the ship can be recovered by means of the system.
[0040] The description of the method on the one hand and of the control unit, the system, and the arrangement on the other hand are to be understood as complementary to each other. Features of the control unit, of the system, and/or of the arrangement which have been explained explicitly or implicitly in conjunction with the method are preferably steps, individually or in combination, of a preferred embodiment of the control unit, of the system, and/or of the arrangement. Method steps which have been explained explicitly or implicitly in conjunction with the control unit, the system, and/or the arrangement, are preferably steps, individually or in combination, of a preferred embodiment of the method. The method is preferably characterized by at least one method step which is required by at least one feature of the control unit, of the system, and/or of the arrangement. The control unit, the system, and/or the arrangement are characterized preferably by at least one feature which is required by at least one method step of the method.
[0041] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, specific objects attained by its use, reference should be had to the drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0042] In the Drawing:
[0043] FIG. 1 shows a schematic diagram of an exemplary embodiment of an arrangement with an internal combustion engine and a system for carrying out a thermodynamic cycle; and
[0044] FIG. 2 shows a schematic diagram of an embodiment of the method in the form of an automatic control circuit.
DETAILED DESCRIPTION OF THE INVENTION
[0045] FIG. 1 shows a schematic diagram of an exemplary embodiment of an arrangement 1 , which comprises an internal combustion engine 3 and a system 5 for a thermodynamic cycle. The system 5 is set up here to carry out an organic Rankine cycle and to use waste heat of the internal combustion engine 3 . For this purpose, waste heat of the internal combustion engine 3 can be conducted to a evaporator 7 of the system 5 , especially the waste heat contained in the exhaust gas and/or in a coolant of the internal combustion engine 3 .
[0046] The system 5 comprises a circuit 9 for a working medium, preferably ethanol, wherein a separation device 11 , an expansion device 13 , a condenser 15 , and a conveying device 17 for conveying the working medium through the circuit are provided around the circuit 9 downstream, in the flow direction of the working medium, from the evaporator 7 . The separation device 11 is preferably configured as a cyclone separator. The expansion device 13 is preferably configured as a helical screw expander. The conveying device 17 is preferably configured as a feed pump with variable speed. In any case, the conveying device 17 comprises variable output, wherein the mass flow of the working medium in the system 5 is adjustable by varying the output of the conveying device 17 .
[0047] The system 5 is set up to operate the thermodynamic cycle, especially the ORC process, in the wet steam region, so that, downstream from the evaporator 7 , in particular at the evaporator outlet, wet steam containing both liquid and vapor components of the working medium is present. To guarantee a stable cycle, the system 5 comprises automatic control for the steam content of the working medium downstream from the evaporator 7 and upstream of the expansion device 13 , especially in the area of the evaporator outlet. In the separation device 11 , liquid components of the working medium are separated from the vapor components, wherein the separated liquid components are conducted to a reservoir 19 . Lubricant, which is provided to lubricate the expansion device 13 , is also preferably separated in the separation device 11 . At least some of this lubricant is conveyed together with the working medium around the circuit 9 , but it is not vaporized in the evaporator 7 . It is therefore in liquid form downstream from the evaporator and therefore is also separated in the separation device 11 . It then arrives in the reservoir 19 along with the liquid components of the lubricant.
[0048] The system 5 comprises a level sensor 21 , by means of which the level and in particular a change in the level in the reservoir 19 can be detected. To regulate the steam content of the working medium downstream from the evaporator 7 , the system 5 is set up to vary a control variable as a function of the level detected by the level sensor 21 , especially as a function of a change in level detected by the level sensor 21 .
[0049] For this purpose, a control unit 23 is provided, which is functionally connected to the level sensor 21 to determine, especially to monitor, the level, especially a change in the level. The control unit 23 is set up to vary a mass flow of the working medium in the system 5 as a function of the level, especially of the change in the level. For this purpose, in the exemplary embodiment shown here, it is functionally connected to the conveying device 17 to vary its output and thus the mass flow of the working medium through the circuit 9 as a function of the signal acquired from the level sensor 21 .
[0050] If, for example, more heat is being supplied from the internal combustion engine 3 to the evaporator 7 , the steam content at the evaporator outlet increases, so that less liquid working medium is separated in the separation device 11 and thus conducted to the reservoir 19 . The level therefore increases more slowly, no longer changes, or perhaps even falls. These data are acquired by the control unit 23 and evaluated quantitatively as an increase in the steam content. The conveying device 17 is actuated by the control unit 23 to increase its output, so that the mass flow in the circuit 9 increases. Thus the increased amount of heat supplied to the evaporator can be absorbed by the system 5 while the steam content remains at least approximately the same.
[0051] If, conversely, the amount of heat supplied by the internal combustion engine 3 decreases, less vaporization will occur and thus the amount of liquid component of the working medium will increase, wherein more liquid is separated in the separation device 11 , which liquid is then conducted to the reservoir 19 . Thus the level in the reservoir 19 rises, which is again detected by the level sensor 21 and quantitatively evaluated by the control unit 23 as a decrease in the steam content. The control unit 23 then actuates the conveying device 17 in such a way that its output is reduced, so that the mass flow in the circuit 9 decreases. It is thus adapted to the smaller amount of available heat in the evaporator 7 , as a result of which the steam content again can be kept at least approximately constant. The control unit 23 is preferably set up automatically to keep the steam content at the evaporator outlet constant. The control unit 23 is also preferably configured to control the rotational speed of the conveying device 17 , configured as a feed pump.
[0052] A sensor device 25 for detecting a pressure and/or a temperature of the working medium is preferably provided downstream from the evaporator 7 , especially at the evaporator outlet. The control unit 23 is preferably functionally connected to this sensor device 25 and is set up to determine a thermodynamic state of the working medium at the evaporator outlet on the basis of the at least one measurement value of the control unit 25 . This information is preferably used as input for the automatic control of the steam content, as a result of which the precision of the control process is increased.
[0053] It has been found preferable to send the lubricant separated in the reservoir to the expansion device 13 to lubricate it by way of a lubricant route 27 , which is indicated only schematically. Alternatively or in addition, liquid present in the reservoir 19 is preferably returned to the circuit along a drain route 29 , preferably downstream from the expansion device and upstream of the condenser 15 . This option is preferably used especially to prevent the reservoir 19 from overflowing. In addition, it is possible in this way to ensure a high lubricant concentration—and thus a small amount of working medium—in the reservoir, which functions to this extent as a lubricant tank.
[0054] In any case, it has been found preferable for liquid to be withdrawn from the reservoir 19 continuously and/or at regular intervals. In particular, the removal of lubricant to lubricate the expansion device 13 depends on the operating state of the system 5 , especially on the rotational speed of the expansion device. In the control unit 23 , preferably at least one characteristic diagram is stored, in which the operating point-dependent removal of liquid from the reservoir 19 is entered. Alternatively or in addition, it is possible for the system 5 to comprise a withdrawal sensor 31 , preferably in the form of a flow sensor, by means of which the withdrawal of liquid from the reservoir 19 can be detected directly. In this case, the control unit 23 is functionally connected to the withdrawal sensor 31 to detect the withdrawal of liquid from the reservoir 19 . In any case, the withdrawal of liquid from the reservoir is preferably used as input for the automatic control of the steam content, which increases its accuracy yet again.
[0055] It has also been found that, in the case of the exemplary embodiment of the system 5 illustrated here, the expansion device 13 is functionally connected to a generator 33 , so that the mechanical work performed by the working medium in the expansion device 13 can be converted into electrical energy by the generator 33 .
[0056] It is especially preferable to provide the arrangement 1 for marine applications, especially for ferries. In this case, the internal combustion engine 3 preferably serves to drive the ship, especially the ferry. The electrical power generated by the generator 33 is especially preferably sent to, i.e., fed into, an on-board power system of the ship, especially of the ferry. Other applications of the use 1 , especially stationary applications or other mobile applications—as previously described in conjunction with the internal combustion engine—are also possible.
[0057] FIG. 2 shows a schematic diagram of an embodiment of the method in the form of an automatic control circuit. The automatic control illustrated schematically here is preferably carried out in its entirety in the control unit 23 . A nominal value 35 for the steam content of the working medium downstream from the evaporator 7 , especially at the evaporator outlet, is sent to the automatic control circuit. In a comparison member 37 , this value is compared with an actual value 39 of the steam content, from which a control deviation 41 is obtained. This is sent to an automatic control device 43 , which calculates from it a control variable 45 , in particular in the form of an actuation signal for the conveying device 17 , to adjust its output. It is possible for the output of the conveying device 17 to be controlled on the basis of the control variable 45 alone. Alternatively, it is preferable, however, for the output of the conveying device 17 , especially the rotational speed of the feed pump, to be regulated to match the control variable 45 by means of a subordinate control process. This increases the accuracy of the method.
[0058] The command variable 45 acts on a controlled system 47 , which comprises in particular the conveying device 17 , the evaporator 7 , the separation device 11 , and the reservoir 19 . On the basis of a change in the control variable 45 , the mass flow of the working medium in the circuit 9 is changed by variation of the output of the conveying device 17 , which influences the steam content of the working medium at the evaporator outlet and thus also the level in the reservoir 19 , which can be detected by the level sensor 21 . The controlled system 47 therefore results ultimately in a measurement value 49 , which represents the level or the change in the level, preferably detected by the level sensor 21 . The measurement value 49 is therefore in particular a measurement signal produced by the level sensor 21 . The measurement value 49 is sent to a calculation member 51 , which is set up to calculate the steam content of the working medium downstream from the evaporator 7 , in particular at the evaporator outlet, as a function of the measurement variable 49 . What therefore results finally from the calculation member 51 is the actual value 39 for the steam content, which is itself sent back to the comparison member 37 .
[0059] Additional variables are preferably also input into the calculation member 51 . It is preferable for a pressure 53 of the working medium downstream from the evaporator 7 , especially at the evaporator outlet, to be entered. Alternatively or in addition, it is provided that a temperature 55 of the working medium downstream from the evaporator 7 , especially at the evaporator outlet, is entered. By means of at least one of these measurement variables, a thermodynamic state of the working medium at the designated point can be determined, as a result of which also—and possibly as a complement to the measurement variable 49 —the steam content of the working medium can also be inferred. This increases the accuracy of the automatic control.
[0060] Alternatively or in addition, preferably a withdrawal 57 of liquid from the reservoir 19 is entered into the calculation member 41 , wherein the withdrawal 57 is read out from a characteristic diagram and/or measured by means of the withdrawal sensor 31 . This also increases the accuracy of the method.
[0061] Overall, it has thus been found that, by means of the method, it is possible to regulate the steam content automatically in a very stable, accurate, and low-cost manner, which ultimately makes it possible to operate the system economically in the wet steam region with all its associated advantages.
[0062] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | A method for automatically controlling a steam content of a working medium heated in an evaporator of a system for carrying out a thermodynamic cycle with the following steps: carrying out a phase separation for the working medium downstream from the evaporator, wherein liquid components are separated from vapor components of the working medium; conducting the separated liquid components to a reservoir; determining a level in the reservoir; and varying a control variable for automatically controlling the steam content as a function of the level. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a method for reinforcing a construction work which makes use of reinforcing bands, and a construction work obtained by this reinforcing method.
It is known to reinforce construction works with additional external prestressing based on carbon/resin composites, such as laminates ortendons. These elements are prefabricated in factory by pultrusion (pulling and extrusion), and are placed on the structure to be reinforced and attached with anchors. The composite elements are then tensioned with a jack system and the stresses are absorbed by friction in the anchors. The system then functions similarly to conventional external prestressing. Such a system can be difficult to implement if there are obstructions around the structure to be reinforced.
Carbon fiber fabric is sometimes used as reinforcement for structures of reinforced concrete. It is directly applied and glued to the structure. For the composite to contribute to the strength of the structure, the support on which the fabric is glued is tensioned, which implies a certain level of fissuring within the support. This poses a problem when a complete seal is necessary, for example in an aggressive environment.
The object of the present invention is to overcome all or part of the above disadvantages, and in particular to provide a method requiring little space for the reinforcing of a construction work. Said method contributes to the strength of the structure even when it is not tensioned, and does not locally impact the mechanical strength of the structure.
BRIEF SUMMARY OF THE INVENTION
The solution of the invention concerns a method for reinforcing a construction work using reinforcing bands. This method comprises the following steps for each of the reinforcing bands:
a) anchoring a first zone of the reinforcing band onto the construction work and establishing a free portion of the reinforcing band; b) tensioning the reinforcing band by applying traction to a second zone of the reinforcing band located in the free portion, said traction causing an elongation of and a reactive force in the reinforcing band, with the free portion of the reinforcing band being free to slide on the construction work as it elongates; and c) mechanically attaching the reinforcing band to the construction work, so as to absorb the reactive force from the reinforcing band in an area of the construction work which can support the reactive force from the reinforcing band.
The construction work can be of any type. In particular, it can be a concrete work. It may or may not be prestressed, using conventional means.
The word “band” is understood to mean an element which may extend in a longitudinal direction over a length significantly greater than its width in a first direction perpendicular to the longitudinal direction, wherein the element has a thickness significantly less than its width. The width and thickness of the band can vary depending on location considered in the longitudinal direction. The band can be curved, for example to follow the contours of the construction work.
The reinforcing bands can be more or less elastic. The tensioning is achieved by traction, for example by applying traction to a free end of the reinforcing band. The traction causes the reinforcing band to elongate, resulting in a reactive force. It is important for the portion of the reinforcing band which elongates to be free to slide on the construction work during the tensioning. In fact, it has been observed that if the band is not free to slide at that time, it does not elongate as much. In addition, in such cases shear stresses are transmitted to the work during the tensioning and afterwards. These stresses are frequently the cause of delamination phenomena (separation of materials) occurring in the work along the tensioned portion of the reinforcing band.
Non-adhesion therefore both improves the behavior of the reinforcing band and reduces the risk of damage to the construction work, particularly by delamination.
The reinforcing band can be impregnated or coated with resin. The non-adhesion of the reinforcing band during tensioning can be obtained in various ways, for example the band is not coated or is not yet coated with resin, or the resin has not yet set.
After the reinforcing band is tensioned, the reinforcing band is mechanically attached to the work. “Mechanically attached” is understood to mean immobilizing at least a portion of the reinforcing band by a direct (anchoring) or indirect (via other elements) mechanical link to the construction work and/or to the reinforcing band itself. This link takes the reactive force from the reinforcing band due to the tensioning. The mechanical link can transmit the reactive force to an area of the construction work provided for this purpose, for example an anchor which distributes the shear stresses into or onto the structure of the construction work. The band can also be positioned so that the transmission of the reactive force to the construction work occurs as compressive force applied to the work. The band can also exert pressure on the work, for example if it completely or partially surrounds all or part of the construction work. In general, the reinforcing band is attached to the work by the zone which has been stretched, but the band can also be attached by another zone of the reinforcing band.
The possible anchorings or the mechanical attachment of the reinforcing band, if there is such, can be achieved by gluing.
Resulting from the above steps is a pretensioned reinforcing band which reinforces the construction work without transmitting shear stresses to it along the tensioned portion of the band.
The method comprises the following steps for two reinforcing bands:
using at least two reinforcing bands to which the above steps are applied; tensioning the reinforcing bands occurs by closing distance between the second zone of a first reinforcing band and a second zone of a second reinforcing band, this being achieved by the use of a tensioning means which is able to contract; and, the tensioning means is maintained in a contracted position and mechanically attaches the free portion of each reinforcing band to the construction work by means of the tensioning means and by means of the other reinforcing band.
At the end of the tensioning step b), the reinforcing bands are located within a reinforcing area which is substantially rectangular and longer in a given direction. The reinforcing area has a first end area and a second end area located opposite one another in the given direction. In step a), a first set of reinforcing bands are anchored by their first zones onto the first end area of the construction work, and a second set of reinforcing bands are anchored by their first zones onto the second end area of the construction work. In step b), a third set of reinforcing bands, containing at least one reinforcing band from the first set and at least one reinforcing band from the second set, is tensioned. The third set is tensioned by means of a spacing tool applying simultaneous tensile forces to the second zones of the reinforcing bands in the third set. The tensile forces applied by the spacing tool move the second zone or zones of the reinforcing bands in the first set away from the second zone or zones of the reinforcing bands in the second set.
The resulting pretensioned reinforcing bands allow applying prestressing to the construction work while requiring little space. The method is therefore particularly indicated for areas in which obstructions render other prestressing solutions difficult to implement.
In certain embodiments, the invention may make use of one or more of the following characteristics:
the reinforcing band is coated with resin prior to tensioning, and the tensioning is done before the resin cures. a thin sliding element is inserted under the free portion of the reinforcing band prior to tensioning in step b). in step b), a fourth set of reinforcing bands containing at least one reinforcing band from the first set and at least one reinforcing band from the second set is tensioned by means of a spacing tool which applies tensile forces simultaneously to the second zones of the reinforcing bands in the fourth set, the tensile forces applied by the spacing tool moving the second zone or zones of the reinforcing bands in the first set further away from the second zone or zones of the reinforcing bands in the second set; and in step c), the free portion of each reinforcing band in the fourth set is mechanically attached to the free portion of a reinforcing band in the third set, and the free portion of each reinforcing band in the third set is mechanically attached to the free portion of a reinforcing band in the fourth set. after tensioning the third set of reinforcing bands and before tensioning the fourth set of reinforcing bands, the free portions of the reinforcing bands in the third set are mechanically attached directly to the construction work. after tensioning in step b), the reinforcing bands are substantially parallel to each other in the given direction. after tensioning in step b), the free portions of the reinforcing bands in the third set are each within the extension of the free portion of a different reinforcing band in the fourth set. the third set of reinforcing bands contains a single reinforcing band from the first set and exactly two reinforcing bands from the second set; and the fourth set of reinforcing bands contains exactly two reinforcing bands from the first set and one reinforcing band from the second set. the tensile forces applied by the spacing tool used in tensioning step b) are balanced both verctorially and in torque. the reinforcing band or bands comprise a carbon fiber fabric (CFF).
For a reinforcing band, a first zone of the band is anchored to the work in step a), which distributes the stresses that the reinforcing band will apply to the work. This attachment defines at least one free portion of the reinforcing band. In fact, if this first zone is located at an end of the reinforcing band, the remainder of the reinforcing band becomes a free portion. If the first zone is a certain distance away from an end, this creates two free portions: the two portions of the reinforcing band on each side of the anchoring.
In step b), the free portion of the reinforcing band is tensioned. The reinforcing bands are relatively elastic. The tensioning occurs by applying traction to a second zone of the reinforcing band, for example a free end of the free portion. It is possible for the second zone not to be an end of the reinforcing band. The traction causes an elongation of the reinforcing band and reactive stress in the band. It is important for the portion of the reinforcing band which elongates to be free to slide on the construction work during the tensioning. It has been noted that, if the band is fixed at that moment, it does not elongate as much. In addition, in such cases shear stresses are transmitted to the construction work during and after the tensioning. These stresses are frequently the cause of delamination (separation of materials) of the work along the tensioned portion of the reinforcing band.
In step c), as the reinforcing band is now tensioned, the free portion of the reinforcing band is mechanically attached to the construction work. Mechanical attachment means immobilizing the reinforcing band with a direct (anchoring) or indirect (via other elements) mechanical link to the work. This link takes the reactive force from the reinforcing band due to the tensioning. The link transfers the reactive force to an area of the work designed for this purpose, for example an anchoring which diffuses the shear stresses into or onto the structure of the work. The band can also be placed so that the transmission of the reactive force to the work does not result in compressive force being applied to the work.
Generally the reinforcing band is attached to the work by the second zone (which was stretched for the tensioning), but the band can also be attached by some other zone of the free portion which is not the first zone.
The above steps yield pretensioned reinforcing bands which reinforce the construction work without the transmission of shear stresses along its length. The stresses are applied by the reinforcing bands to the construction work at the anchors for the first zones and in the area of the work where the band's mechanical attachment transfers the reactive force after tensioning.
In one particular embodiment, the reinforcing band is coated with resin prior to tensioning and tensioning is done before the resin cures. Thus it is possible to apply tension without the band adhering and therefore without creating local shear stresses that are transmitted to the work along the portion that is tensioned. Once the resin cures, the band adheres to the work and contributes to the seal.
To facilitate the sliding of the reinforcing band on the work during tensioning, a thin sliding element can be inserted under the free portion of the band prior to tensioning. This element allows creating an area of adjustable length in which adhesion is prevented. This length can be up to that of the free portion of the reinforcing band.
Each of the bands undergoes steps a) to c) above. Each is anchored to the construction work by a first zone (step a). The free portion of each band is tensioned by traction on a second zone (step b). Lastly, each band is mechanically attached to the construction work (step c). “Mechanically attaching the free portion” is understood to mean that a point or zone is anchored directly or indirectly to the construction work. Preferably, the attachment is done in the second zone.
The tensioning can be done by a means capable of contracting, comprising a jack for example, which brings together the second zones of the two bands. Because of elasticity and the fact that they can slide, the free portions of the two bands are aligned to become coaxial. The tensioning means also serves to mechanically attach each band to the construction work. Each band is therefore integrally attached via the tensioning means in its contracted position and via the other reinforcing band. The reactive force is transferred from the band to the work via the anchoring of the first zone of the other reinforcing band. The tensioning and the mechanical attachment are therefore achieved in a simple and practical manner. The reactive forces of the two reinforcing bands cancel each other out. No shear stress is transferred to the work along the tensioned bands.
In a first embodiment, the method makes use of reinforcing bands which reinforce the work over a reinforcing area (or area to be reinforced) that is substantially rectangular and elongated. Each of the bands undergoes steps a) to c) above. Each one is anchored to the work by a first zone (step a). Each one is tensioned by traction on a second zone (step b). Lastly, each one is attached to the work (step c).
Some bands defining a first set are anchored to a first end area of the reinforcing area. The other bands defining a second set are anchored to a second end area of the reinforcing area, located opposite the first one.
For the tensioning (step b), several bands defining a third set are tensioned simultaneously using a spacing tool. The third set consists of at least one band from the first set, preferably only one, and at least two bands from the second band, preferably exactly two. Thus the third set contains bands anchored on each side of the reinforcing area.
Note that two contiguous reinforcing bands (superimposed or juxtaposed) of width I/2 are equivalent, from the tensioning point of view and all else being equal, to tensioning a single band of width I.
The bands of the third set are tensioned using a spacing tool. This allows gripping the bands by their second zones and distancing the second zones of the bands in the first set from those of the bands in the second set. The bands in the third set are then mechanically attached to the work as described above for an individual band.
The third set can also be mechanically attached as described above for two bands: while maintaining the spacing tool in the spread-apart position. A part for attaching the third set and intended to be left in place may also be substituted.
Time is saved by simultaneously tensioning the reinforcing bands of the third set. Using the spacing tool is simple as it is supported by the reinforcing bands themselves. The other previously mentioned advantages remain (particularly better band behavior, no local shear stresses along the bands).
In one particular embodiment, several bands defining a fourth set are tensioned simultaneously, again by using a spacing tool. The reinforcing bands of the fourth set are generally distinct from those of the third set. The fourth set contains at least two bands from the first set, preferably exactly two, and at least one band from the second set, preferably exactly one. Thus the fourth set also contains bands anchored before or after tensioning the bands of the third set on each side of the reinforcing area. The spacing tool allows gripping the bands by their second zones and distancing the second zones in the first set from those of the bands in the second set.
The free portion of each reinforcing band in the fourth set is mechanically attached to the free portion of a reinforcing band in the third set, and vice versa. Thus the reactive forces of each band in the third set are assumed by a band in the fourth set and transmitted to the construction work via this band. The reactive forces of two reinforcing bands linked in this manner cancel each other out. No shear stress is transmitted to the construction work along these tensioned bands.
This attachment of a free portion of one band to another (meaning to the construction work via another band) is preferably done in the second zones of each band, which are preferably located at the free end of the bands.
It is possible, after tensioning the third set of reinforcing bands and before tensioning the fourth set of reinforcing bands, to mechanically attach the free portions of the reinforcing bands of the third set directly to the construction work.
This allows stabilizing the bands of the third set before tensioning the fourth set. Then, but only temporarily, shear stresses are locally transmitted at the point where the bands of the third set are directly attached to the work. The advantage of this operation is that it allows easily removing the spacing tool used to apply tension to the third set. This facilitates the mechanical attachment of the bands of the fourth set to those of the third. After this attachment, the shear stresses locally transmitted by the bands of the third set are decreased or even canceled out.
By appropriately choosing the geometry, the layout, and the mechanical properties of the reinforcing bands of the third and fourth sets, the reactive forces from the bands of the same set (third or fourth) to which the spacing tools are exposed are balanced both vectorially and in torque, meaning the resultant is zero. Thus, it is not necessary to anchor the spacing tools, which remain balanced during tensioning the reinforcing bands.
In addition, again with the bands placed in an appropriate manner, it can be arranged so that the reactive stresses in the bands of a same set (third or fourth) do not apply forces to the spacing tool that could cause it to rotate. Thus it is not necessary to apply an opposing force to the spacing tool to prevent its rotation during tensioning.
In the invention, regardless of the number of reinforcing bands used, the bands can comprise a composite material. This material can be woven fibers. It can also be a bundle of fibers. It can also be in the form of thin layers. In addition to the fibers and/or layers, the reinforcing bands comprise resin.
The fibers can comprise carbon (carbon fiber). They can comprise glass. They can comprise aramid as well.
The composite materials (carbon, glass, aramid . . . ) can be combined, as well as their mode of use (layers, fabric, bundle, etc.).
Carbon fiber fabric is commonly referred to as “CFF.”
The invention additionally concerns a construction work comprising pretensioned reinforcing bands. The pretensioned reinforcing bands are obtained by applying the method as described above.
BRIEF DESCRIPTION OF DRAWINGS
Other features and advantages of the invention will become apparent from the following description of some non-limiting examples with reference to the attached drawings, in which:
FIGS. 1A and 1B schematically represent different phases of a reinforcing technique using two reinforcing bands attached to each other;
FIGS. 2A , 2 B and 2 C show details of a means for simultaneously tensioning two reinforcing bands;
FIGS. 3A , 3 B and 3 C represent different phases of a method of the invention which makes use of reinforcing bands tensioned simultaneously;
FIGS. 4A , 4 B and 4 C represent phases which can supplement those illustrated in FIGS. 3A , 3 B and 3 C, in another method of the invention; and
FIG. 5 represents a reinforcing band mechanically attached to itself.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
For clarity, the dimensions of the various elements represented in these figures are not necessarily in proportion with their actual dimensions. Identical references in the figures correspond to identical elements, although not necessarily implemented in an identical manner.
In FIG. 1A , a reinforcing band 2 is represented, for example one of CFF (carbon fiber fabric). It is anchored in or on a construction work 1 . The anchoring is done in a first zone 1 a of the band 2 , for example by gluing onto the work 1 . This anchoring defines a free portion 2 b , which is the portion of the band 2 which is not anchored to the structure.
FIG. 1B illustrates the use of a means 5 to apply tension to the band 2 . To do this, tensile force R 2 ′ is applied to a second zone 2 c of the band 2 . The means 5 acts by contraction which is obtained by means of a jack system 5 a , 5 d comprised within the means 5 . The tensile force R 2 ′ on the band 2 causes an elongation d 2 of the band 2 and a reactive force R 2 from the band 2 on the tensioning means 5 .
The band 2 is then mechanically attached to the construction work 1 . In FIGS. 1A and 1B , this is done via another reinforcing band 3 . The reactive force R 2 is transmitted to the work within an area which can support this stress. Here, this area is an area 3 a which anchors the band 3 .
In FIG. 2A , one can see that the force R 2 can be transmitted by a mesh of fibers 2 d originating from the weave of the band 2 or glued to it. The mesh 2 d and the band 2 are joined by one or more layers of fanned-out threads. The mesh 2 d is connected, by means of a head 5 c with an eye, to a threaded rod 5 d inserted into a turnbuckle 5 a.
FIG. 2B shows an enlargement of the head 5 c , which has an eye on one end and threading on the other for engaging the threaded rod 5 d.
FIG. 2C shows how the mesh 2 d can be inserted in the eye of the head 5 c . Here the mesh 2 d is a loop having two layers of fanned-out threads at the connection with the second zone 2 c of the band 2 .
Part 2 b of the band 2 can be coated with slow setting resin. The reinforcing band 2 is tensioned before the resin cures, so that the band 2 is more free to slide on the work 1 during its elongation d 2 .
To facilitate sliding, a thin sliding element (not represented) can be inserted under the free portion 2 b of the reinforcing band 2 before tensioning. For example, adhesion can be temporarily prevented by means of an appropriate membrane such as polyane or anti-adhesive paint.
All the above characteristics of this band 2 can be found in any other reinforcing bands made use of by the method of the invention.
FIGS. 1A and 1B also illustrate the case where a reinforcing band 3 of CFF is tensioned at the same time as the band 2 . The band 3 is anchored by a second zone 3 a . The tensioning means 5 brings the second zones 2 c and 3 c closer to each other, causing a simultaneous elongation and tensioning of the two bands 2 and 3 . The means 5 is contracted by means of the jack formed by the elements 5 a , 5 d and an analog of 5 d situated on the other side of the turnbuckle 5 a , next to the band 3 .
The band 3 is elongated by d 3 and applies a reactive force R 3 to the means 5 . The forces R 2 and R 3 are balanced both vertorially and in torque (zero resultant). The resultant moment is also zero. The tensioning means 5 is therefore in equilibrium and it is not necessary to prevent it from rotating.
The means 5 then remains in a contracted position, ensuring the mechanical attachment of the band 3 to the work 1 via the other band 2 , and vice versa.
FIGS. 3A to 4C represent embodiments which make use of reinforcing bands in a method of the invention.
FIGS. 3A to 3C concern three bands 2 , 3 , 4 for reinforcing an elongated area 10 of the work 1 . A first set of bands, here band 2 , is anchored by the first zone 2 a to an end area 10 a of the region 10 . A second set of bands, here bands 3 and 4 , is anchored by the first zones 3 a and 4 a to a second end area 10 b , located opposite the area 10 a in the area to be reinforced 10 .
The free ends of the bands 2 to 4 , which here are their second zones, are positioned in a median area 10 c of the area 10 to be reinforced. The second zones 2 c , 3 c , 4 c , are inserted into a spacing tool 5 , 5 a . The part 5 is for example equipped with jaws that can fasten onto the second zones 2 c , 3 c , 4 c of the bands. Alternatively, a spacing tool can be used which rolls up the bands.
The bands form a third set of bands which therefore comprises the first set (passively anchored on one side of the area to be reinforced) and a second set (passively anchored on the other side of the area to be reinforced). This third set is tensioned by reshaping the spacing tool for example using a jack 5 a . The spacing tool 5 moves the second zones 2 c of the bands in the first set away from the second zones 3 c and 4 c of the bands in the second set.
When the desired degree of tension is achieved, each of the three bands is attached to the work 1 , while maintaining the spacing tool 5 in a spaced-apart position. The bands can also be attached directly to the construction work if its structure so allows. A locking part to be left in place could also be substituted for the spacing tool.
In one embodiment, the bands 3 and 4 are two times wider than the band 2 and the bands are all of the same length. The stress R 2 is two times greater than the stresses R 3 and R 4 and in the reverse direction. If the distances between two consecutive bands are identical, the moments of the stresses are balanced (zero resultant moment). This facilitates the use of the spacing tool.
The method can be supplemented with the use of a fourth set of reinforcing bands of CFF 6 , 7 and 8 . In FIG. 4A , the bands 7 and 8 belong to the first set (these are anchored by their first zones 7 a and 8 a in the first end area 10 a , before or after tensioning band 2 of the third set), and the band 6 belongs to the second set (band anchored by its first zone 6 a in the second end area 10 b , before or after tensioning bands 3 and 4 of the third set).
Bands 6 , 7 and 8 of the fourth set are tensioned similarly to bands 2 , 3 , and 4 of the third set (see FIG. 4B ) by using a spacing tool 9 .
After tensioning, the second zone of each band of the third set is mechanically attached ( FIG. 4C ) to the second zone of a band corresponding to the third set. Then the spacing tool 9 is removed. In FIG. 4C , the band 6 is glued to the band 2 , said gluing occurring within the second zones 6 c and 2 c which are approximately superimposed. The band 7 is glued to the band 3 , said gluing occurring within the second zones 7 c and 3 c . Lastly, the band 8 is glued to the band 4 , said gluing occurring within the second zones 8 c and 4 c . Thus the reactive forces R 6 , R 7 , R 8 of the bands in the fourth set are canceled out by the paired forces R 2 , R 3 , R 4 of the bands in the third set.
In one specific embodiment, the bands 6 , 7 , 8 of the fourth set have the same length and the same width as the analogous bands of the third set to which they are integrally attached, in a manner that forms a layout complementary to the one formed by the third set. The bands can then be arranged so that in the end they occupy three contiguous tracks ( 2 , 6 ), ( 3 , 7 ) and ( 4 , 8 ), in a manner that completely covers the area to be reinforced 10 .
FIG. 5 represents a reinforcing band mechanically attached to itself. The reinforcing band 2 almost completely encircles the construction work 1 . It encircles it completely if the tensioning means 5 , 5 a is included. Tension is applied by traction on the second zone 2 c . Zone 2 c ′ is held in place (for example by anchoring) or is stretched as well. The reinforcing band is mechanically coupled to itself via the tensioning means. The tension of the band is transmitted to the work by the pressure that the band 2 exerts on the work 1 . The band 2 is anchored to the work, at a point located along its length for example, by gluing. | The method comprises the following steps for each of the reinforcing bands: a) anchoring a first zone ( 2 a, 3 a, 4 a ) of the reinforcing band onto the construction work and establishing a free portion of the reinforcing band; b) tensioning the reinforcing band ( 2, 3, 4 ) by applying traction to a second zone of the reinforcing band located in the free portion, said traction causing an elongation (d 2 , d 3 , d 4 ) of and a reactive force (R 2 , R 3 , R 4 ) in the reinforcing band, with the free portion of the reinforcing band being free to slide on the construction work as it elongates; and c) mechanically attaching the reinforcing band to itself and/or to the construction work, so as to absorb the reactive force from the reinforcing band within a region of the construction work which can support the reactive force from the reinforcing band. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention concerns a medical examination apparatus for imaging of the type having a front wall with an opening to a cylindrical examination area into which a patient to be examined can be moved.
[0003] 2. Description of the Prior Art
[0004] For the examination of a patient using a medical imaging apparatus, a part to be examined of the patient is brought into an examination area of the medical imaging apparatus. For example, in magnetic resonance tomography devices, computed tomography devices, and positron emission tomographs, the examination areas are usually cylindrical in shape. So that the entire patient can be brought into the examination area, the examination area has a diameter that is somewhat larger than the average shoulder width (approx. 60 cm). The examination area is surrounded by elements for imaging that are contained in a large housing, generally filling most of a room.
[0005] Upon seeing the large examination apparatus, simply the thought of being placed inside the tunnel-shaped examination area causes unpleasant feelings in most patients; when the patient is actually placed in the examination area these feelings can become stronger, to the point of claustrophobic panic attacks caused by the narrow surroundings. In other words, the sight of the examination apparatus, as well as the later placement of the patient into the examination area, together with its perceived narrowness, causes feelings of concern, anxiety or even fear in the patient.
[0006] In order to enable an examination to be carried out in spite of this fear, the patient is given a more or less strong sedative. This has the effect of limiting the patient's reactions well beyond the time required for the examination, and is often felt by the patient to be unpleasant or even damaging to the patient's health.
[0007] Translucent material is used in the illumination of, for example, advertising spaces or designer furniture. Due to its optical properties, e.g. its light conductivity due to its internal total reflection, it can be illuminated over large surfaces. An example of such a material is the polyester PET-G (polyethylene terephthalate glycol).
[0008] Light-emitting diode modules, for example the LINEARlight module made by the firm OSRAM, are used for example for light coupling in emergency beacons, in illuminated advertisements, or in path markers.
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to design the appearance of a medical imaging apparatus in such a way that the patent will be pleasantly affected, and his or her feelings of fear will be reduced.
[0010] According to the present invention, this object is achieved by a medical imaging apparatus, having a front wall with an opening to a cylindrical examination area into which a patient to be examined can be moved, and having an illumination arrangement for the illumination, over a large surface, of the front wall.
[0011] A front wall illuminated over a large surface using such an illumination arrangement dominates the perceived appearance of the examination apparatus, in relation to the opening to the examination area. By an appropriate choice of the illumination arrangement, the mood of the patient can be influenced by, for example, color and brightness. This has the advantage that in many cases it becomes unnecessary to administer a sedative. The resulting improved cooperation of the patient accelerates the examination, and reduces the amount of time he or she must spend in the examination apparatus.
[0012] In one embodiment of the present invention, the front wall and the adjacent inner housing wall form a hermetically sealed component around the hollow space. This has the advantage that no foreign objects can alter the optical properties of the system. For example, foreign objects situated on the backside of the front wall would hinder the illumination effect, and thus would change the visual appearance. With the use of PET-G polyester for the front wall and for the inner housing wall, the two parts can be formed, for example, using a deep-drawing method, and can be connected to one another at their contact points, e.g. by heating. This has the advantage that the hermetically sealed hollow space is created already when the front wall is made, and can be kept free of foreign objects.
[0013] A further advantage that does not relate solely to a completely hermetically sealed hollow space is that due to the double wall system of the component, formed by the front wall and the adjacent inner housing wall, in the area of the front wall there is an acoustic decoupling of the examination apparatus from the surrounding environment. This is particularly advantageous in a magnetic resonance apparatus, because here the noise to which the patient under examination is exposed is in considerable part communicated through the front wall to the air before reaching the patient. With the aid of an additional layer of foam between the component and the magnetic resonance apparatus, a noise suppression of several tens of decibels can easily be achieved.
[0014] In a further development, the illumination arrangement is an arrangement for the emission of light and/or a control and regulation unit for controlling and regulating the intensity and/or the color of the illumination. This has the advantage that the illumination, for example by lamps or light-emitting diodes, can be monitored and can be varied dependent on the course of the examination, including the preparations. Thus, for example, when the examination room is entered a warmer, calming color tone can be selected, which can for example be reduced in intensity while the patient is being placed on a patient bed of the examination apparatus. If the head of the patient is situated in the examination area during the examination, the illumination can be adapted to the needs of the user during the examination. If the head is situated outside the examination area, the patient can also be influenced, e.g. calmed, by the illumination during the examination.
[0015] In another embodiment, the arrangement for light emission includes one or more different light-emitting diodes, fashioned for example for the emission of light of different colors. The use of different light-emitting diodes has the advantage that the illumination can be varied in many ways, and can be controlled through the use of different combinations of light-emitting diodes. If the light-emitting diodes are used with the hermetically sealed component, the hermetic seal can be maintained by arranging the light-emitting diodes in the accessible edge of the front wall.
[0016] In a further embodiment, the arrangement for emitting light and the front wall are situated in relation to another such that colored light produced by the light-emitting means is mixed at or in the front wall to form an illuminating color. This simplifies the design, because no additional elements are required for the light mixing.
[0017] In another particular specific embodiment, a number of light-emitting diodes are combined in a light-emitting diode module, and in particular a number of these diodes, arranged in an annular row, surround the opening to the examination area. This has the advantage that commercially available light-emitting diode modules can be used, which can be individually exchanged in case of failure of one or more light-emitting diodes of the light-emitting diode modules.
[0018] In another embodiment. a number of light-emitting diodes are situated between an outer edge of the front wall and the examination area. This has the advantage that a homogenous illumination of the front wall is made easier, for example by positioning the light-emitting diodes in the midpoint of a bulge in the front wall.
[0019] The arrangement for emitting light can be situated on the outer edge of the front wall. This has the advantage that it is easily accessible and can be exchanged easily in case of failure.
[0020] In another embodiment, a light-emitting diode is situated in a bored hole in the front wall, in order to couple light produced by it into the front wall. This placement of the light-emitting diode in a bored hole, which for example runs parallel to the front wall on the outer edge of the front wall, enables an efficient coupling of light into the front wall.
[0021] In a further embodiment, the front wall has, on an outer side, a deflector for deflecting light from inside the front wall outwardly. Here, the deflector can include, for example, prism-shaped recesses in the outer side of the front wall. Alternatively, or in addition, the deflector can include layers that can be fastened to the front wall, which are suitable in particular for modifying the refractive index transition from the front wall to the surrounding air. The use of a deflector for deflecting light from the interior of the front wall outwardly makes it possible to achieve a homogenous illumination of the front wall by adapting the arrangement of the light deflector to the design of the illumination arrangement.
[0022] In another embodiment, the illumination arrangement is a projector and a number of light guides that conduct light produced by the projector to the front wall and couple it into the front wall. This has the advantage that the illumination and coloring can be monitored and influenced with the aid of the projector.
[0023] In an embodiment of the examination apparatus, the front wall has a text projection area onto which text can be projected using a projection system. In particular the projection can take place onto the inner or outer side of the front wall. An advantage of this specific embodiment is that the optical characteristics of the front wall are exploited in order to make additional information easily available, for example for the operating personnel.
DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows a schematic medical imaging apparatus having an illumination arrangement in accordance with the invention.
[0025] FIG. 2 shows a section through the front wall of the apparatus of FIG. 1 , with a light-emitting diode integrated into the front wall.
[0026] FIG. 3 shows a section through the front wall of a further embodiment of a medical imaging apparatus according to the invention. employing a projector and light guides.
[0027] FIG. 4 shows a section through the front wall of the apparatus of FIG. 1 , with a light-emitting diode arranged behind it.
[0028] FIG. 5 shows a front view of the front wall of a further embodiment of a medical imaging apparatus according to the invention with openings for operating elements and for a text projection area.
[0029] FIG. 6 shows two possible variants for the projection of text onto the text projection area of a further embodiment of a medical imaging apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] FIG. 1 shows a hollow cylindrical scanner 1 , as is often present in a medical imaging apparatus 2 . For example, the hollow cylindrical scanner 1 can contain a basic magnet of a magnetic resonance tomography device, or radiation detectors of a computed tomography device or of a positron emission tomography device. The hollow cylindrical scanner 1 dominates the visual appearance of the examination apparatus 2 . A patient can be introduced into opening 3 , for example on a patient bed (not shown). The opening 3 is surrounded by front wall 5 , which is composed of an upper front wall part 5 A and a lower front wall part 5 B, each manufactured from translucent material. This division simplifies the handling of the front wall 5 . In cross-section, front wall 5 has the shape of a ring and, for example, is curved away from the hollow cylinder of the scanner 1 in the center radial region. On its outer edge there are situated a number of light-emitting diode modules 7 A, 7 B, which are connected with a control and regulation unit 8 , which, for example, is integrated into a control unit of the examination apparatus 2 . From the control and regulation unit 8 , the light-emitting diode modules 7 A, 7 B are supplied with power, and individual light-emitting diodes, or all the light-emitting diodes, of the light-emitting diode modules 7 A, 7 B, can be driven to emit light. In particular, the control and regulation unit 8 is used to control the intensity and/or the color of the illumination.
[0031] FIG. 2 shows a section through the upper front wall part 5 A of front wall 5 from FIG. 1 . The front wall part 5 A has been manufactured from two plates of translucent material, for example the polyester PET-G, in a deep-drawing process. One of the plates forms an adjacent inner housing wall 10 A, and the other forms front wall 10 B. The curvature of the front wall 10 B toward the front can be seen. In the transition area of the two plates, which enclose a hermetically sealed hollow space 10 C, a light-emitting diode 9 is placed into a bored hole 11 , and radiates light into the translucent material of front wall 10 B. The front side of the front wall 11 B is roughened slightly, so that a total reflection of the light propagated in the material is prevented, and light exits through the front side. The illumination effect of the front wall 10 B is increased if the back wall 10 A is manufactured of a translucent material that has been tinted white and the front wall 10 B is manufactured of a translucent material that has been only slightly tinted green, for example as imitation glass. Due to the hermetic sealing of the front wall part 5 A, the optical appearance cannot be affected by contamination in the interior. For example, the coloring is produced by the colors of the translucent material, and the colors can be accentuated by white light-emitting diodes. The desired optical impression also can be produced without active illumination. If it is desired to vary the illumination effect, it is advantageous to use a controllable active illumination arrangement, the intensity and color of which can be adjusted.
[0032] Due to the higher intensity of the coupled-in light near the light-emitting diode 9 , prism-shaped recesses 13 are additionally made in the front side of front wall part 5 . The recesses 13 effect an increased emission of light due to a modified angle of incidence. The distribution density of the recesses 13 increases with the distance from light-emitting diode 9 , so that the intensity of the light in the translucent material, which decreases due to the coupling out and the propagation, is compensated, and a homogenous illumination of the front wall 5 is achieved.
[0033] FIG. 3 shows another embodiment for coupling light into the front wall part 5 A. A projector 15 produces colored light that is coupled into light guides 17 . Light guides 17 are routed along the outer edge of the front wall part 5 A. There, the exiting light is coupled into the front wall part 5 A. For the coupling in, light guides 17 can be distributed uniformly around the outer edge.
[0034] As an alternative to the prism-shaped recesses, refractive index layers 19 can be attached on the outer side of front wall part 5 A, for example in the form of stickers or decals. The refractive index of refractive index layers 19 preferably lies between the refractive index of the front wall 5 A and that of the surrounding air. In this way, the layers 19 prevent total reflection, and result in an increased coupling out of the light from the interior of the front wall part 5 A. This effect, due to so-called “phase-shifted printing,” can achieve a uniform illumination or radiation.
[0035] FIG. 4 shows an alternative design for the illumination of an upper front wall part 5 A′ of the front wall 5 from FIG. 1 . In the direction of the hollow cylinder of the scanner 1 , an adjacent inner housing wall 21 is additionally situated on which there is fastened, approximately in the center, a light-emitting diode 9 A. The light-emitting diode 9 A can for example be part of a light-emitting diode module that is situated annularly around the opening 3 . If the curvature of the front wall part 5 A′ is such that the distance D from various points of the front wall part 5 A′ to the light-emitting diode 9 A is essentially equal, this results in a uniform illumination. In the area of the opening 3 , a sheathing 23 is additionally attached that produces an funnel-shaped entry for light to the opening 3 , and enables easy assembly of the front wall part 5 A′.
[0036] FIG. 5 shows a front view of a front wall 5 ′ with opening 3 . In two operating areas situated at operating height, the front wall 5 ′ has openings 27 into which operating units 25 A, 25 B can be introduced. The operating units 25 A, 25 B, similar to that of front wall 5 ′, have a circuit board for the required electronic elements. Illuminated operating buttons situated in the openings 27 are set off in a particularly well-contrasted fashion from the operating units 25 A, 25 B, which, for example, are weakly illuminated. In addition, the front wall 5 ′ has an opening for a text projection unit 29 on which, for example, patient data or information accompanying the examination are projected. The text projection unit 29 can be illuminated with particular colors such that a high contrast to the text is achieved. In addition, indications for the patient or for the operating personnel can be incorporated into the text projection, for example technical data concerning the position of the patient bed, the brightness of the illumination, etc.
[0037] The front wall 5 ′ preferably is subdivided further into an upper part and a lower part, each of which is hermetically sealed.
[0038] FIG. 6 shows two possible positions of a projection system required for projection or illumination. For example, projector 31 can be fastened, at some distance from the examination apparatus, to a ceiling 33 of a room in which the examination apparatus is located. In addition to the illumination of text projection unit 29 , it can also be used to illuminate the front wall 5 ′. Alternatively, a projection system 35 can be used having a deflecting mirror 37 that is situated in the intermediate space between the front wall 5 ′ and the adjacent housing wall 21 ′.
[0039] If the front wall 5 ′ is illuminated, for example by the projector 31 , colored translucent materials can be used for front wall 5 ′, and it can be illuminated with white light. In this case as well, a variation of the illumination intensity then results in a calming effect on the patient. Alternatively, colored light or a colored image can be projected on a front wall 5 ′ that is for example colored white.
[0040] In the described embodiments, various types of light mixing are possible for the production of mood-influencing colors. Light having the desired color can be produced by differently colored light-emitting diodes 11 , or in a projector 15 , and can be coupled into the front wall 5 directly or via light guides 17 . Alternatively, the light mixing can take place in the translucent material itself, by the coupling of light of various colors into the front wall 5 ′.
[0041] The color of the light can be adjusted with respect to its psychological effect as well as with respect to the coloring of the surrounding premises and of the examination apparatus. In the former case, such adjustment makes it possible to induce particular moods or to neutralize feelings of fear.
[0042] In addition, alternative light effects, for example lighting patterns or transitions between different colors, can be used. For example, upon entering the examination room bright color tones such as green and white preferably are selected. Subsequently, a change preferably is made to reddish yellow-orange color tones, in order to exert a calming influence on the patient. Using remote controlling or local controlling, the light intensity or the color mixing can be subsequently controlled or adjusted in an adaptive fashion. The coloring can be adapted during the course of the examination, or can be adapted to different examinations. For example, in an examination in which the head of the examination subject is situated outside the examination area, the color can be selected to be stimulating or calming during the examination itself.
[0043] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art. | A medical imaging examination apparatus has a front wall with an opening to a cylindrical examination area into which a patient to be examined can be moved, and has an illumination arrangement for the illumination of the front wall over a large surface. The illumination of the front wall reduces feelings of fear on the part of a patient, and thus simplifies conducting examinations using the examination apparatus. | 0 |
PRIORITY DOCUMENTS
This application corresponds to and derives priority from U.S. Provisional Application Ser. No. 60/100,648, filed Sep. 16, 1998
TECHNICAL FIELD
The present invention relates to electric control circuits and, more particularly, to a method and apparatus for using a self-powered current loop to transmit a process variable using only the current that drives the loop.
BACKGROUND AND OBJECTS OF THE INVENTION
The use of current loops enables the most popular, safe and easy method of transmitting a process variable to a distance limited only by the electromotive force (EMF) that drives the loop. A current loop's simple, two-wire connection allows for fast and simple interconnection to as many devices in the loop (in series) as desired, limited only by the loop's EMF.
Traditional current-loop controllers are externally powered through AC Mains or direct current voltage. They are expensive, complex and bulky. It is desirable, then, to provide a current-loop controller that avoids these shortcomings and that has other advantages as described below. The control circuit should, in addition to driving desired devices, be able to provide, control, and/or indicate outputs and control or manage processes.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus in the form of a current-loop controller and associated method that is driven by the EMF in the loop. The current-loop controller provides, controls and indicates output to control and manage a process without the need for external power. Since the current industry standard for current-loops is 4-20 maDC, the preferred embodiment is designed to reliably operate devices connected in the loop (in series) within the current operating range of 4-20 mA. This is not, however, intended to limit the present invention to such range.
In the preferred embodiment of the controller electric current is initially applied to the circuit formed by the controller, causing a first light-emitting diode (LED) and a first pair of transistors to tum on. The transistors allow current to flow through a zener diode and a resistor, and out to an −L current loop to close the circuit. A zener diode regulates voltage extracted from the current to power another reference diode and a comparator. If the signal variable monitored by the first resistor drops below the set point value of the comparator, the comparator will switch its output to a high (VCC) level turning the first transistor off and allowing the current to flow through an LED, the opto-isolator's internal LED, another diode, and a second transistor which is on. The opto-isolator's internal LED turns on its phototransistor causing its collector and emitter terminals to have a very low resistance energizing and external device.
When the signal variable exceeds the set point value of the first comparator, it switches to low (ground) turning on the first transistor which turns off the LED and the opto-isolator's internal LED and phototransistor. The same is true for the high-limit second comparator, but in reverse. If the signal in the current loop exceeds the set point, the second comparator will turn off the second transistor, thereby routing the current through its associated LED and opto-isolator turning on the LED and phototransistors in the same manner as in the “low” comparator, but reversed for “high” comparison.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of the preferred embodiment controller according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the circuit diagram illustrated in FIG. 1, a circuit ( 10 ) forms a loop-powered controller according to the present invention. The +L current is applied to the first terminal ( 12 ). A first light-emitting diode (LED) ( 14 ) is provided to prevent reversed voltage from damaging circuitry and to give a visual display indicative of current flow in the loop. First and second zener diodes ( 16 , 18 ) protect the circuitry from over-voltages that may result from inadvertent connections. First and second transistors ( 20 , 22 ), when “on” (no alarm condition), pass the current through the circuitry and the flow out to the −L current-loop ( 24 ). From the instant current is applied, first and second voltage comparators ( 26 , 28 ) are off (low) and the transitors ( 20 , 22 ) are “on.” A third zener diode ( 30 ) clamps the loop's current to a voltage for safe operation of the circuitry. A first resistor ( 32 ) converts that current flow to voltage (current shunt) for the comparators ( 26 , 28 ) variable input. A fourth diode ( 34 ) is a voltage reference for the comparators' ( 26 , 28 ) set points through potentiometers ( 36 , 38 ) to compare to the variables at its pins ( 27 , 29 ). Upon the limit (set point) being exceeded, the output of one of the comparators ( 26 or 28 ) switches from “Low” to “High” turning pass transistor ( 20 or 22 ) off, forcing the current to flow through the opto-isolator ( 25 ) LED turning its phototransistor on, energizing their load and at the same time turning “on” one of the LEDs ( 44 or 46 ) for visual indication of out of limit condition. A pair of diodes ( 40 , 42 ) compensate for voltage drop across the opto-isolator's ( 25 ) photodiodes for the LEDs ( 44 or 46 ) to operate. Since the voltage level at the collector of the transistors ( 20 or 22 ) changes due to the voltage drop across the diodes ( 44 or 46 ), the internal LEDs of the opto-isolator ( 25 ) and the magnitude of the current loop, the circuit combination of the resistor ( 48 ), the diode ( 50 ), and the resistor ( 52 )—or the resistor ( 54 ), the diode ( 56 ), and the resistor ( 58 )—are used to shift the voltage level at the base of the transistors ( 20 or 22 ) for their correct “on-off” operation from the logic level output of the first comparator ( 26 ) or the second comparator ( 28 ).
In operation, the preferred embodiment controller ( 10 ) operates as described below. When electric current is initially applied to the circuit formed by the controller ( 10 ), the first LED ( 14 ) turns on and the first and second transistors ( 20 , 22 ) turn on. The transistors ( 20 , 22 ) allow current to flow through the third zener diode ( 30 ) and the first resistor ( 32 ) and out to the −L current loop ( 24 ) closing the circuit. The third zener diode ( 30 ) regulates voltage extracted from the current to power the fourth diode ( 34 ) and the comparators ( 26 , 28 ). If the signal variable monitored by the first resistor ( 32 ) drops below the set point value of the second comparator ( 28 ), the second comparator ( 28 ) will switch its output to a high (VCC) level turning the first transistor ( 20 ) off and allowing the current to flow through the diode ( 44 ), the opto-isolator's ( 25 ) internal LED (not shown), the diode ( 42 ), and the second transistor ( 22 ) which is on. The optoisolator's ( 25 ) internal LED turns on its phototransistor causing its collector and emitter terminals to have a very low resistance energizing an external device.
When the signal variable exceeds the set point value of the second comparator ( 28 ), it switches to low (ground) turning on the first transistor ( 20 ) which turns off the diode ( 44 ) and the opto-isolator's ( 25 ) internal LED and phototransistor. The same is true for the high-limit first comparator ( 26 ), but in reverse. If the signal in the current loop exceeds the set point, the first comparator ( 26 ) will turn off the second transistor ( 28 ), thereby routing the current to the diodes ( 46 , 40 ) and the second opto-isolator half ( 25 ).
The loop-powered technique described herein and its low component count and size allows the controller ( 10 ) of the present invention to be used anywhere within the “loop” run | An apparatus in the form of a current-loop controller driven by the EMF in the loop without the need for external power operates devices connected in the loop (in series) within the current operating range. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates generally to a torque sensor which may be employed to measure torque transmitted to a steering shaft of automotive electric power steering devices, and more particularly to an improved structure of such a torque sensor which is simple and high in operational reliability.
[0003] 2. Background Art
[0004] Japanese Patent First Publication No. 8-159887 teaches a torque sensor including a magnet and a magnetic sensor. The magnet and the magnetic sensor are so secured to ends of a torsion bar that they are moved relative to each other upon twisting of the torsion bar. The magnetic sensor works to produce an output as a function of the torque applied to the torsion bar.
[0005] Japanese Patent First Publication No. 6-281513 teaches a torque sensor which, like the above publication, includes a magnet and a magnetic sensor. The torque sensor also includes a torque converting gear mechanism which works to convert the torsion of a torsion bar into movement of a gear in a longitudinal direction of input and output shafts. The magnetic sensor is secured to a housing, thereby eliminating the need for electric contact parts such as brushes and a slip ring used to supply power to the magnetic sensor and pick up a signal from the magnetic sensor.
[0006] The former torque sensor has the magnet and the magnetic sensor connected to the torsion bar, thus requiring electric contact parts such as brushes and a slip ring used to supply power to and pick up a signal from the magnetic sensor, which leads to a greater concern about the reliability of the sensor.
[0007] The latter torque sensor has the disadvantage that the backlash or wear of the torque converting gear mechanism may result in error or delay in measurement of the torque.
SUMMARY OF THE INVENTION
[0008] It is therefore a principal object of the invention to avoid the disadvantages of the prior art.
[0009] It is another object of the invention to provide a torque sensor which is simple in structure and high in operational reliability.
[0010] According to one aspect of the invention, there is provided a torque sensor which may be employed in measuring the torque applied to a steering shaft of an electric power steering device for automotive vehicles. The torque sensor comprises: (a) a first shaft; (b) a second shaft; (c) an elastic member coupling the first shaft to the second shafts in alignment with each other, upon input of torque, the elastic member undergoing torsion; (d) a hard magnetic member joined to the first shaft, the hard magnetic member having magnetic poles arrayed on a periphery thereof to produce a magnetic field therearound; (e) an assembly of a first and a second soft magnetic member which is joined to the second shaft and placed around the hard magnetic member within the magnetic filed produced by the hard magnetic member to form a magnetic circuit so that upon a change in position of the first and second magnetic members relative to the hard magnetic member arising from the torsion of the elastic member, density of magnetic flux developed within the magnetic circuit changes; and (f) a magnetic sensor placed in non-contact with the first and second soft magnetic members. The magnetic sensor works to measure the density of magnetic flux within the magnetic circuit. The first and second soft magnetic members are opposed to each other through a given gap in a direction of the alignment of the first and second shafts. The first and second soft magnetic members have as many claws as the poles of the hard magnetic member which are arrayed at regular intervals on peripheries of the first and second soft magnetic members, respectively. Each of the claws of the first soft magnetic member is interposed between adjacent two of the claws of the second soft magnetic member. Each of the claws has a base portion and a head portion to have substantially a trapezoidal shape. The base portion has a width A extending in a circumferential direction of the first and second soft magnetic members. The head portion has a width B extending in the circumferential direction which is smaller than the width A. The widths A and B are selected to meet relations below.
0.6 ×F<L< 1.2 ×F
A< 0.5 ×P
B< 0.15 ×P
where F is a distance between the first and second soft magnetic members in the direction of the alignment of the first and second shafts, L is a length of each of the claws from the base portion to the head portion, and P is a distance between one of outer edges of each of the claws of the first soft magnetic member and one of outer edges of an adjacent one of the claws of the second magnetic member which lies on the same side as the first soft magnetic member in the circumferential direction of the first and second soft magnetic members.
[0011] Upon input of torque, the elastic member twists, thus resulting in a shift in position between the assembly of the first and second soft magnetic member and the hard magnetic member which causes the density of magnetic flux flowing in the magnetic circuit to change. The magnetic sensor is responsive to such a change to produce an output as a function of the torque applied to the elastic member. This structure eliminates the need for the magnetic sensor to measure the density of magnetic flux directly emerging from the hard magnetic member, thus enabling the magnetic sensor to be installed to be stationary. This eliminates the need for electric parts used in contact with the magnetic sensor, thus resulting in improved reliability of operation of the torque sensor.
[0012] Additionally, the satisfaction of the above relation among the widths A and B, the distance F, the length L, and the distance P allows the interval between the top of the claws of the first soft magnetic member and the second shaft magnetic member and the interval between adjacent two of the claws of the first and second soft magnetic members to be selected as to increase the density of magnetic flux produced in the first and second soft magnetic members. This results in improved sensitivity of the magnetic sensor.
[0013] In the preferred mode of the invention, the torque sensor may further include auxiliary soft magnetic members which have magnetic flux collecting portions, respectively, which serve to collect the magnetic flux from the first and second soft magnetic members at the magnetic sensor. This permits the magnetic sensor to measure the average of the density of magnetic flux produced over the periphery of the assembly of the first and second soft magnetic members.
[0014] Each of the first and second soft magnetic members has a ring-shaped flange to which the claws are affixed. The base portion of each of the claws extends from the ring-shaped flange. The head portion extends from the base portion. This structure facilitates ease of arrangement of the claws over the periphery of each of the first and second soft magnetic members at equi-intervals.
[0015] The magnetic sensor is disposed within the given gap between the first and second soft magnetic members to measure the density of magnetic flux flowing between the first and second soft magnetic members. Specifically, when the twisting of the elastic member causes the hard magnetic member to be moved relative to the assembly of the first and second soft magnetic members, the claws of the first soft magnetic member move close to the N-poles or S-poles, while the claws of the second soft magnetic member move close to the S-poles or N-poles of the hard magnetic member, thereby causing magnetic fluxes having opposite polarities to flow through the first and second soft magnetic members, respectively. This causes plus and minus densities of magnetic fluxes to be created within the gap between the first and second soft magnetic members which are substantially proportional to the degree of torsion of the elastic member. The determination of the degree of magnetic flux proportional to the degree of torsion of the elastic member is, thus, achieved by exposing the magnetic sensor to the magnetic fluxes between the first and second soft magnetic members.
[0016] The magnetic flux collecting portions of the auxiliary soft magnetic members are opposed to each other in the direction of alignment of the first and second shafts. The magnetic sensor is interposed between the magnetic flux collecting portions to measure the density of magnetic flux flowing between the first and second soft magnetic members through the magnetic flux collecting portions. This increases the efficiency of measuring the density of magnetic flux.
[0017] According to another aspect of the invention, there is provided a torque sensor which comprises: (a) a first shaft; (b) a second shaft; (c) an elastic member coupling the first shaft to the second shafts in alignment with each other, upon input of torque, the elastic member undergoing torsion; (d) a hard magnetic member joined to the first shaft, the hard magnetic member having magnetic poles arrayed on a periphery thereof to produce a magnetic field therearound; (e) an assembly of a first and a second soft magnetic member which is joined to the second shaft and placed around the hard magnetic member within the magnetic filed produced by the hard magnetic member to form a magnetic circuit so that upon a change in position of the first and second magnetic members relative to the hard magnetic member arising from the torsion of the elastic member, density of magnetic flux developed within the magnetic circuit changes; and (f) a magnetic sensor placed in non-contact with the first and second soft magnetic members, working to measure the density of magnetic flux within the magnetic circuit. The first and second soft magnetic members are opposed to each other through a given gap in a direction of the alignment of the first and second shafts. The first and second soft magnetic members have as many claws as the poles of the hard magnetic member which are arrayed at regular intervals on peripheries of the first and second soft magnetic members, respectively. Each of the claws of the first soft magnetic member is interposed between adjacent two of the claws of the second soft magnetic member. Each of the claws has a base portion and a head portion. The base portion has a width A extending in a circumferential direction of the first and second soft magnetic members which is greater than a width of the head portion extending in the circumferential direction. The width A and a distance P between one of outer edges of each of the claws of the first soft magnetic member and one of outer edges of an adjacent one of the claws of the second magnetic member which lies on the same side as the first soft magnetic member in the circumferential direction of the first and second soft magnetic members meet a relation of 0.5×P<A<P.
[0018] Upon input of torque, the elastic member twists, thus resulting in a shift in position between the assembly of the first and second soft magnetic member and the hard magnetic member which causes the density of magnetic flux flowing in the magnetic circuit to change. The magnetic sensor is responsive to such a change to produce an output as a function of the torque applied to the elastic member. This structure eliminates the need for the magnetic sensor to measure the density of magnetic flux directly emerging from the hard magnetic member, thus enabling the magnetic sensor to be installed to be stationary. This eliminates the need for electric parts used in contact with the magnetic sensor, thus resulting in improved reliability of operation of the torque sensor.
[0019] Additionally, the satisfaction of the above relation among the width A and the distance P ensures improved linearity of a changing density of magnetic flux to be measured by the magnetic sensor.
[0020] In the preferred mode of the invention, the torque sensor may further include an auxiliary soft magnetic member which has a magnetic flux collecting portion serving to collect the magnetic flux from the first and second soft magnetic members at the magnetic sensor. This permits the magnetic sensor to measure the average of the density of magnetic flux produced over the periphery of the assembly of the first and second soft magnetic members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The present invention will be understood more fully from the detailed description given hereinbelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments but are for the purpose of explanation and understanding only.
[0022] In the drawings:
[0023] FIG. 1 is a perspective exploded view which shows a torque sensor according to the first embodiment of the invention;
[0024] FIG. 2 is a longitudinal sectional view which shows the torque sensor as illustrated in FIG. 1 ;
[0025] FIG. 3 ( a ) is a transverse sectional view which shows a magnet assembly and an assembly of magnetic rings installed in the torque sensor of FIG. 1 ;
[0026] FIG. 3 ( b ) is a side view of FIG. 3 ( a );
[0027] FIGS. 4 ( a ), 4 ( b ), and 4 ( c ) are views each of which shows a positional relation between the magnet and the magnetic rings as illustrated in FIGS. 3 ( a ) and 3 ( b );
[0028] FIG. 4 ( d ) is a graph which shows a relation between the density of magnetic flux and a torsional angle of a torsion bar (i.e., an angular shift between the magnet and the magnetic rings as illustrated in FIGS. 3 ( a ) and 3 ( b )) in terms of an ambient temperature;
[0029] FIG. 5 is an enlarged view which shows magnetic rings;
[0030] FIG. 6 is a graph which shows a relation between the density of magnetic flux and a torsional angle of a torsion bar (i.e., an angular shift between the magnet and the magnetic rings as illustrated in FIGS. 3 ( a ) and 3 ( b )); and
[0031] FIG. 7 is a perspective exploded view which shows a torque sensor according to the second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Referring to the drawings, wherein like reference numbers refer to like parts in several views, particularly to FIG. 1 , there is shown a torque sensor 1 according to the first embodiment of the invention which may be employed in an electric power steering device for automotive vehicles. The following discussion will refer to, as an example, a case where the torque sensor 1 is installed in the electric power steering device.
[0033] The torque sensor 1 is disposed between an input shaft 2 (i.e., a steering shaft of the vehicle) and an output shaft 3 and works to measure torque transmitted to the input shaft 2 which is produced by turning a steering wheel of the vehicle.
[0034] The torque sensor 1 consists essentially of a torsion bar 4 (elastic member), a magnet assembly 5 made of a hard magnetic material, a pair of magnetic yokes 6 made of a soft magnetic material, and a magnetic sensor 7 . The torsion bar 4 couples the input shaft 2 and the output shaft 3 together in alignment to each other. The magnet assembly 5 is installed on an end of the input shaft 2 . The magnetic yokes 6 are retained by a yoke holder 9 and joined to an end of the output shaft 3 . The magnetic sensor 7 works to measure the density of magnetic flux flowing between the magnetic yokes 6 .
[0035] The torsion bar 4 is joined at ends thereof to the input shaft 2 and the output shaft 3 through pins 8 so that it exhibits a required input torque-to-torsion characteristic. Twisting of the torsion bar 4 causes the input shaft 2 to rotate or twist relative to the output shaft 3 .
[0036] The magnet assembly 5 is of a ring-shape and consists of, for example, twenty four (24) poles having N-faces and S-faces arrayed alternately around the outer periphery thereof.
[0037] The pair of magnetic yokes 6 (as will also be denoted as 6 A and 6 B below), as shown in FIG. 1 , are made of annular members disposed in the vicinity of the periphery of the magnetic assembly 5 . Each of the magnetic yokes 6 is made up of an annular flange and as many claws 6 a as the poles (N- and S-poles) of the magnetic assembly 5 arrayed over the circumference of the flange at regular intervals. The yoke holder 9 , as shown in FIG. 2 , retains the magnetic yokes 6 so that each of the claws 6 a of one of the magnetic yokes 6 is located between adjacent two of the claws of the other magnetic yoke 6 in a circumferential direction thereof.
[0038] The magnetic yokes 6 and the magnet assembly 5 are so positioned that each of longitudinal center lines of the claws 6 a of the magnetic yokes 6 , as clearly shown in FIG. 3 ( b ), coincides with a boundary of the N-pole and S-pole in a condition where the torsion bar 4 is not twisted, that is, torsion or torque is not developed between the input and output shafts 2 and 3 .
[0039] The magnetic sensor 7 is, as clearly shown in FIG. 3 , disposed within a gap G between the magnetic yokes 6 A and 6 B opposed to each other in a longitudinal direction of the torque sensor 1 (i.e., a direction of alignment of the input and output shafts 2 and 3 ) and works to measure the density of magnetic flux flowing between the magnetic yokes 6 A and 6 B. The magnetic sensor 7 is secured rigidly by a sensor housing (not shown) at a given interval away from the magnetic yokes 6 A and 6 B.
[0040] The magnetic sensor 7 may be made of a Hall IC or a magnetoresistor which works to convert the magnetic flux density into an electric signal and output it.
[0041] In operation, when the torque sensor 1 is in a neutral position where the torque is not inputted to the input shaft 2 , that is, the torsion bar 4 is not twisted, the longitudinal center line of each of the claws 6 a of the magnetic yokes 6 , as clearly illustrated in FIG. 4 ( b ), coincides with one of the boundaries of the N-poles and S-poles of the magnet assembly 5 . In this case, as many magnetic lines of force as the poles (N- and S-poles) of the magnet assembly 5 pass through the claws 6 a of each of the magnetic yokes 6 , so that they are closed in the magnetic yokes 6 A and 6 B. This cause no magnetic flux to leak into the gap G between the magnetic yokes 6 A and 6 B, so that the magnetic sensor 7 detect magnetic flux density of zero (0), as illustrated in FIG. 4 ( d ).
[0042] When the torque is applied to the input shaft 2 , so that the torsion bar 4 is twisted, it will cause the magnet assembly 5 installed on the input shaft 2 to rotate relative to the magnetic yokes 6 secured on the output shaft 3 , thereby resulting in, as shown in FIG. 4 ( a ) or 4 ( c ), shifting between the claws 6 a and the boundaries of the magnetic poles (N- and S-poles) of the magnet assembly 5 , so that the magnetic lines of force having an N- or S-polarity are increased in the magnetic yokes 6 . Specifically, the magnetic lines of force in the magnetic yoke 6 A is reverse in polarity to the magnetic lines of force in the magnetic yoke 6 B, thus causing the density of magnetic flux to be created in the gap G between the magnetic yokes 6 A and 6 B which is, as shown in FIG. 4 ( d ), substantially proportional to the degree of torsion of the torsion bar 4 and reversed in polarity upon reversal of the direction in which the torsion bar 4 is twisted. The magnetic sensor 7 senses the density of magnetic flux and outputs an electric signal indicative thereof.
[0043] As apparent from the above discussion, the torque sensor 1 is so designed that when the torsion bar 4 is twisted, and the magnet assembly 5 is shifted relative to the magnetic yokes 6 in the circumferential direction thereof, it results in a change in density of magnetic flux between the magnetic yokes 6 over the circumference thereof. Specifically, the density of magnetic flux will be uniform over the circumference of the magnetic yokes 6 . It is, thus, possible for the magnetic sensor 7 to detect the density of magnetic flux correctly anywhere in the gap G between the magnetic yokes 6 A and 6 B without any physical interference with the magnetic yokes 6 A and 6 B. This eliminates the need for electric contact parts such as a slip ring and brushes in the magnetic sensor 7 , thus ensuring the reliability of operation of the torque sensor 1 .
[0044] We performed tests, as described below, on the geometry of the magnetic yokes 6 in order to increase the density of magnetic flux produced therein within a measuring range of the magnetic sensor 7 .
[0045] We prepared some test pieces of the magnetic yokes 6 , as shown in FIG. 5 . Each of the claws 6 a is substantially trapezoidal in shape and made up of a base portion 6 a 1 and a head portion 6 a 2 and symmetric with respect to a center line thereof extending parallel to the longitudinal center line of the torque sensor 1 . The base portion 6 a 1 has the width A greater than the width B of the head portion 6 a 2 in the circumferential direction of the magnetic yokes 6 . The with B may alternatively be zero (0). In other words, each of the claws 6 a may be of substantially a triangular shape.
[0046] Under the experimental conditions where the number of poles of the magnet assembly 5 is twenty four (24), the inner diameter r, as shown in FIG. 3 ( a ), of the magnetic yokes 6 is 31 mm, and the distance F between the magnetic yokes 6 A and 6 B in the direction parallel to the longitudinal direction of the torque sensor 1 is 8 mm, we rotated the test pieces of the magnetic yokes 6 through 2.5 degrees from the neutral position in the circumferential direction thereof and measured the density of magnetic flux created for different values of the width A of the base portion 6 a 1 , the width B of the head portion 6 b 2 , and the length L of the claws 6 a . Results of the tests are shown in table 1 below.
TABLE 1 A (mm) B (mm) L (mm) Density (mT) 1 st test 5.5 1.9 7 14.80 2 nd test 5.5 1.9 9 17.14 3 rd test 3.7 1.5 5 18.39 4 th test 4.6 1.2 7 19.25 5 th test 3.7 1.9 7 21.10
[0047] Comparison between the first and fifth tests in table 1 shows that the density of magnetic flux in the magnetic yokes 6 greatly depends upon the width A of the base portions 6 a 1 of the claws 6 a . Comparison between the first and second tests shows that the density of magnetic flux in the magnetic yokes 6 greatly depends upon the length L of the claws 6 . It is, thus, found that the density of magnetic flux produced in the magnetic yokes 6 is sensitive to the width A of the base portions 6 a 1 and the length L of the claws 6 a.
[0048] Next, we prepared four test pieces, as listed in table 2 below, which have different values of the length L of the claws 6 a and different values of the width A of the base portion 6 a 1 of the claws 6 a , rotated the test pieces of the magnetic yokes 6 through 2.5 degrees from the neutral position, and measured the density of magnetic flux in each of the test pieces under the same experimental conditions as described above.
TABLE 2 A (mm) 1 st test 2 nd test 3 rd test 3.2 3.7 4.2 L (mm) 1 st test 6.5 19.38 (mT) 19.91 (mT) 19.52 (mT) 2 nd test 7.0 20.06 (mT) 20.31 (mT) 19.94 (mT) 3 rd test 7.5 19.56 (mT) 19.78 (mT) 19.84 (mT) 4 th test 8.0 19.68 (mT) 19.78 (mT) 18.94 (mT)
[0049] Table 2 shows that the density of magnetic flux produced in the magnetic yokes 6 has a maximum value in the second test piece in which the length L of the claws 6 is 7.0 mm, and the width A of the base portions 6 a 1 of the claws 6 is 3.7 mm.
[0050] It is, thus, found that an optimum value of the length L of the claws 6 is 7 mm.
[0051] The theory on increasing of the density of magnetic flux produced in the magnetic yokes 6 will be described below.
[0052] When the length L of the claws 6 is changed in proportional to the distance F between the magnetic yokes 6 A and 6 B, a flow and amount of magnetic flux between the magnet assembly 5 and the magnetic yokes 6 remain unchanged.
[0053] Comparison between the second and third tests in table 1 shows that the test piece in which the length L is 9 mm is greater in density of magnetic flux than the test piece in which the length L is 5 mm. The distance F between the magnetic yokes 6 A and 6 B of the torque sensor 1 of this embodiment has a constant value of 8 mm. Constants of proportion of the length L of the claws 6 to the distance F in the second and third test pieces are, thus, obtained by dividing the length L by 8 mm, which are listed below.
L (5 mm )/ F (8 mm )=0.625 (1)
L (9 mm )/ F (8 mm )=1.125 (2)
[0054] In the following discussion, adjacent two of the claws 6 a of the magnetic yoke 6 B will be, as shown in FIG. 5 , denoted at numeral 61 and 62 . If the width A of the base portion 6 a 1 of the claws 6 and the distance P between the leftmost edge, as viewed in the drawing, of the base portion 6 a 1 of the first claw 61 and the leftmost edge of the base portion 6 a 1 of the second claw 62 are changed, an interval between the first and second claws 61 and 62 in the circumferential direction of the magnetic yokes 6 changes, thus resulting in a change in amount of magnetic flux flowing through the magnet assembly 5 and the magnetic yokes 6 .
[0055] Since the number n of poles of the claws 6 a of each of the magnetic yokes 6 is twelve (12), the distance P between the outermost edges of the base portions 6 a 1 of the first and second claws 61 and 62 in the circumferential direction of the magnetic yokes 6 may be expressed as
P ( mm )=π× r (31 mm )/ n (12)≈8.11 (3)
[0056] It is, as described above, found from table 2 that the second test piece in which the length L of the claws 6 is 7.0 mm, and the width A of the base portions 6 a 1 of the claws 6 is 3.7 mm has a maximum density of magnetic flux produced in the magnetic yokes 6 . The density of magnetic flux produced in the second test piece varies is represented by a solid curved line in FIG. 6 . The density of magnetic flux produced in the third test piece in which the width A is 4.2 mm varies as represented by a sine curve indicated by a broken line in FIG. 6 .
[0057] Therefore, this embodiment determines a threshold (i.e., an upper limit) of the width A of the base portions 6 a of the claws 6 as 4.2 mm used in the third test piece. A constant of proportion of the width A of the base portions 6 a 1 of the claws 6 to the distance P between the outer edges of the base portions 6 a 1 of the claw 61 and the claw 62 is, thus, determined as
A (4.2 mm )/ P (8.11 mm )≈0.517 (4)
[0058] If the width B of the head portions 6 a 2 of the claws 6 and the distance P between the outermost edges of the base portions 6 a 1 of the first claw 61 and the second claw 62 are changed, the interval between the first and second claws 61 and 62 in the circumferential direction of the magnetic yokes 6 changes, thus resulting in a change in amount of magnetic flux flowing through the magnet assembly 5 and the magnetic yokes 6 .
[0059] It is found from table 1 that if the width B of the head portions 6 a 2 is increased more than 1.2 mm, the density of magnetic flux produced in the magnetic yokes 6 decreases. This embodiment, therefore, determines a threshold (i.e., an upper limit) of the width B of the head portions 6 a 2 as 1.2 mm. A constant of proportion of the width B of the head portions 6 a 2 of the claws 6 to the distance P between the outer edges of the base portions 6 a 1 of the claw 61 and the claw 62 is, thus, determined as
B (1.2 mm )/ P (8.11 mm )≈0.15 (5)
[0060] Therefore, if the length L of the claws 6 is, as obtained from Eqs. 1 and 2, defined within a range, as expressed in Eq. 6 below, the width A of the claws 6 is, as obtained from Eq. 4, defined within a range, as expressed in Eq. 7 below, and the width B of the claws 6 is, as obtained from Eq. 5, defined within a range, as expressed in Eq. 8 below, the density of magnetic flux produced in the magnetic yokes 6 has values which fall, as indicated by the solid curved line in FIG. 6 , within dead zones where the density of magnetic flux hardly undergoes a change and also has absolute values greater than those on the broken sine curved line within a torque measuring range of the magnetic sensor 7 which is defined between ±15 deg. This results in increased sensitivity of the torque sensor 7 to the density of magnetic flux to be measured. Note that the constants of proportion are determined in consideration for some errors in the experimental data.
0.6 ×F<L< 1.2 ×F (6)
A< 0.5 ×P (7)
B< 0.15 ×P (8)
The torque sensor 1 of this embodiment is, as described above, so designed that the number n of poles of the magnet assembly 5 and a total number n of poles of the magnetic yokes 6 are twenty four (24), the inner diameter r of the magnetic yokes 6 is 31 mm, and the distance F between the magnetic yokes 6 A and 6 B is 8 mm. Even if the size of the magnetic yokes 6 is changed, so that the number n of poles, the inner diameter r, and the distance F are changed proportional to the change in size of the magnetic yokes 6 , the amount and a path of magnetic flux flowing through the magnet assembly 5 and the magnetic yokes 6 remain unchanged. In any case, the density of magnetic flux produced in the magnetic yokes 6 , therefore, has absolute values greater than those on the broken sine curved line within the torque measuring range of the torque sensor 1 as long as the conditions, as given by Eqs. 6, 7, and 8, are met.
[0061] The density of magnetic flux in the magnetic yokes 6 has been described to show a maximum value when the width A of the base portions 6 a 1 is 3.7 mm, but it is possible that there are value around 3.7 mm which result in an increase in the density of magnetic flux.
[0062] Next, the theory on improvement of linearity of the density of magnetic flux produced in the magnetic yokes 6 will be described below.
[0063] The density of magnetic flux produced in the third test piece, as listed in table 2, in which the width A is 4.2 mm varies, as already above, as represented by the broken sine curved line in FIG. 6 . The density of magnetic flux produced in the second test piece in which the length L of the claws 6 is 7.0 mm, and the width A of the base portions 6 a 1 of the claws 6 is 3.7 mm varies, as represented by the solid curved line in FIG. 6 , and has values which fall within the dead zones where the density of magnetic flux hardly undergoes a change. It is, thus, difficult to establish the linearity of the density of magnetic flux within ranges around magnetic angles of +90 deg. Also, for this reason, this embodiment determines a threshold of the width A of the base portions 6 a of the claws 6 as 4.2 mm used in the third test piece. The constant of proportion of the width A of the base portions 6 a 1 of the claws 6 to the distance P between the outer edges of the base portions 6 a 1 of the claw 61 and the claw 62 is, as described above, determined as
A (4.2 mm )/ P (8.11 mm )=0.517 (9)
[0064] By determining the value of the width A to fall within a range, as expressed by Eq. 10 below, a change in the density of magnetic flux generated in the magnetic yokes 6 will conform to the sine curve, as indicated by the broken line in FIG. 6 , thereby enabling the magnetic sensor 7 to measure the density of magnetic flux which changes linearly within the torque measuring range.
0.5 ×P<A<P (10)
[0065] While the present invention has been disclosed in terms of the preferred embodiments in order to facilitate better understanding thereof, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments witch can be embodied without departing from the principle of the invention as set forth in the appended claims. | A torque sensor is provided which consists of a magnet, an assembly of magnetic rings, and a magnetic sensor. The magnetic rings have claws arrayed thereround at regular intervals. Each of the claws of one of the rings is interposed between adjacent two of the claws of the other ring. Upon input of torque, the magnet is rotated relative to the ring assembly, thereby causing the density of magnetic flux to change as a function of the torque which is sensed by the magnetic sensor. Each of the claws is geometrically shaped so as to increase the density of magnetic flux flowing through the ring assembly, thereby improving the sensitivity of the sensor. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/350,948 filed on Jun. 3, 2010, entitled “Chamber Venting Valve.”
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to four stroke internal combustion engines and exhaust gas scavenging. More specifically, the present invention pertains to an improved exhaust port venting system in which exhaust valve guides are fitted with a compressed air functionality that forces air into the combustion chamber, accelerating the outflow of exhaust gases and promoting their exit through the exhaust manifold.
[0004] An internal combustion engine is akin to an air pump, in which air is pumped into a combustion chamber, compressed with atomized fuel by a piston-cylinder device, ignited and then exhausted from the chamber. The intake and exhaust of gases is accomplished by a series of valves that open and close at predetermined times in the piston cycle. Four stroke combustion engines, in particular, are internal combustion engines that comprise one power stroke for every four strokes of the piston. The four strokes of these engines are the intake stroke, the compression stroke, the combustion stroke, and finally the exhaust stroke. Air and fuel are brought into the cylinder during the intake stroke, compressed and ignited during the compression stroke, burned and expanded during the combustion stroke, and then combustion byproducts are exited from the cylinder during the exhaust stroke.
[0005] The volumetric efficiency of an internal combustion engine is measured as the ratio of fuel and air that actually enters a combustion cylinder during intake to the capacity thereof under static conditions. Volumetric efficiency measures the efficiency with which air can be move through an engine, with higher values leading to more powerful and more efficient engines. Higher amounts and uninterrupted passage of air through the engine provides for higher quantities of fuel that can be added, and in turn produce a higher power output. Volumetric efficiency can be improved through several means, including larger valves or an increased quantity of valves for improved passage of air and fuel, application of secondary induction systems like turbochargers and superchargers which force air into the cylinders, or improved intake manifolds that streamline the ports of an engine for smoother air flow. Still other systems focus solely on clearing exhaust gases from the combustion chamber and exhaust manifold after combustion to reduce back pressure or stalling of air within the exhaust manifold.
[0006] The process of drawing in fresh air into and removing exhaust gases from a combustion chamber is known as scavenging. During the exhaust stroke, the piston reduces the volume in the cylinder as it advances from bottom dead center (BOC) to top dead center (TOC). As the volume within the cylinder reduces, its contents become compressed, manifesting in a pressure on the exhaust gas that forces it from the cylinder through an open exhaust valve. Engine timing systems control the opening and closing of the valves as the cylinder advances through its four strokes. The path from intake to exhaust must be kept in sync to utilize the full potential of the engine's power and efficiency.
[0007] It is sometimes common for an engine to insufficiently clear the exhaust gases from a cylinder during the exhaust stroke. Conventional engine timing systems may not operate with 100% efficiency, especially during times of high back-pressure in the exhaust system, which retards the air flow out of the engine prior to the beginning of the next intake stroke. A common method of treating this deficiency includes reducing the head loss or drag within the exhaust system, including making its path a more free-flow design. Removing emission systems and muffling means from the exhaust system have been used in closed-course racing, however these solutions are not suitable for commercial use, where everyday driving introduces considerable emissions into the atmosphere and the noise generated from an unmuffled engine is not appropriate in most settings.
[0008] Still other methods are directed at increasing the flow of exhaust gases from the cylinder, the exhaust manifold or the exhaust system. The present invention is an engine component that is specifically designed to compensate for a deficiency in removing exhaust gases from a cylinder and exhaust manifold, without the drawbacks related to removing exhaust and emissions components. The present invention is designed to be installed within any four-stroke internal combustion engine, and functions by forcibly removing exhaust gases from an engine cylinder during the exhaust stroke. The device utilizes a modified valve guide that delivers compressed air into the combustion chamber directly under the exhaust valve. The exhaust is thoroughly vented from the system by the introduction of pressurized air, as the compressed air forces the exhaust gas through the exhaust port and through the exhaust manifold prior to the exhaust valve reclosing.
[0009] 2. Description of the Prior Art
[0010] Several devices have been disclosed in the art that attempt to forcibly remove exhaust gases from an engine via compressed air or similar means. U.S. Pat. No. 6,167,700 to Lampert is one such device, in which a ram air port is disclosed for capturing outside air through an intake, compressing it through a nozzle, and combining it with exhaust gases exiting a cylinder via a plenum chamber. This device discloses a system that is utilized downstream of the engine exhaust ports, along the exhaust pipes prior to entering the catalytic converter and muffler. While it may be useful for efficiently moving air through an exhaust pipe, its structure and intent is sufficiently different from the present invention. The forced air is captured from ambient air rushing passed the moving vehicle, as opposed to a system utilizing on-demand compressed air to force out exhaust gases from an engine cylinder.
[0011] U.S. Pat. No. 3,522,702 to Grosseau is a system more closely related to the present invention, wherein an air pump and associated pipeline is provided to inject air into the exhaust manifold of an engine to purify exhaust gases as they exit the engine. The system promotes efficient conversion of carbon monoxide (CO) in to carbon dioxide (CO 2 ) as the exhaust gases leave the manifold and enter the catalytic converter. While this system utilizes compressed air, its placement is within the exhaust manifold, and its structure significantly diverges from the present invention, wherein an exhaust valve guide is utilized to introduce compressed air. The present invention allows efficient airflow through the cylinder as the piston reaches top dead center and when the exhaust port is open. This aids in the pressurization and circulation of the exhaust gases, and allows efficient evacuation thereof through an open exhaust port or ports.
[0012] U.S. Pat. No. 3,948,229 to Abthoff describes a specifically designed intake and suction manifold for controlling the air flow through a v-shaped cylinder block engine. Similar to the Grosseau patent, the Abthoff patent relies on a forced air supply that forces air into the exhaust manifold for aiding escaping exhaust gases, rather than one that introduces the compressed air from a valve seat into the engine cylinder.
[0013] U.S. Pat. No. 3,116,596 to Boehme is another exhaust flow devices that describes a specifically designed flywheel that supplies air induction into an exhaust system downstream from an engine block. While this air induction system is useful for improving airflow through an exhaust system and preventing back pressure, the structure of the device and its installation are considerably different from the present invention. The air induction is supplied farther downstream than the engine exhaust valves, which are situated adjacent to the engine cylinders within the engine block.
[0014] The devices disclosed in the prior art involve improving air flow through an exhaust system, starting from the exhaust manifold through the exhaust system. The primary function of these devices and the field of the invention pertain to efficient flow of air through an engine, and efficient evacuation of exhaust gases. These devices may improve downstream flow in an exhaust and aid in relieving backpressure on the system; however they are not suited for thoroughly discharging exhaust gases directly from an engine cylinder for evacuation into the exhaust manifold. They rely on devices that improve air circulation, suction or pressure to draw gases away from an exhaust manifold, while the present invention is seated directly below the exhaust valves and delivers compressed air during the exhaust stroke to drastically improve evacuation of gases. This provides a clean combustion chamber prior to the initiation of the intake stroke, wherein a fresh charge of air and fuel are brought back into the cylinder prior to combustion. By removing unburned fuel and combustion byproducts from the cylinder, the engine can operate more efficiently. The improved flow from intake to exhaust also increases the amount of air that can be introduced in the intake charge, resulting in higher amounts of fuel and added power. Overall, the volumetric efficiency of the system is considerably improved, as air is efficiently removed from the engine cylinders during an exhaust stroke prior to intake of a fresh charge.
[0015] In this way, the present invention substantially diverges in design elements from the prior art. Consequently it is clear that that present invention is not described by the art and that a need exists for an improved forced air exhaust system that provides efficient evacuation of exhaust gases via compressed air delivered through a modified valve guide device. In this regard the instant invention substantially fulfills these needs.
SUMMARY OF THE INVENTION
[0016] In view of the foregoing disadvantages inherent in the known types of forced air exhaust systems now present in the prior art, the present invention provides a new forced air exhaust system wherein the same can be utilized for providing convenience for the user when utilizing compressed air to forcibly remove exhaust gases from an internal combustion cylinder.
[0017] It is therefore an object of the present invention to provide a modified valve guide device with a working end and a body structure that accepts an exhaust valve stem and circumferentially mates thereto. The working end of the valve guide includes a port for forcibly introducing compressed air into an engine cylinder when the exhaust valve is lifted and the exhaust port is open.
[0018] Another object of the present invention is to provide a modified valve guide device with a working end that is flushly mated with the underside of an exhaust valve and its stem when the valve is seated.
[0019] Another object of the present invention is to provide a device that improves scavenging during an exhaust stroke, promoting efficient evacuation of exhaust gases from the engine cylinder, and consequently an improvement in volumetric efficiency.
[0020] Another object of the present invention is to provide a compressed air system that is ties to the modified valve sleeve for introducing compressed air into an engine cylinder during the exhaust stroke, and one that operates continuously or on-demand as necessary.
[0021] Another object of the present invention is to provide an simple engine venting device and system that requires minimal modification to incorporate into existing engine designs, and one that allows adequate lubrication of the valve stem when installed.
[0022] Yet another object of the present invention is to provide a valve guide venting device comprised of a material that is designed to withstand the intense thermal cycling introduced by its proximity to the combustion chamber, and one that does not expand or contract beyond a limit that interferes with exhaust valve operation.
[0023] Finally, it is an object of the present invention to provide a new and improved valve guide venting device that has all of the advantages of the prior art and none of the disadvantages.
[0024] Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0025] FIG. 1 shows a perspective view of the present invention, including the body of the valve guide, its working end and compressed air inlet.
[0026] FIG. 2 shows a cross section side view of the present invention in its working position, positioned within an engine block and surrounding an exhaust valve.
[0027] FIG. 3 shows a cross section side view of the present invention again in its working position within an engine block, and in its working state.
[0028] FIG. 4 shows an overhead view of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring now to FIG. 1 , there is shown a perspective view of the present invention, which comprises a modified exhaust valve guide with a working end 11 and a sleeve body 12 . The guide is designed to integrally fit around and below an exhaust valve within the block of an internal combustion engine. The body 12 is seated circumferentially about the exhaust valve stem, while the working end 11 of the guide rests against the base of the valve head. A compressed air inlet port 13 is provided along a shelf region of the guide, wherein compressed air is forced into the inlet port 13 and into the cavity 14 of the shelf. The cavity 14 is an enclosed structure that is either welded or otherwise sealed to allow air flow from the inlet port 13 , around the shelf region and up through ports 15 within the working end 11 of the valve guide.
[0030] Air is continually fed into the inlet port 13 and held within the guide while the exhaust valve is seated in its closed position. When the exhaust valve is seated and the exhaust port is closed, the base of the exhaust valve mounts flush against the ports 15 on the working end 11 of the valve guide and prevents leakage of compressed air. When the exhaust valve is pushed into its working position, opening the exhaust port by way of a rotating cam device, the base of the valve is forced away from the ports 15 and the internal compressed air is released from the guide tube and into the engine cylinder.
[0031] The device is a once piece construction, with air inlet port 13 and the shelf region attached and enclosed with a layer of welding. The enclosure provides a pathway for the compressed air, starting from the inlet 13 , extending around the shelf and up through the ports 15 . The enclosed air supply prevents interaction with oil lubrication of the valve stem. The pressure from the compressed air is contained, rather than forced along the valve stem. This prevents any pressure from forcing lubrication away from the valve stem or interfering with factory oiling design. Without an enclosure, air pressure would inhibit oiling of the guide as the oil would not enter the valve stem oil seal that controls lubrication of the assembly.
[0032] Referring now to FIG. 2 , there is shown a cross section side view of the valve guide in its working position below an exhaust valve 16 in its seated position. The guide is positioned around the exhaust valve stem, similar to a standard valve guide. The working end 11 of the valve guide is modified from a standard guide to accept compressed air functionality. Compressed air is fed from a feed line 17 to the air inlet port 13 of the guide. Once the air passes the inlet port 13 , it circulates around a shelf region and up through the working end 11 of the guide. Ports 15 along the working end 11 allow the air to exit at a high pressure when the exhaust valve 16 is moved into its working position and lifted above its seated position. In its seated position, as shown in FIG. 2 , the base of the valve 16 closes the outlet ports 15 on the valve guide, preventing any air leakage. The base of the valve 16 mounts flush against the ports 15 , which may require modified valve 16 or a specifically designed guide working end 11 .
[0033] Referring now to FIG. 3 , there is shown another cross section side view of the valve guide device in its working position within an engine block and in its working state. This figure illustrates the function of the present invention, highlighting the device in its working state. During the exhaust stroke of the engine, the exhaust valve 16 is lifted from its seated position into its working position. This opens the exhaust port and allows exhaust gases to exit the cylinder while the piston 19 reaches top dead center. Once the exhaust valve 16 is lifted, the ports along the working end 11 of the valve guide are opened, allowing a jet of compressed air to enter the engine cylinder and circulate 18 the exhaust gases. Air is supplied via a compressed air feed line 17 to the air inlet port 13 along the shelf of the valve guide. Air circulates around the shelf and up through the working end 11 , exiting into the cylinder when the valve 16 is lifted.
[0034] Once the jet of compressed air is introduced into the cylinder, the exhaust gases are further pressurized and circulated 18 within the cylinder and forced out of the open exhaust port or ports. The exhaust gases are rapidly and efficiently evacuated from the cylinder, not only from the compression induced by the approaching piston, but also the compressed air introduction. The exhaust exits the cylinder and enters the exhaust manifold just prior to the exhaust valve 16 reseating on the exhaust port and sealing off the two chambers. Exhaust gases are efficiently removed from the cylinder to allow a fresh charge of air and fuel to be drawn into the cylinder during the proceeding intake stroke.
[0035] Referring now to FIG. 4 , there is shown an overhead view of the present invention. A plurality of ports 15 run through the working end 11 of the valve guide, extending vertically from the shelf region 19 . Within the shelf 19 is an enclosed cavity that connects an air inlet port 13 to the ports 15 along the working end 15 . The cavity allows air flow around the valve guide, and is enclosed with a layer for weld or similar air tight enclosure means that one skilled in the art would utilize.
[0036] In use the device replaces a standard exhaust valve guide within an internal combustion engine. A compressed air system, located within the vehicle and powered thereon, provides pressurized air from a pressure vessel to the valve guides. A feed line is provided that connects the compressed air to the valve guide, which can either sit in the exhaust manifold or be build into the engine block for a more advanced design. The system provides a forced air exhaust system that clears out combustion cylinders during an exhaust stroke, and one that can be retrofitted onto existing engines or designed into a new engine block.
[0037] The number of valve guides placed within the engine is dependent upon the user preference and the number of valves per cylinder. At least one compressed air guide valve should be present per cylinder to achieve efficient evacuation of each cylinder. Likewise, the location of the air inlet port along the valve guide may be oriented to accommodate different exhaust manifold and engine block geometries. This provides modularity, especially when incorporating the disclosed invention onto an existing engine without modification.
[0038] The compressed air system may run as an auxiliary system, drawing power directly from the engine in the form of a belt and pulley, or from a draw of the onboard electrical system. The type of system is dependent upon user application and preferences. The system is parasitic on either the engine output or the electrical system, but provides increases in volumetric efficiency that may compensate for any loss in efficiency. Increased power of the engine may also be a desired effect, in which a small drag on the electrical system or from a belt-driven auxiliary system may not be a concern.
[0039] Pressure from the compressed air system is fed continuously as the engine cycles through its different strokes. When a particular exhaust valve is lifted, air is fed into that cylinder for a period of time defined by the cam timing that controls the valve motion. The air system must be sufficient to accommodate any drops in pressure as a result of the constant opening and closing of valves along the cylinder bank.
[0040] The air inlet port, the enclosed air cavity and the ports along the working end of the guide comprise an air guide means. The structure of the air guide means may incorporate any means to communicate air from a compressed air feed line, through the valve guide and into the cylinder when the exhaust valve is lifted. Alternative embodiments of the air guide means may include variations in structure and design of an air tight enclosure, or specific tailoring of the ports. It is not desired to limit these means to the illustrations show in FIG. 1 through FIG. 4 . A primary requirement of the device is an air tight communication of compressed air through the valve guide, and one that does not force air around the valve stem oil seal or interfere with proper lubrication of the valve stem.
[0041] Finally, the material choice for the present invention must accommodate the intense thermal cycling that occurs in this region of the engine. The close proximity of the valve guides to the combustion chamber results in very high temperature spikes and thermal effects that can cause material to expand and contract based on thermal loads developed from conduction and friction loads.
[0042] In a preferred embodiment, the material choice for the present invention may include 347 stainless steel, UNS S34700. This steel alloy is a stabilized stainless steel which offers excellent resistance to intergranular corrosion following exposure to temperatures in the chromium carbide precipitation range of 800 to 1500° F. The material is stabilized by the addition of columbium and tantalum, and is advantageous for high temperature service because of its good mechanical properties. Alloy 347 stainless steel offers high creep and stress rupture properties, which might also be considered for exposures where sensitization and intergranular corrosion are concerns.
[0043] Although it is not desired to limit the present invention to this material type, this stainless steel has proven to withstand the thermal loading in an internal combustion chamber region while satisfactorily operating under required mechanical loads. Any material of adequate thermal and material properties may be substituted if deemed suitable by one skilled in the art.
[0044] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0045] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | Disclosed is a modified valve guide for a four-stroke internal combustion engine that utilizes compressed air to accelerate the outflow of exhaust gases from a combustion chamber and through the exhaust manifold. The device comprises a ported valve guide that is concentrically mounted about an exhaust valve stem. The valve guide is a hollow cylinder that surrounds the exhaust valve stem, and includes a vertically mounted port on its working end. Below the port is a circumferential ring and guide tube connection that accepts compressed air input, communicating forced air through the valve guide port on its working end into the combustion chamber and exhaust manifold. The introduction of forced air increases volumetric efficiency of the system by improving scavenging and forcibly removing exhaust gases from the cylinder during the exhaust stroke. Both the power and efficiency of the engine are improved, along with reduced emissions from the engine exhaust. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a backstop net assembly for use in combination with a basketball hoop assembly. More particularly, the present invention relates to a backstop net assembly for collecting and gathering errant basketball shots entering spatial regions adjacent to a backboard of a basketball hoop assembly for easy retrieval purposes.
[0003] 2. Description of the Prior Art
[0004] A player engaging in the sport of basketball typically shoots, throws or propels a basketball with general projectile motion toward a basketball hoop assembly from an infinite number of possible locations around a basketball hoop assembly. Each shot, having general projectile motion, has a certain vertical component of motion, a certain horizontal component of motion, and often a certain lateral component of motion, and is typically aimed at either a horizontally-oriented, targeted rim of the basketball hoop assembly or a vertically-oriented backboard of a basketball hoop assembly, which backboard is adjacent or behind the rim for banking shots into the rim. A skilled player often can often shoot the basketball in such a manner so as to consistently hit the target, or propel the basketball so that it enters the targeted rim at some point along its trajectory. Should the shot basketball hit its target or enter the targeted rim, the player has achieved a basket and the basketball is typically directed via a basketball net of the basketball hoop assembly in a general downward motion for retrieval either by the player who shot the basketball or by other basketball players for re-executing the described procedure.
[0005] It is noted that basketball players often shoot, propel or throw basketball shots in a general projectile motion toward basketball hoop assemblies from an extreme anterior viewpoint thus visualizing a typical vertically-oriented backboard having either an arcuate or straight superior backboard border and straight lateral backboard borders are readily viewable. Further, it is noted that during play, a basketball player will frequently shoot a basketball in such a manner that the basketball will miss its targeted rim or targeted backboard and enter the open regions adjacent to the backboard borders. Such errant basketball shots thus often become cumbersome and time-consuming to retrieve. Further, it is noted that basketball hoop assemblies are often set up on playgrounds or in areas where errant shots can cause damage to various valuables located in or around the open regions surrounding a basketball hoop assembly. In light of the deleterious or burdensome effects of frequently experienced errant basketball shots, a number of apparatuses and devices have been developed in an effort to help collect, catch, and often return basketball shots, errant or otherwise, to the basketball player. In this regard, the prior art teaches a variety of basketball collection and/or retrieval apparatuses and devices, some of which are described hereinafter.
[0006] U.S. Pat. No. 4,762,319 ('319 Patent), which issued to Krumholz, discloses a Convertible Sports Stand Construction. The Convertible Sports Stand Construction comprises a frame which has spaced-apart support members adapted to reset upon a supporting surface, a net extending between the support members, and a backboard carrying a basketball goal hoop supported between the support members above the net. The backboard may be adjustably rotated horizontally between a vertical position and a horizontal position, whereby the basketball goal hoop can be positioned to extend horizontally or vertically.
[0007] It will thus be seen that the '319 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '319 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '319 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0008] U.S. Pat. No. 5,016,875 ('875 Patent), which issued to Joseph, discloses a Portable Basketball Retrieval Apparatus. The Portable Basketball Retrieval Apparatus comprises a vertically-extensible and collapsible support frame, support arms pivotally connected to the support frame, and netting material attached to the support arms for retrieving and collecting shot basketballs and a chute permanently secured to the netting material for directing retrieved basketballs therethrough to a guideway. The apparatus is adapted for use with a post-mounted or wall-mounted backboard or alternatively, with a backboard member, which is removably secured to the top of the support frame in a position substantially the same vertical plane as the support frame.
[0009] It will thus be seen that the '875 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '875 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '875 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0010] U.S. Pat. No. 5,129,648 ('648 Patent), which issued to Sweeney et al., discloses a Basketball Throw Shot Practice Arrangement and Method. The Basketball Throw Shot Practice Arrangement and Method comprises a net supported by a longitudinally extending main support with lateral support arms engaging an upper edge of the net to position the net adjacent a basketball hoop on a backboard. The main support abuts the playing surface at its lower end and the hoop and backboard adjacent its upper end. Support members of substantially less longitudinal extent than the main support engage the lower edge of the net and rest on the playing surface to position the net to form a trough that is inclined downwardly and forwardly from the upper net edge to the lower net edge to guide a basketball from the hoop or backboard toward the lower edge of the net for retrieval.
[0011] It will thus be seen that the '648 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '648 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '648 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0012] U.S. Pat. No. 5,171,009 ('009 Patent), which issued to Filewich et al., discloses a Basketball Apparatus. The Basketball Apparatus generally comprises a support member, a backboard mounted on the support member, and a hoop mounted on the backboard. The backboard is mounted on the support member for rotation with respect thereto, wherein the backboard is locatable in selected angular positions with respect to a predetermined location that is disposed remote from the support member and the backboard mounted thereon. The Basketball Apparatus further comprises tubular sockets. Mounted on the tubular sockets and extending in a vertical direction is a plurality of shortened holder sockets. The holder sockets receive bent lowermost ends of spaced inclined support elements that support a chute that is defined by two dish-like complimentary chute members that are disposed beneath the backboard and the hoop.
[0013] It will thus be seen that the '009 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '009 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '009 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0014] U.S. Pat. No. 5,540,428 ('428 Patent), which issued to Joseph, discloses a Basketball Retrieval and Return Apparatus. The Basketball Retrieval and Return Apparatus comprises a bracket removably mountable to the lowest portion of a backboard of a basketball hoop assembly, an elongated support bar pivotally mounted to the bracket, and a U-shaped ring bar attached to the support bar and which extends outwardly from and perpendicular to the backboard when the ring bar is pivoted from a non-use to a use position. The Basketball Retrieval and Return Apparatus further comprises a support member fixed in an angled disposition by a brace means. The brace means includes a post brace having a first end, which is integrally attached to the support member at a portion of support member. The brace means further comprises a post bracket, which is removably securable to a post.
[0015] It will thus be seen that the '428 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '428 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '428 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0016] U.S. Pat. No. 5,971,873 ('873 Patent), which issued to Balducci, discloses a Backstop Screen for Basketball hoop. The Backstop screen for Basketball hoop comprises an elongated post that vertically extends from a basketball post of a basketball hoop assembly to an upper horizontal support arm. The upper support arm supports a screen or net that hangs down behind the backboard of a basketball hoop assembly. A shot basketball hits the retrieval device and causes the shot basketball t roll back onto the court instead of landing off the court. A lower support arm is attached to the bottom of the post of the basketball hoop assembly and secures the bottom of the net in tension.
[0017] It will thus be seen that the '873 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '873 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '873 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0018] U.S. Pat. Nos. 6,056,652 ('652 Patent), which issued to Lees et al. discloses a Basketball Retrieval Device. The Basketball Retrieval Device comprises front net support arms, which are pivotally attached to an attachment plate. The front net support arms are received in tubes, which are welded to the attachment plate. The tubes define hollow channels for receiving the tubular front net support arms. The orientation of the tubes on the attachment plate is depicted in a perspective view in FIG. No. 8 . These features further disclose elements that are pertinent to a discussion of obviousness, discussed below.
[0019] It will thus be seen that the '652 Patent does not teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that the '652 Patent does not teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that the '652 Patent does not teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0020] U.S. Pat. No. 6,074,313 ('313 Patent), which issued to Pearson, discloses a Basketball Return Net Assembly. The Basketball Return Net Assembly comprises a flexible foldable return net having an upper end with an upper sleeve portion extending therealong, an elongated rigid net carrying member removably insertable into the upper sleeve portion to enable the net to be suspended in a laterally-extended configuration from the net-carrying member, and at least one attachment member for securing the net-carrying member to an upper portion of the hoop support behind the hoop. The net also has a lower end portion for receiving ballast to retain the lower end of the net in a laterally extended configuration at a selected location on the ground. Further, United States Patent Application Publication No. 2002/0025865 ('865 Disclosure), which was published on Feb. 28, 2002 to applicant Pearson, discloses a Basketball Return Net Assembly with Adjustment Bracket. The Basketball Return Net Assembly with Adjustment Bracket comprises a post extending upwardly from the ground and carrying a basketball hoop adjacent an upper end thereof. The return net assembly includes a flexible foldable return net and an elongated rigid net-carrying member extending along the upper end of the net to enable the net to be supported in a laterally-extending configuration. The upper end of the net and the net-carrying member can be suspended from an upper portion of the hoop support behind the hoop, and an attachment bracket is connected to opposite lower corner portions of the net and is adjustably securable to the post to enable the bracket to be adjusted relative thereto.
[0021] It will thus be seen that neither the '313 Patent nor the '865 Disclosure teach the use of a backstop net assembly in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. It will be further seen that neither the '313 Patent nor the '865 Disclosure teach a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Further, it is noted that neither the '313 Patent nor the '865 Patent teach a backstop net assembly, which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard.
[0022] Of the numerous basketball retrieval and/or collection apparatuses that have been developed, many provide a net assembly for catching or collecting errant basketball shots either for return to the basketball court or for return to basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. In this regard, it has been shown that basketball retrieval and/or collection apparatus of various types are known in the prior art. However, in addition to often being exorbitantly priced, the numerous basketball retrieval or collection apparatuses that have been developed are often cumbersome to practice or require a structurally specific basketball hoop assemblage with which to operate. Further, the numerous basketball retrieval or collection apparatuses that have been developed often do not fold or collapse into compact arrangements for shipment or storage. Further, the numerous basketball retrieval or collection apparatuses that have been developed are not configured to be installed onto existing basketball hoop assemblies from a kit.
[0023] The prior art thus perceives a need for a basketball-gathering backstop net assembly, installable on basketball hoop assemblies, which assembly is less cumbersome to practice and which assembly may properly be utilized in combination with a wide variety of basketball hoop assemblies. Further, the prior art perceives a need for a backstop net assembly usable in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in or attachable to the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. Further, the prior art perceives a need for a basketball-gathering backstop net assembly kit, which kit may be delivered or stored in a compact state, and which, when unpacked, may be installed on existent basketball hoop assemblies for catching, collecting or gathering errant basketball shots. Further, the prior art perceives a need for a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Still further, the prior art perceives a need for a backstop net assembly, which is sized and shaped to concentrically mirror or appear concentrical with the superior border and lateral borders of a typical vertically-oriented backboard. In this regard, the prior art perceives a need for a backstop net assembly, usable in combination with a basketball hoop assembly, which backstop net assembly is both more visually appealing and more efficient at catching, collecting or gathering errant basketball shots.
[0024] In this last regard, it is contemplated that the prior art perceives a need for a backstop net assembly that concentrically mirrors or appears concentrical with a typical vertically-oriented backboard. A structurally concentrical backstop net assembly is thought to be both more efficient at catching collecting or gathering errant basketball shots and less visually distracting to players taking visual aim at a vertically-oriented backboard. In this regard, it is contemplated that a structurally concentrical backstop net or screen is more efficient insofar as the outermost borders of a structurally concentrical backstop net assembly provide a border gathering region behind and beyond the borders of the typical vertically-oriented backboard, which gathering region has a structural dimension of substantially the same width measured from the outer borders of a typical vertically-oriented backboard.
[0025] Basketball players with moderate shooting skills are more likely than not to propel errant shots into the described border gathering region, which is immediately adjacent the outer borders of a typical vertically-oriented backboard, or in effect, just miss the vertically-oriented backboard. Basketball players are less likely to propel shots into other less concentrical area regions adjacent the typical vertically-oriented backboard. In this last regard, it is recognized that errant shots do, from time to time, travel to regions that are not immediately adjacent a typical vertically-oriented backboard. However, it is further contemplated that the prior art perceives a need for a selectively expandable system for increasing the structural width of the border gathering region behind and beyond the borders of the typical vertically-oriented backboard for catching, collecting or gathering extremely errant basketball shots, while maintaining a substantially concentrical structural appearance of the backstop net assembly from an anterior viewpoint.
SUMMARY OF THE INVENTION
[0026] Accordingly, it is an object of the present invention to provide a basketball-gathering backstop net assembly, installable on basketball hoop assemblies, which backstop net assembly, is less cumbersome to practice and which backstop net assembly may properly be utilized in combination with a wide variety of basketball hoop assemblies. It is a further object of the present invention to provide a backstop net assembly usable in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in or attachable to the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly. Further, it is an object of the present invention to provide a basketball-gathering backstop net assembly kit, which kit may be delivered or stored in a compact state, and which, when unpacked, may be installed on existent basketball hoop assemblies for catching, collecting or gathering errant basketball shots. Still further, it is an object of the present invention to provide a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Still further, it is an object of the present invention to provide a backstop net assembly which is sized and shaped to be concentrical with the superior border and lateral borders of a typical vertically-oriented backboard. In this regard, it is a further object of the present invention to provide a backstop net assembly which is both more visually appealing and more efficient at catching, collecting or gathering errant basketball shots.
[0027] To achieve these and other readily apparent objectives, the present invention provides a backstop net assembly and kit for use in combination with a basketball hoop assembly, which generally comprises a multi-socketed mounting block, a plurality of net extension rods, and a ball-gathering net assembly. The mounting block comprises a superior face, an inferior face, a left lateral face, a right lateral face, an anterior face, and a posterior face. The mounting block further comprises a superior mounting flange adjacent the superior and anterior faces, and an inferior mounting flange adjacent the inferior and anterior faces. The mounting block further comprises a plurality of rod-receiving sockets intermediate the superior face and the inferior face.
[0028] The net extension rods each comprise a male block attachment end, a female net attachment end, and a flexible rod intermediate the male block attachment end and the female net attachment end. The male block attachment ends are for removable insertion in the rod-receiving sockets. The ball-gathering net assembly comprises a ball-gathering net and a plurality of spaced net markers. The ball-gathering net comprises a superior net portion, an inferior net portion, and opposing lateral net portions. The spaced net markers are fixedly attached to the superior net portion and the female net attachment ends each have connector means for removably connecting the female net attachment ends to the superior net portion adjacent the spaced net markers. The connector means may be further defined by comprising in combination laterally-aligned tie strap-receiving apertures and a tie strap. The tie strap-receiving apertures have tie aperture pairing for threadably receiving the tie strap. The tie straps each have a male tie end and a female tie end. The male tie end may be threaded through the tie aperture pairing, around the appropriately marked superior net portion and through the female end for removably connecting the female net attachment ends to the superior net portion adjacent the spaced net markers. The female net attachment ends are further sized and shaped to receive male block attachment ends of additional net extension rods should a user wish to couple the net extension rods in the described manner to increase the extending length of the extension rod system.
[0029] The backstop net assembly further comprises means for securing the mounting block in vertically-oriented relation to a basketball hoop assembly. In this regard, it is contemplated that the mounting block may preferably either be welded to the upright support post of a basketball hoop assembly or be clamped to the upright support post of a basketball hoop assembly. When clamping the mounting block to the upright support post of a basketball hoop assembly, a superior hose clamp secures the superior mounting flange to the upright support post of a basketball hoop assembly and an inferior hose clamp secures the inferior mounting flange to the upright support post of a basketball hoop assembly.
[0030] The backstop net assembly further comprises means for securing the inferior net portion either to a playing surface or to the upright support post. When securing the inferior net portion to a playing surface, it is contemplated that ground stakes may be utilized in situations where the playing surface is easily piercable by a ground stake. Further, when securing the inferior net portion to a playing surface, which is not easily piercable, any suitable weighty material may be placed on laterally opposite corners of the inferior net portion to weigh down the inferior net portion. Further, the opposite corners of the inferior net portion may further comprise lengths of cord to tie the laterally opposite corners of the inferior net portion to the upright support post, thus producing a ball-gathering sack-like configuration.
[0031] The mounting block may be further summarized whereby the superior face has a vertically-oriented superior rod-receiving socket. Furthermore, the left lateral face has an angled left superior rod-receiving socket and an angled left inferior rod-receiving socket, and the right lateral face has an angled right superior rod-receiving socket and an angled right inferior rod-receiving socket. The superior, vertically-oriented rod-receiving socket has a longitudinal axis 90° from the inferior face. The left superior angled rod-receiving socket has a longitudinal axis 45° from the inferior face and the left inferior angled rod-receiving socket has a longitudinal axis 10° from the inferior face. Similarly, the right superior angled rod-receiving socket has a longitudinal axis 45° from the inferior face and the right inferior angled rod-receiving socket has a longitudinal axis 10° from the inferior face.
[0032] Typically, on a basketball playground, one can find at least one upright support post, a backboard mounted on the post, and a basketball rim and net structure mounted on the backboard. The present invention thus provides an improved basketball backstop screen to contain errant basketball shots launched by a basketball shooter to minimize basketball retrieval time and possible damage to surrounding valuables. The ball-gathering net is a reticulated net having a size and width, which extends vertically and laterally via the extension rods a sufficient distance to capture errant basketball shots and to assist in keeping the basketball in play. Additionally, a heavy perimeter cord peripherally bounds the reticulated portion of the net to provide added strength to the reticulated, ball-gathering net.
[0033] Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or apparent from, the following description and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Other features of our invention will become more evident from a consideration of the following detailed description of our patent drawings, as follows:
[0035] FIG. No. 1 is a front plan view of the preferred embodiment of the backstop net assembly in combination with a basketball hoop assembly.
[0036] FIG. No. 2 is a side plan view of the preferred embodiment of the backstop net assembly in combination with a basketball hoop assembly showing an errant basketball shot being gathered at an inferior location.
[0037] FIG. No. 3 is a fragmentary side plan view of the preferred embodiment of the backstop net assembly in combination with a basketball hoop assembly showing an errant basketball shot being gathered at a superior location.
[0038] FIG. No. 4 is a fragmentary top plan view of the preferred embodiment of the backstop net assembly in combination with a basketball hoop assembly with parts removed to show an errant basketball shot being gathered at an inferior location.
[0039] FIG. No. 5 is a fragmentary back plan view of the preferred embodiment of the backstop net assembly in combination with a basketball hoop assembly with parts broken away to show the mounting block attached to an upright support post.
[0040] FIG. No. 6 is a fragmentary back plan view of the mounting block secured to an upright support post of a basketball hoop assembly with fragmentary net extension rods in various stages of removable insertion in the mounting block.
[0041] FIG. No. 7 ( a ) is an enlarged perspective view of a female net attachment end showing cooperative tie aperture pairing.
[0042] FIG. No. 7 ( b ) is an enlarged perspective view of a female net attachment end showing a tie strap inserted laterally through cooperative tie aperture pairing.
[0043] FIG. No. 7 ( c ) is an enlarged frontal view of a tie strap attaching a female net attachment end to the superior net portion adjacent a net marker.
[0044] FIG. No. 8 is a fragmentary back view of the mounting block with coupled net extension rods inserted in the mounting block.
[0045] FIG. No. 9 is a fragmentary side view of an alternative embodiment of the backstop net assembly in combination with a basketball hoop assembly, showing phantom basketball hoop and backboard support means.
[0046] FIG. No. 10 is a front plan view of the preferred embodiment of the backstop net assembly in combination with a basketball hoop assembly showing opposite corners of the inferior net portion tied to the upright support post of the basketball hoop assembly.
[0047] FIG. No. 11 is a fragmentary perspective view of the backstop net assembly kit in a disassembled state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] Referring now to the drawings, the preferred embodiment of the present invention concerns a backstop net assembly for use in combination with a basketball hoop assembly or a backstop net assembly kit for outfitting a basketball hoop assembly. In this regard, FIG. No. 1 illustrates a basketball hoop assembly and backstop net assembly combination as viewed from an extreme anterior or frontal view and FIG. No. 11 illustrates a backstop net assembly kit as boxed for shipment or storage. The basketball hoop assembly and backstop net assembly combination generally comprises a backstop net assembly 100 as illustrated in FIG. Nos. 1 - 3 , 5 , 9 and 10 for use in combination with a basketball hoop assembly 200 as illustrated in FIG. Nos. 1 - 3 , 9 , and 10 . It is recognized that generic basketball hoop assemblies are well known in the prior art. To meet the structural requirements of the disclosed combination, basketball hoop assembly 200 may typically comprise a horizontally-oriented, basketball-receiving hoop 210 as illustrated in FIG. Nos. 1 - 4 , 9 and 10 ; a vertically-oriented backboard 220 as illustrated in FIG. Nos. 1 - 5 , 9 and 10 ; and support means or means for supporting the backboard and hoop assemblage in vertical relation to the ground or playing surface 300 as illustrated in FIG. Nos. 1 , 2 and 10 . It is noted that typical vertically-oriented backboards comprise a substantially arcuate superior border 221 as illustrated in FIG. Nos. 1 and 10 , or a substantially straight superior border (not illustrated), and substantially straight lateral borders 222 as further illustrated in FIG. Nos. 1 and 10 .
[0049] Typically, basketball hoop assemblies of the portable type comprise support means, which may further be defined as comprising an upright support post 230 as generally illustrated in FIG. Nos. 1 , 2 - 6 , 9 and 10 . It is further contemplated, however, that the present invention can be utilized in combination with many different types of basketball hoop assemblies, including, but not limited to, those that comprise permanent vertical support posts fixedly attached to a horizontal surface, such as playing surface 300 or to a ceiling 400 as illustrated in FIG. No. 9 . Further, it is contemplated that the present invention can be utilized in combination with a horizontal support post fixedly attached to a vertical surface, such as a wall 500 as further illustrated in FIG. No. 9 . However, should the user desire to utilize backstop net assembly 100 in combination with a horizontal support post of the type described and illustrated, the user must slightly modify the backstop net assembly. Specifically, ball-gathering net assembly 60 must comprise means for allowing a horizontal post to pierce the body portion of the ball-gathering net 61 and mounting block 20 must have means for attachment to the horizontal post so that the longitudinal axes of the rod-receiving sockets are disposed in a vertical orientation.
[0050] The support means or means for supporting the backboard and hoop assemblage must support the backboard and hoop assemblage such that the support means posits the backboard and hoop assemblage in anterior or forwardly spaced relation to the support means. The present invention thus may be used in combination with a basketball hoop assembly having both some means for supporting the backboard and hoop assemblage in vertical relation to the ground or playing surface 300 and additionally some means for supporting the backboard and hoop assemblage in anterior or forwardly spaced relation to the support means.
[0051] In this last regard, it is noted that many different types of basketball hoop assemblies comprise means 600 for supporting the backboard and hoop assemblage in anterior or forwardly spaced relation to the support means, an example of which is illustrated in FIG. Nos. 2 , 3 and 9 . So long as means 600 for supporting the backboard and hoop assemblage does not structurally interfere with the posterior side or posterior portions of upright support post 230 or the support means, backstop net assembly 100 may be successfully attached to the basketball hoop assembly for catching, collecting or gathering errant basketball shots. It is further contemplated that many basketball hoop assemblies comprise further peripherals such as a basketball net 700 as generally illustrated in FIG. Nos. 1 - 4 , 9 and 10 . So long as further peripherals such as basketball hoop net 700 do not structurally interfere with the posterior side or posterior portions of upright support post 230 or the support means, backstop net assembly 100 may be successfully attached to the basketball hoop assembly for catching, collecting or gathering errant basketball shots.
[0052] Backstop net assembly 100 generally comprises a mounting block 20 , a plurality of net extension rods 40 and a ball-gathering net assembly 60 . Mounting block 20 is preferably constructed by welding a block having measured dimensions of 1.5 inches by 3 inches by ¾ inch to a mounting plate having measured dimensions of 1.5 inches by 4 inches by ⅛ inch. Source material for the mounting plate and block is not limited to one specific type. Possibilities for choice include stainless steel, stock steel, molded aluminum, and high density plastic. It is contemplated that mounting block 20 may be integrally fabricated with upright support post 230 in which case mounting block 20 may be welded directly to the pole or upright support post 230 during processing. In such case, only materials suitable for welding should be used. Further, when mounting block 20 is fabricated with upright support post 230 , no mounting plate is required.
[0053] Mounting block 20 , as generally illustrated in FIG. Nos. 2 , 3 , 5 , 6 , 8 , 9 and 11 , further comprises a superior face 21 , an inferior face 22 , a left lateral face 23 , a right lateral face 24 , an anterior face (not shown), and a posterior face 25 as illustrated in FIG. No. 6 . Mounting block 20 further comprises a superior mounting flange 26 adjacent superior face 21 and the anterior face and an inferior mounting flange 27 adjacent inferior face 22 and the anterior face as further illustrated in FIG. Nos. 6 and 8 . Mounting block 20 further preferably comprises net extension rod attachment means or means for attaching net extension rods 40 to mounting block 20 . In this regard, it is contemplated the net extension rod attachment means or means for attaching net extension rods 40 to mounting block 20 preferably comprise a plurality of threaded rod-receiving sockets intermediate superior face 21 and inferior face 22 as further generally illustrated in FIG. No. 6 . Superior mounting flange 26 and inferior mounting flange 27 are extensions of the mounting plate which has been welded to the block as described. Correctly welded, the block should be centered on the welding plate preferably leaving at least a ½-inch flange on either side.
[0054] It is further contemplated that the anterior face or preferable mounting plate construction may further comprise means for allowing the anterior face to lie in flush adjacency with upright support post 230 or be attached to upright support post 230 such that the anterior face does not rock against a differently shaped upright support post. For example, should a round upright support post support the basketball hoop and backboard assemblage, a rounded or concave-like anterior face is contemplated. Further, it is contemplated that a flat anterior face with forwardly-extending, upright support post-engaging protuberances may snugly fit the anterior face portion of the mounting block to the upright support post so as to provide structure to prevent a rocking effect when the anterior face is not similarly shaped as compared to the shape of the upright support post.
[0055] Backstop net assembly 100 preferably further comprises means for mounting mounting block 20 to upright support post 230 . It is here recognized that there are many ways to attach or mount the described mounting block to a support means or upright support post, an exhaustive list of which is excluded from this writing. It is understood that it is within the ordinary skill of a person skilled in the art to devise obviously equivalent means for attaching or mounting the described mounting block to a support means or upright support post and an exhaustive list would be unduly lengthy. Excellent results have been achieved in this last regard, however, where the mounting means are preferably further defined by comprising a superior hose clamp 28 and an inferior hose clamp 29 as illustrated in FIG. Nos. 6 and 11 . Superior hose clamp 28 and inferior hose clamp are preferably constructed of stainless steel and are sized and shaped to fit circular cross-section support posts or poles having measured diameters of about 3.5 inches to 6 inches. It is contemplated that additional hose clamps may be made available if the support post is of greater diameter or has square cross sectional configuration. Superior hose clamp 28 attaches or mounts superior mounting flange 26 to upright support post 230 and inferior hose clamp 29 attaches or mounts inferior mounting flange 27 to upright support post as illustrated in FIG. No. 6 . Superior hose clamp 28 and inferior hose clamp 29 are illustrated in an unassembled state in FIG. No. 11 . The preferred mounting means thus engage with superior mounting flange 26 and inferior mounting flange 27 of mounting block 20 in vertically spaced relation. The rod-receiving sockets are located between or intermediate superior hose clamp 28 and inferior hose clamp 29 to enable net extension rods 40 to engage in the rod-receiving sockets without interference with either superior hose clamp 28 or inferior hose clamp 29 .
[0056] Superior face 21 preferably has a vertically-oriented superior rod-receiving socket 31 . Further, left lateral face 23 has an angled left superior rod-receiving socket 32 and an angled left inferior rod-receiving socket 33 ; and right lateral face 24 has an angled right superior rod-receiving socket 34 and an angled right inferior rod-receiving socket 35 all as illustrated in FIG. No. 6 . Preferably, vertically-oriented superior rod-receiving socket 31 has a longitudinal axis preferably measuring 90° from a horizontal or from inferior face 22 . Further, left superior angled rod-receiving socket 32 has a longitudinal axis preferably measuring 45° from a horizontal or from inferior face 22 and left inferior angled rod-receiving socket 33 has a longitudinal axis preferably measuring 10° from a horizontal or from inferior face 22 . Right superior angled rod-receiving socket 34 has a longitudinal axis preferably measuring 45° from a horizontal or from inferior face 22 and right inferior angled rod-receiving socket 35 has a longitudinal axis preferably measuring 10° from a horizontal or from inferior face 22 . Preferably, socket 31 , socket 32 , socket 33 , socket 34 , and socket 35 are either ⅜ inch or ¼ inch National Pipe Thread (NPT) tapped and threaded sockets, which tapping and threading preferably occurs prior to welding the block to the mounting plate.
[0057] As earlier noted, backstop net assembly 100 further comprises net extension rods 40 as illustrated in FIG. Nos. 1 - 3 , 5 , 8 , 10 and 11 . Each net extension rod 40 comprises block attachment means for removably attaching net extension rods 40 to mounting block 20 . Preferably, each block attachment means comprises a male block attachment end 41 as illustrated in FIG. Nos. 5 , 6 , 8 and 11 . Each net extension rod 40 further preferably comprises a female net attachment end 43 opposite male block attachment end 41 as illustrated in FIG. Nos. 1 - 3 , 6 and 9 and a flexible rod 42 intermediate male block attachment end 41 and female net attachment end 43 as illustrated in FIG. Nos. 6 , 7 ( a ), 7 ( c ) and 8 . Male block attachment ends 41 are primarily for removable insertion in the rod-receiving sockets as generally illustrated in FIG. Nos. 6 and 8 . It should be further noted from an inspection of FIG. No. 8 that male block attachment ends 41 may also be inserted in female net attachment ends 43 as a means to increase or effectively double the overall net extension rod length. In this regard, female net attachment ends 43 are sized and shaped to receive male block attachment ends 41 . Female net attachment ends 43 preferably have a female fitting and male block attachment ends 41 each preferably have a male fitting, the male fittings for removable insertion in the female fittings. It is further contemplated that backstop net assembly 100 may comprise either 5 or 10 net extension rods 40 depending on whether users may wish to effectively double the net extension rod length. Male block attachment ends 41 and female net attachment ends are each preferably constructed of pressed steel and sized at either ⅜ inch or ¼ inch NPT. Flexible rods 42 are each preferably constructed of 90,000 psi tensile strength fiberglass, are minimally conductive when wet and may be Ultraviolet (UV) protected where required. Flexible rods 42 each have a preferred maximum measured length of about 5 feet (maximum doubled or extended length of about 10 feet) and a preferred minimum measured length of about 4 feet. It is recognized that errant shots do, from time to time, travel to regions that are not immediately adjacent a typical vertically-oriented backboard. In this regard, the described selectively expandable system for increasing the structural width of a border gathering region 65 behind and beyond the borders of the typical vertically-oriented backboard for both catching, collecting or gathering extremely errant basketball shots as illustrated in FIG. Nos. 2 , 3 and 9 , and maintaining a substantially concentrical structural appearance of the backstop net assembly from an anterior viewpoint as needed as generally illustrated in FIG. Nos. 1 , 5 and 10 .
[0058] Female net attachment ends 43 each further comprise connector means for removably connecting female net attachment ends 43 to ball-gathering net assembly 60 as generally illustrated in FIG. Nos. 1 , 2 , 3 , 5 , 7 ( c ), 9 and 10 . In this regard, the connector means may preferably be further defined by comprising in combination laterally-aligned tie strap-receiving apertures 44 and a tie strap 45 . Tie strap-receiving apertures 44 are preferably constructed by boring a ⅛ inch hole through the female net attachment ends 43 as illustrated in FIG. Nos. 7 ( a ), 7 ( b ) and 7 ( c ). One tie strap 45 is illustrated in FIG. Nos. 7 ( b ) and 7 ( c ) and a bunch of tie straps 45 is illustrated in FIG. No. 11 . The tie strap-receiving apertures 44 of each female net attachment end 43 have tie aperture pairing for threadably receiving a tie strap 45 ; that is a tie strap 45 may thus be threaded through the tie strap-receiving apertures 44 or through the tie aperture pairing. Tie straps 45 each comprise a male tie end 46 and a female tie end 47 as illustrated in FIG. No. 7 ( b ) and 7 ( c ). Each male tie end 46 may thus be threaded through the described tie aperture pairing, around a specified portion or marked portion of ball-gathering net assembly 60 , and through female tie end 47 for removably connecting female net attachment ends 43 to a specified portion of ball-gathering net assembly 60 , as will be discussed in more detail below and as specifically illustrated in FIG. No. 7 ( c ). It is contemplated that each backstop net assembly 100 , when sold, will preferably be provided with a large quantity of tie straps for frequent storage or replacement. Tie straps 45 preferably have a minimum 18 pound tensile strength and are UV protected. Each tie strap 45 preferably has a minimum length of 4.03 inches (102.40 mm) and a minimum width of 0.094 inch (2.390 mm).
[0059] Ball-gathering net assembly 60 preferably comprises a ball-gathering net 61 as illustrated in FIG. Nos. 1 - 3 , 5 , 7 ( c ), 9 and 10 , and a plurality of spaced net markers 62 as illustrated in FIG. Nos. 1 , 5 , 7 ( c ) and 10 . Ball-gathering net 61 comprises a superior net portion 63 and an inferior net portion 64 . Superior net portion 63 is generally illustrated in FIG. Nos. 1 - 3 , 5 and 10 and inferior net portion 64 is generally illustrated in FIG. Nos. 1 , 2 , 4 and 10 . Ball-gathering net 61 preferably comprises minimum net weave sized at 1¾ inches square and has a minimum break strength of about 164 pounds (74.7 kilograms). Preferably, ball-gathering net 61 has a minimum net life of five (5) years in outdoor application. The preferred minimum net dimensions are sized at approximately thirteen feet by eight feet. In this last regard, it is noted, however that the preferred ball-gathering net 61 comprises a superior net portion 63 , which comprises angled attachment points, which angled attachment points, when connected to female net attachment ends 43 form a structural net assembly having the appearance of being concentric with a vertically-oriented backboard when attached to a basketball hoop assembly as generally illustrated in FIG. Nos. 1 , 5 and 10 . It is further noted that should the user elect to increase the net extension length, a ball-gathering net having larger dimensions is required.
[0060] Superior net portion 63 of backstop net assembly 100 , when attached to basketball hoop assembly 200 , thus concentrically mirrors or appears concentrical with a typical vertically-oriented backboard 220 . As earlier noted, a structurally concentrical backstop net assembly is thought to be both more efficient at catching collecting or gathering errant basketball shots and is less visually distracting to players taking visual aim at vertically-oriented backboard 220 or basketball-receiving hoop 210 . A structurally concentrical backstop net or screen is thought to be more efficient insofar as the outermost borders of superior net portion 63 of a structurally concentrical backstop net assembly provide a border gathering region 65 (as illustrated in FIG. Nos. 2 , 3 and 9 ) behind and beyond arcuate superior border 221 and straight lateral borders 222 of a typical vertically-oriented backboard 220 , which border gathering region 65 has a structural dimension of substantially the same width measured from arcuate superior border 221 and straight lateral borders 222 of a typical vertically-oriented backboard 220 . Basketball players with moderate shooting skills are thus more likely than not to propel errant shots into border gathering region 65 as specifically illustrated in FIG. No. 3 , which border gathering region is immediately adjacent arcuate superior border 221 and straight lateral borders 222 of a typical vertically-oriented backboard, or in effect, just miss the vertically-oriented backboard 220 . Basketball players are less likely to propel shots into other regions beyond this substantially concentrical border area or border gathering region 65 .
[0061] The basketball hoop assembly and backstop net assembly combination preferabrly further comprises means for securing inferior net portion 64 to playing surface 300 or to upright support post 230 . When securing inferior net portion 64 to playing surface 300 , it is contemplated that ground stakes 70 may preferably be utilized in situations where playing surface 300 is easily piercable by a ground stake 70 , such as on grass or earth or gravel surfaces. Ground stakes 70 are illustrated in FIG. Nos. 1 and 2 staking laterally opposite corners 66 of inferior net end 64 to the ground and preferably comprise constructed heavy duty molded plastic stakes having rounded edges and molded tie hooks. The outdoor life of ground stakes 70 should be about 2 years minimum and each stake should preferably have a length ranging from 6 inches to 12 inches. Further, when securing inferior net portion 64 to a playing surface 300 , which is not easily piercable, any suitable weighty material may be placed on laterally opposite corners 66 of inferior net portion 64 to weigh down inferior net portion 64 . In this regard, it is contemplated that sand bags or similar other massive bag-like weights may be used to weigh down inferior net portion 64 in adjacency to playing surface 300 . The means for securing inferior net portion 64 to upright support post 230 preferably comprises a length of cord 67 attached to each opposite comer 66 as illustrated in FIG. Nos. 4 and 10 . By thus attaching opposite corners 66 to upright support post 230 , the user creates a sack-like inferior net portion 64 as generally illustrated in FIG. No. 10 for further gathering errant shots.
[0062] Ball-gathering net 61 preferably further comprises a thickened perimeter cord 68 , which circumscribes the entire ball gathering net as illustrated in FIG. Nos. 1 - 5 , 7 ( c ), 9 and 10 . Perimeter cord 68 preferably comprises {fraction (5/16)} inch poly rope cross-stitched onto the net proper or ball-gathering net 61 as a border on all sides. Perimeter rope 68 thus provides added strength to ball-gathering net 61 and preferably may be inserted underneath the typical support base 240 of portable basketball hoop assemblies as illustrated in FIG. Nos. 2 , 4 and 10 . This is an added beneficial feature, particularly when the user elects to attach opposite corners 66 to upright support post 230 for creating a sack-like inferior net portion 64 for further gathering errant shots as generally illustrated in FIG. No. 10 . It is further helpful when the user stakes inferior net portion 64 to the playing surface as illustrated in FIG. No. 1 . By thus feeding perimeter cord 68 underneath support base 240 of portable basketball hoop assemblies, errant shots are less likely to exit backstop net assembly 100 between playing surface 300 or the ground and inferior net portion 64 .
[0063] Further, spaced net markers 62 are preferably attached to perimeter cord 68 at angled portions of superior net portion 63 in an assembled state as shown in FIG. Nos. 1 , 5 and 10 . Net markers 62 thus denote attachment points for female net attachment ends 43 so that users may quickly attach female net attachment ends 43 to perimeter cord 68 at the designated locations so as to provide a more concentric superior net portion 63 when in an assembled state. Further, net markers 62 are preferably of a different color than the remainder of ball-gathering net 61 . In this regard, it is contemplated that ball-gathering net preferably comprises light absorbent coloration and net markers 62 each preferably comprise light reflective coloration. The light absorbent coloration decreases distracting visual effects of backstop net assembly 100 and the light reflective coloration improves attracts the user to those attachment points for female net attachment ends 43 .
[0064] The disclosed backstop net assembly, in kit form, comprises mounting block 20 , a plurality of net extension rods 40 (preferably 3-10 net extension rods), superior hose clamp 28 , inferior hose clamp 29 , a plurality of tie straps 45 (supplied in large quantity), ball-gathering net assembly 60 , and ground stakes 70 , all as illustrated in an unassembled, compact state in FIG. No. 11 . The backstop net assembly kit may thus be utilized to outfit an existing basketball hoop assembly in the manner described herein.
[0065] Alternative Embodiment
[0066] An alternative embodiment of the present invention concerns a backstop net assembly for use in combination with a basketball hoop assembly, virtually identical to the preferred embodiment of the present invention save for the number of net extension rods 40 inserted into mounting block 20 . For example, users may elect to selectively remove net extension rods 40 from vertically-oriented superior rod-receiving socket 31 , left superior angled rod-receiving socket 32 , left inferior angled rod-receiving socket 33 , right superior angled rod-receiving socket 34 , or right inferior angled rod-receiving socket 35 . For example, if the user elects to remove net extension rods 40 from left superior angled rod-receiving socket 32 and right superior angled rod-receiving socket 34 , the resultant backstop net assembly comprises three net extension rods 40 , the female net attachment ends 43 of which attach at three junction points on superior net portion 63 . While not specifically shown, it is believed that removal of net extension rods 40 in the described manner to create a backstop net assembly comprising three extension rods is within the skill of a person skilled in the art and hence no further description is required.
[0067] It will thus be seen that the present invention provides a basketball-gathering backstop net assembly, installable on basketball hoop assemblies, which backstop net assembly is less cumbersome to practice and which backstop net assembly may properly be utilized in combination with a wide variety of basketball hoop assemblies. It will be further seen that the present invention provides a backstop net assembly usable in combination with a basketball hoop assembly, which backstop net assembly comprises a multi-socketed mounting block attachable to the basketball hoop assembly, a plurality of net extension rods removably insertable in the mounting block, and a basketball-gathering net attachable to the net extension rods for catching, collecting and gathering errant basketball shots for easy retrieval by basketball players or for preventing basketball landings in regions adjacent to the basketball hoop assembly.
[0068] Still further, it will be seen that the present invention provides a basketball-gathering backstop net assembly kit, which kit may be delivered or stored in a compact state, and which, when unpacked, may be installed on existent basketball hoop assemblies for catching, collecting or gathering errant basketball shots. Still further, it will be seen that the present invention provides a backstop net assembly kit for outfitting existent basketball hoop assemblies so that basketball players may selectively outfit basketball hoop assemblies for catching, collecting and/or gathering errant basketball shots for easier basketball retrieval. Still further, it will be seen that the present invention provides a backstop net assembly which is sized and shaped to concentrically mirror or appear concentrical with the superior border and lateral borders of a typical vertically-oriented backboard from an anterior viewpoint. In this regard, it will be seen that the present invention provides a backstop net assembly which is both more visually appealing and more efficient at catching, collecting or gathering errant basketball shots.
[0069] While the above description contains much specificity, this specificity should not be construed as limitations on the scope of the invention, but rather as an exemplification of the invention. For example, mounting means for attaching mounting block 20 to upright support post 230 need not comprise superior hose clamp 28 and inferior hose clamp 29 . So long as the mounting means fixedly connects the mounting block to the upright support post, with the longitudinal axes of the rod-receiving sockets disposed in some vertical relation, the mounting means successfully fulfills its mounting purpose. Further, the means for securing inferior net portion 64 to playing surface 300 need not comprise ground stakes. So long as the means for securing inferior net portion 64 to playing surface 300 , the means successfully fulfills is securing purpose. Further, the net extension rod attachment means need not necessarily comprise a plurality of rod-receiving sockets and the block attachment means need not necessarily comprise a male block attachment end. It is contemplated that a plurality of male mounting protuberances, integrally formed with the mounting block, may replace the rod-receiving sockets and that female block attachment ends may replace the male block attachment ends for receiving the male mounting protuberances. The mounting block, thus configured, may further act a central junction hub for attaching radially extending net extension rods for providing a border gathering region above and behind the borders of a given basketball backboard. Furthermore, in this last regard, it is contemplated that basketball backboards come in various shapes and sizes. It is thus contemplated that the net extension rods may come in various lengths and be selectively attached to the mounting block in the manner described to structurally achieve a plurality of differently sized and shaped border gathering regions which appear concentrical with variously shaped basketball backboards from an anterior viewpoint.
[0070] Accordingly, although the invention has been described by reference to a preferred embodiment and an alternative embodiment, it is not intended that the novel device be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosure, the following claims and the appended drawings. | The present invention provides a backstop net assembly and kit for use in combination with a basketball hoop assembly, which comprises a multi-socketed mounting block, a plurality of net extension rods, and a ball-gathering net assembly. In a basketball playground, one can find an upright support post, a backboard mounted on the post, and a basketball rim and net structure mounted on the backboard. The present invention provides a basketball backstop net assembly to gather errant basketball shots launched by a basketball shooter to minimize basketball retrieval time and possible damage to surrounding valuables. The ball-gathering net is a reticulated having a size and width, which extends vertically and laterally via the net extension rods a sufficient distance to capture errant shots and to assist in keeping the basketball in play. Additionally, a perimeter cord bounds the reticulated portion of the net to provide added strength to the ball-gathering net. | 0 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a process for dynamic monitoring of changes to deformable media, and for predicting these changes.
In domains such as air traffic control, it is important not only to monitor trajectories followed by aircraft to guide them, but also to know the weather conditions within the radius of action of the instruments used for this control, and particularly for detecting and precisely localizing cloud formations that could be dangerous or simply unpleasant for persons in the aircraft. This is usually done using weather radars, for which the echo images are displayed on the control center screen after eliminating echoes due to fixed obstacles. Human interpretation of these types of image is often complicated and these images cannot be used to forecast changes to cloud formations. Furthermore, an air traffic controller needs to know the weather conditions and how they will change in order to optimize routing of aircraft that he is responsible for guiding and to understand any route changes decided upon by the captain to avoid cloud formations that he considers are dangerous. The article by F. BARBARESCO, S. BONNEY, J. LAMBERT and B. MONNIER published in IEEE International Conference on Image Processing—I.C.I.P. 96, in Lausanne (Switzerland) in September 1996 entitled “Motion Based Segmentation and Tracking of Dynamic Radar Clutter” describes a process for processing this type of image by determining active contours with a constraint model, but this process has two disadvantages; firstly it requires a prohibitive calculation time, and secondly it cannot manage complex deformations (it simply manages deformations that can be approximated by an affine deformation model).
The purpose of this invention is a process for dynamically monitoring the variation of deformable media that can be used for this monitoring and for creating relatively reliable forecasts of how the deformations will change, without requiring a prohibitive calculation time.
The process according to the invention for dynamic monitoring of deformable media consists of using at least two images taken at different times obtained by at least one sensor, establishing the skeleton of each distinct assembly in this medium for each image, and then making the image skeletons in question correspond to each other.
This correspondence is made by vectorizing the skeletons of the processed images, examining the vectors of these skeletons taken in pairs, and each time attempting to match two vectors with approximately the same geometric characteristics. Skeletons of assemblies, and if required the corresponding assemblies, can be rebuilt from these matched skeletons.
Advantageously, the image may be preprocessed before the skeletons are built up. This preprocessing may include a filter step (frequency and/or morphological filtering), and a thresholding step eliminating image components that are not relevant for the problem in question. The processing can advantageously be facilitated by simplifying the skeletons by vectorization (thinning and/or search for points at which curves representative of skeletons have a curvature greater than a determined value and then linearization) and/or elimination of insignificant artifacts or barbules.
According to one aspect of the process according to the invention, a map of displacement vectors is created for at least one area of interest in the processed images.
According to another aspect of the invention, a predicted image is built up starting from displacement vectors and/or the skeleton. Another possible way of rebuilding the above mentioned image is to use the skeleton displacement vectors to calculate the displacement of each pixel image and to rebuild the predicted image from the newly predicted pixel locations.
According to another aspect of the process according to the invention, attributes are applied to at least some of the pixels in several images taken at different times, the characteristics of the corresponding areas are determined, and information about the variation and/or the nature of areas is thus enriched. These attributes are particularly the change in the area or volume of deformable media, their density, and the local variation of density within these media.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be better understood after reading the detailed description of one embodiment used as a non-restrictive example and illustrated by the attached drawing, in which:
FIG. 1 is a simplified diagram of a weather radar display screen, which shows the skeletons of several cloud formations built up according to the invention, and
FIG. 2 shows diagrammatic views demonstrating correspondences between radar image skeletons taken in accordance with the invention at different times, for different cases of changes to cloud formations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will be described in detail below for application to weather radar systems, but obviously it is not restricted to this application alone, and it may be used in many other domains in which deformable media are to be dynamically monitored and for which data may be available (for example signal shapes, images, etc.) obtained using at least one appropriate sensor, and for which it may be necessary to predict changes. For the purposes of this description, a “deformable medium” is a set of particles and/or groups of particles and/or sets of objects and/or organisms, that may be gaseous and/or liquid and/or solid, these elements changing in a non-uniform manner with time, with deformation gradients that may vary with time and/or from one assembly to another.
Some of other domains to which this invention may be applied are particularly:
space observations: monitoring of natural phenomena and/or man-controlled phenomena such as flooding, snow cover, desertification of arable land and/or new crop land, river or sea pollution (by oil, etc.), etc.,
oceanography: monitoring the variation of the ocean temperature gradient (fronts, vortices, submarine currents, etc.) on infrared or near ultraviolet space images (due to phyto-plancton). The collected images are useful for marine meteorology, and for modeling the propagation of sonar waves (communications and detection of submarines, etc.),
medicine: for the treatment of medical images (M.R.I., tomography, etc.) for monitoring pathologies; study of heart dynamics, monitoring of cerebral activity, monitoring changes to tumors, etc.,
fluid mechanics: monitoring of volutes (by coloring) of non-stationary flows such as flows that occur along a wall, or injection of fuel into a combustion chamber, etc.
FIG. 1 shows the contours of a few cloud formations 1 , such as those recorded using a weather radar and displayed on a screen, for example an air traffic control station screen. The image thus displayed has been preprocessed in a known manner in itself, to eliminate all ground clutter (due to relief, swell, fixed obstacles) if necessary.
The corresponding skeleton 2 has been plotted for each of these cloud formations. Obviously, cloud covers 3 with a negligible. radar reflection intensity which cannot present any risk at the moment considered, are ignored. The calculation of closed contour skeletons is known in itself; for example the Danielson algorithm (see the article entitled “Euclidean Distance Mapping” published in the Computer Graphics & Image Processing review, volume 14, pages 227-248, 1980), or the ultimate eroded algorithm (mathematical morphology), can be used.
It will be seen that the images mentioned above are two-dimensional, but it is obvious that three-dimensional information can be obtained, for example by studying a series of two-dimensional images parallel to each other (cutting cloud masses into “slices”) or by processing skeletons in 3 D.
This first step may be used to compress data for an image. It is then simply necessary to build up skeletons of the different assemblies in the image as described above, and only to keep information about these skeletons. Obviously, this compression will lead to a certain loss of data.
We will now describe the second step in the process according to the invention, namely creating correspondences between skeletons obtained for successive images of a same area of space.
FIG. 2 shows three such successive images references 4 , 5 and 6 related to cloud phenomena recorded by a weather radar at times t−Δt, t, t+Δt (where t is the time at which the current situation is analyzed). In this case, the time lapse Δt is equal to a few minutes, for example 5 minutes, but obviously this time lapse could be different depending on the phenomena observed, the field of application of the process, the rate at which the phenomena concerned change and the required resolution.
Image 5 at time t shows contours of two cloud formations 7 , 8 . It can be seen on image 4 , produced a few minutes before time t, in other words at time t−Δt, that formations 7 and 8 were already present but were closer to each other than at time t, and that they were slightly smaller than they are at time t.
The process according to the invention is used firstly by plotting the skeletons 9 , 10 representing formations 7 , 8 respectively at time t−Δt, and then skeletons 11 , 12 respectively at time t. These skeletons are then made to correspond. This is done, as shown in an illustrative manner in FIG. 2, by joining the corresponding ends of skeletons 9 to 12 by vectors 13 to 16 , images 4 and 5 being placed side by side with image. 5 being to the right of image 4 . Thus, vector 13 joins the “upper” end of skeleton 9 to the upper end of skeleton 11 , vector 14 joins the “lower” end of skeleton 9 to the lower end of skeleton 11 , similarly for skeletons 10 and 12 to obtain vectors 15 and 16 . The example in FIG. 2 is very much simplified since skeletons 9 to 12 are almost straight lines, but obviously if the shapes of these skeletons were more complex the procedure would be similar, joining the corresponding characteristic points in the skeletons by a larger number of vectors (ends and junction points of skeleton segments). Details of the embodiment of this correspondence are known in themselves, for example in the article by S. LEGOUPIL & al., “Matching of Curvilinear Structures: Application to the Identification of Cortical Sulci on 3 D magnetic Resonance Brain Image”, Pattern Recognition in Practice IV. E. S. Gelsema & L. N. Kanal, pp. 185-195, Elsevier Science B.V., 1994.
To obtain the skeleton at time t+Δt (from image 6 , placed side by side with image 5 at its right), each of the vectors 13 to 16 is extended by a length equal to its own length, respectively, thus obtaining vectors 17 to 20 . Skeleton 21 is obtained by joining the ends of vectors 17 and 18 , and skeleton 22 is obtained by joining the ends of vectors 19 and 20 . In the case shown in FIG. 2, vectors 13 and 14 are slightly divergent towards the right, in the same way as for vectors 15 and 16 , such that skeletons 11 and 12 are slightly longer than skeletons 9 and 10 respectively. The result is that skeletons 21 and 22 are larger than skeletons 11 and 12 respectively, and consequently the corresponding cloud formations become larger from (t−Δt) to (t) and from (t) to (t+Δt). Obviously, image 6 is simply a prediction calculated at time (t) and it may be corrected if necessary using measurements made at time (t+Δt) so that forecasts for time (t+2Δt) can be calculated.
For the example described above, image 6 in FIG. 2 was obtained by linear extrapolation, but obviously other types of non-linear extrapolations would be possible, particularly when it is observed that forecast images are very different from measured images (due to the rate of change of the size of skeletons and deformations) and it is also obvious that if large variation gradients occur, the time intervals Δt can be reduced, and that the extrapolation may be modified if the gradients vary.
In other cases, the cloud formations may disappear (or their radar echo amplitude may become negligible). Their representations on images also disappear, so that if necessary forecasts concerning neighboring areas can be modified. Conversely, cloud formations can appear and as soon as the amplitude of their radar echo exceeds an experimentally determined value, the corresponding skeleton can be plotted and modified as a function of the change in these cloud masses.
Obviously, the images to be processed to obtain the skeletons may be subjected to different appropriate preprocessing known in itself. This preprocessing may include thresholding and filtering (frequency and/or morphological) in order to eliminate parasites due for example to background noise, elimination of components that are not useful for the problem that arises (in particular, elimination of static image components).
The skeletons obtained may be simplified by vectorization (thinning, search for skeleton points with high curvature, linearisation), and insignificant barbules or different artifacts may be eliminated.
Starting from the skeletons thus obtained, it is easy (if necessary) to plot the contours corresponding to cloud formations, in a manner known in itself. The method of rebuilding a predicted image starting from the predicted skeletons is described above. Another possibility is to use the displacement vectors field (such as vectors 17 to 20 in FIG. 2) and apply these displacement vectors to all image pixels (or at least to all pixels in areas in which cloud formations can vary). Thus, the predicted image is rebuilt by placing the pixels at their new location as determined by these vectors.
The operations mentioned above may obviously be carried out in three-dimensions (3 D). In this case, either the observed space may be cut into parallel “slices” perpendicular to the direction of observation, or data supplied by radar may be in 3 D form (records made for different distance ranges for different elevation angles).
Thus, with the process according to the invention, the shape information (cloud shapes in the example described above) is compressed (data necessary to encode skeletons are much less voluminous than with known processes) so that images can be processed quickly. Cloud displacements and deformations are easy to analyze and extrapolate to give more reliable forecasts. The presentation in the form of an approximate polygonal skeleton (particularly the trunk of the skeleton) is more stationary than a presentation in the form of approximate polygonal contours. These advantages can also be applied in other possible application domains, some of which were mentioned above. | The process according to the invention used for weather radar images is used for dynamic monitoring of cloud masses, particularly to predict future changes. It consists essentially of creating the skeleton of each cloud mass, for several images at different times, determining the displacement vectors for segments of vectorized skeletons, and extrapolation to rebuild the predicted skeletons. | 6 |
DESCRIPTION
1. Technical Field
The present invention relates generally to fluidized bed gasifiers systems and, more particularly, to rotating fluidized bed gasifiers systems especially useful in compound engines.
2. Background Art
In recent years fluidized beds have found many diverse uses in power generating systems and chemical processes. They have served as chemical reactors, particularly for finely divided materials; as incinerators for liquid, solid or gaseous substances; as pressurized or atomspheric, coal-, lignite-, petroleum-, peat-, wood- and/or paper-fired boiler or combustor units for power generation; and, as sites for various process treatments such as drying, baking, coating, oxidizing, etc.
Typically, fluidized beds which are in use today are static beds established when air or other fluidizing gas is introduced into a plenum chamber under pressure and forced upwardly through a diffusing medium (e.g., membrane, grate) to a superimposed chamber containing a particulate bed, of inert or reactive, finely divided, pulverulent solid material, Gas, forced upwardly through the diffusing medium into the fluidizing chamber under a sufficient predetermined pressure, fluidizes the particulates. The gas pressure requied to accomplish this is determined, in part, by the nature and degree of fineness of the powder to be fluidized. Other influencing factors are the depth of the bed and the size, number and design of the plenum chamber compartments and passages into the superimposed fluidizing chamber.
The rate at which an endothermic chemical reaction takes place in a fluidized bed between a solid material and a gaseous agent depends to a major extent on the rate at which the reactants are brought together, the rate at which the heat of reaction is funished and the rate at which the reaction products are removed. By and large the gaseous agent also serves as the fluidizing agent. In conventional static fluidized beds, the rate at which the fluidizing gaseous agent can be blown through the bed is limited by the fact that the fluidizing currents within the fluidized zone are vertical, i.e., only the gravity force on the bed particles opposes the balancing gaseous agent force needed to maintain fluidization. If the force opposing the balancing fluidizing force could be increased, then the fluidizing agent flow rate through the bed and the reaction rate of the system would be increased. This can be accomplished using rotating fluidizing beds wherein the fluidizing gaseous agent forced through the bed from its periphery opposes the centrifugal force tending to throw the bed particles outwardly from the bed axis of rotation toward the bed periphery. The extent of the centrifugal force and, thus, of the opposing fluidizing gaseous agent rate can be controlled by controlling the speed of bed rotation.
Gasifiers, in which steam typically reacts with carbon (coal) to form carbon monoxide and hydrogen, may be fluidized beds in which the steam fluidizes a bed containing carbon and the endothermic reaction takes place at temperatures of at least about 1800° F. These high temperatures are advantageously achieved by channeling the heat generated in a combustor from a conventional carbon-oxygen exothermic reaction into the gasifier fluidized bed. The chemical reactions are well known and proceed generally as follows:
In the combustor:
C+O.sub.2 →CO.sub.2 +174,000 BTU/mole
In the gasifier:
C+H.sub.2 O+54,000 BTU/mole→CO+H.sub.2
C+2H.sub.2 O+40,000 BTU/mole→CO.sub.2 +2H.sub.2
As a result of increasing the reaction rate due to the ability to increase the steam feed rate, rotating fluidizing beds used as gasifiers, e.g., in conventional compound engines, are extremely compact and can much more readily be integrated into powerplants. In some applications where size is critical this can be a considerable advantage, especially when the gasifier is combined with a combustor which burns fuels inherently requiring large volumes, such as powdered coal.
A form of rotating fluidized bed combustor system has been suggested by J. Swithenbank in his article "Rotating Fluidized Bed Combustor/Gasifier". The Swithenbank system includes a vertical shaft around which rotates a generally cylindrical combustor using natural gas as the fuel. The gas in introduced at the center of the combustor, i.e., along the axis of rotation, and is mixed with fluidizing air forced through the bed particles from the bed periphery toward the center. The bed, which is heated by the combustion heat generated and the mixing action accompanying rotation, preheats the entering fluidizing air. Most of the combustion between the heated air and the natural gas appears to occur outside, rather than within, the bed itself. Cooling coils passing through the bed carry air which is heated by the combustion and serve to control the bed and exhaust gas temperature. Swithenbank states that his combustion system may be operated by burning or gasifying coal granules in the fluidized bed, but discloses no combustor configuration suitable for use with coal fuels. Moreover, Swithenbank's configuration, requiring introduction of the fuel along the axis of rotation, detracts from the attainment of maximum energy density because it diminishes the compactness of the system. See also, Demircan et al, Rotating Fluidized Bed Combustor, published in "Fluidization" by Cambridge University Press (1978). Other publications of interest in connection with the heat transfer and combustion characteristics of natural gas fueled rotating fluidized beds are J. Broughton and G. E. Elliott, Heat Transfer and Combustion in Centrifugal Fluidized Bed, I. Chem E. Symposium Series No. 43 (paper presented at June, 1975 meeting) and G. C. Lindauer et al, Experimental Studies on High Gravity Rotating Fluidized Bed, U.S. Atomic Energy Commission, BNL-50013 (Sept. 1966).
Gasifiers are particularly desirable stages to include in powerplants since the water in the system serves to deter the formation of nitrous oxide type emissions in the combustion gases. However, due to the high thermal input requirement of gasifiers it has proven difficult to devise a gasifier and thermal source which is particularly compact. Accordingly, the present invention is directed to overcoming one or more of the problems as set forth above.
DISCLOSURE OF INVENTION
In one aspect of the present invention this is accomplished by providing a rotating fluidized bed gasifier including a fluidization chamber in whch steam reacts with a carbon containing bed of pulverulent solid particles as it is forced through the bed. The bed particles are fluidized by a gaseous agent forced through the chamber in the same direction as the steam. The gaseous reaction products and unreacted steam exit the chamber and are directed away therefrom.
In another aspect of the invention, the chamber includes first and second spaced apart apertured or perforated walls, means are provided for rotating the chamber about an axis to cause the bed particles to centrifugally gravitate toward the first perforated wall, the steam is forced into the chamber through the first perforated wall and the reaction products and unreacted steam exit the chamber through the second perforated wall.
In a particularly preferred form of the invention, the rotating fluidized bed gasifier is combined with a rotating fluidizing bed combustor for outstanding compactness. The first and second walls are substantially cylindrical and comprise the outer and inner coaxial walls, respectively, of the fluidization chamber. As the chamber is rotated about its axis, the bed particles centrifugally gravitates toward the outer wall. Compressed air, a combustible fuel and steam, enter the chamber through the outer perforated wall and fluidize the bed particles. Generally, the fuel is fed to the fluidized bed with the air stream, particularly if the fuel is solid, such as powdered coal. The air reacts with the fuel to form hot combustion gases and to raise the bed temperature to at least about 1800° F. At this temperature the steam reacts with the carbon to form the gaseous reaction products which exit the fluidized bed with the hot combustion gases and unreacted steam and air through the perforated inner wall.
In an especially useful application, the rotating fluidized bed gasifier-combustion combination of the present invention is employed as a hot gas generator in a conventional compound engine. The compressed air is furnished to the gasifier combustor by one or more turbo and/or positive displacement compressors and the generated gases and unreacted air and steam exiting the fluidization chamber are directed into and through one or more turbo and/or positive displacement expanders.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematically simplified sectional view of one embodiment of the fluidized bed gasifier system of the present invention.
FIG. 2 is a side elevational schematic view of a combined rotating fluidized bed gasifier-combustor of the present invention showing the use thereof in a conventional compound engine system.
BEST MODE FOR CARRYING OUT THE INVENTION
The rotating fluidized bed gasifier system of the present invention has wide utility whereever gasifiers may be used but, due to its outstanding compactness, is particularly adaptable for integration into powerplants, whether stationary or mobile. Referring to FIG. 1 a preferred form of rotating fluidized bed gasifier 101 of the present invention is more clearly depicted. As can be seen in detail the gasifier 101 includes an inlet plenum chamber 102 into which steam passes before it is directed through the rotating fluidized bed portion 106 of the gasifier as the fluidizing medium therefor and to react with the carbon content of the bed particles. In a preferred embodiment the bed particles include powdered coal, desirably solvent refined coal to minimize ash removal problems. In an alternative form of the invention a gaseous agent, such as compressed air, may be fed to the bed to fluidize or assist in fluidizing the bed particles. The steam reacts with the carbon in the bed at temperatures of about 1800° F. to form carbon monoxide and/or carbon dioxide and hydrogen as reaction products which exit the fluidized bed portion 106 through outlet plenum chamber 116 and are thereafter directed away therefrom.
The rotating fluidized bed portion 106 comprises an outer perforated cylindrical wall 108, an inner perforated cylindrical wall 110 and appropriate enclosing walls 109 defining therebetween an annular fluidizing chamber 112 in which pulverulent solid particles 114 are disposed. The perforations in walls 108 and 110 are small enough to contain particles 114 within chamber 112 and to control the exhaust of solid reaction products but large enough to sustain the free flow of steam and/or fluidizing air from the inlet plenum chamber 102 through wall 108, into and through chamber 112, through wall 110 and into outlet plenum chamber 116. The fluidized bed portion 106 rotates on horizontal, vertical or other appropriate axis, preferably about a longitudinal axis 119 which corresponds to the axis of coaxial cylindrical walls 108, 110. Rotation is motivated by available rotational means lll, such as appropriate gearing to drives for other conventional engine functions, and is controlled to a speed sufficient to impart a centrifugal force to the particles 114 within the bed. The centrifugal force causes the particles 114 to gravitate away from axis 119 toward outer perforated wall 108. The flow of fluidizing steam from inlet plenum chamber 102 through perforated outer wall 108 opposes the centrifugally induced movement of the particles 114 and, in so doing, fluidizes the bed. As long as temperatures within the fluidized bed are maintained sufficiently high for the desired gasification reaction to occur, e.g. about 1800° F. to generate carbon monoxide and hydrogen, reaction occurs within the fluidizing chamber 112 between the fluidizing steam and the carbon particles, e.g., powdered coal, in the bed to produce hot reaction product gases within the bed. These hot reaction product gases are swept out of the bed through inner perforated wall 110 by the continuing flow of fluidizing steam through the bed. The unreacted fluidizing steam and the hot reaction product gases pass from outlet plenum chamber 116 into the core 118 of the gasifier 101. In the preferred embodiment, core 118 is an elongated cylindrical chamber which directs the flow of unreacted fluidizing steam and reaction product gases through turbo and/or positive displacement expanders to produce useful engine work output.
The bed particles 114 are preferably an admixture of inert materials, e.g., sand, dolomite, other sulfur absorbers, or any other inert material generally found suitable for use in fluidized beds, and a carbonaceous fuel, such as powdered coal. For example, a suitable combination of materials comprises a particulate mixture of coal, dolomite, sand and coal ash. A generally useful proportion of bed particles is 95% inert materials, 5% fuel. As the reaction with steam proceeds, coal ash is formed and becomes either a part of the inert particulate portion of the bed or passes out of the bed through the inner perforated wall 110 with the unreacted fluidizing steam and reaction product gases. Any ash which passes out of the bed may be removed from the gas stream by a cyclone separator, not shown. Ash and sulfur remaining in the bed will eventually have to be circulated to a cleaning reclaiming device, not shown. If solvent refined coal is used, ash and sulfur removal is generally not a problem since this type of coal permits operation for lengthy periods without any interruption. From time to time the carbon content of the bed will have to be replenished. This may be accomplished by known conventional techniques or by the carbon addition and bed replenishment method discussed in connection with FIG. 2 hereof.
The temperature within the bed may be controlled in any desired manner. Desirably bed temperature is controlled by controlling the amount of heat transferred to the bed from tubes (or coils) 120 which pass substantially longitudinally through the bed. The tubes 120 may, if desired, rotate with the bed portion 106 and are supplied with a high temperature fluid from a heat source, such as combustor 200 shown in phantom in FIG. 1. The combustor may be conventional in design or may be a fluidized bed type. Thermal energy generated in the combustor 200 is transferred to the gasifier 101 by heat pipes 202 which are in thermal communication with tubes 120. It is recommended to control the temperature of the gasifier bed to about 1800° F. To accomplish this, as a practical matter, the combustor 200 will have to operate at a considerably higher temperature, e.g. at about 2200° F. The combustor 200 may also be used to furnish thermal energy from the combustor products to water fed to tubes or coils 204 to produce the steam used as the fluidizing agent and reactant in the gasifier. In an alternative embodiment a stationary heat exchanger (not shown) may be employed to furnish thermal energy from the hot combustor gases to water and air. The water is converted to steam for use in the gasifier while the heated air is directed to the combustor as a reactant in the combustion process.
In a most preferred embodiment, the rotating fluidized bed gasifier of the present invention is combined with a combustor, desirably of the rotating fluidized bed type, which generates the thermal energy to achieve the at least 1800° F. temperatures needed within the gasifier. The resulting combination is so outstandingly compact that it is readily incorporated as the hot power gas generation source in integrated powerplants. With reference to FIG. 2 the combined fluidized bed gasifier-combustor of the present invention is shown in combination with exemplary compressor and expander elements of an otherwise conventional compound engine. The gasifier-combustor system includes a compressor means 20, which may include one or more turbo and/or positive displacement compressors, for furnishing compressed air to the gasifier-combustor and expander means 22, 24, which may include one or more turbo and/or positive displacement expanders, for producing useful work from the hot combustion and reaction product gases exiting the gasifier-combustor. In some instances it may be desirable to integrally associate at least one compressor and one expander via a shaft assembly 14 to provide a means for driving the compressor. In such a case the rotating fluidized bed gasifier-combustor is advantageously mounted for rotation about the shaft assembly 14.
Continuing with reference to FIG. 2 the rotating fluidized bed gasifier-combustor includes a housing 100 through which passes a rotatable shaft assembly, such as shaft assembly 14. Compressed air is ducted within housing 100 into inlet plenum chamber 102. The compressed air is desirably preheated air, such as exits the recuperator section of a gas turbine engine. Fuel fed through entry port 104 is mixed with the compressed air prior to entering the inlet plenum chamber 102 and is conveyed by the air to the rotating fluidized bed portion 106 of the gasifier-combustor. In a preferred embodiment the fuel is powdered coal, desirably solvent refined coal to minimize ash removal problems. As in the gasifier embodiment described in connection with FIG. 1, steam is fed via stream inlets 105 to the rotating fluidized bed portion 106 via inlet plenum chamber 102. The fluidized bed portion 106 is the same as has been described in connection with FIG. 1. Inasmuch as at least some combustion will occur within the bed, the perforations in walls 108 and 110 should be small enough to control the exhaust of solid combustion products which may be formed but large enough to permit the entry of powdered fuel as well as to sustain the free flow of fluidizing air and steam from the inlet plenum chamber 102. Combustion occurs within the fluidizing chamber 112 between the fluidizing air and the fuel, e.g., powdered coal, to produce hot combustion gases within the bed. Combustion may also occur outside the fluidizing chamber 112, for example within elongated cylindrical core chamber 118.
Most importantly in connection with the FIG. 2 embodiment, the combustion of the powdered coal and fluidizing air is an exothermic reaction which produces, in situ, approximately 174,000 BTU/mole of carbon combusted. This large generation of heat within or immediately adjacent fluidization chamber 112 rapidly raises the temperature within the bed to the about 1800° F. range desired for the endothermic gasification reaction between the carbon particles in the bed and the steam. The gasification reactions which take place produce hot reaction product gases, namely carbon monoxide, carbon dioxide and hydrogen, within the bed. The hot combustion and reaction product gases produced within the chamber 112 are swept out of the bed through inner perforated wall 110 by the flow of fluidizing air and stream through the bed. The unreacted fluidizing air and steam and the hot combustion and reaction product gases pass from outlet plenum chamber 116 into core 118 where they admix with any combustion gases which may have formed as a result of combustion within core 118. In the preferred embodiment, where the gasifier-combustor of the present invention is used in connection with a conventional powerplant, core 118 directs the flow of unreacted fluidizing air, unreacted steam and combustion and reaction product gases gases through positive displacement reciprocating expander 22. The expander exhaust gases may usefully be further expanded by passage through the vanes or blades of turbine 24.
The combustion temperature within the gasifier-combustor bed is controlled in part by the ratio of air to fuel fed into the bed. In addition, bed temperature may be controlled by controlling the amount of heat transferred from the bed tubes (or coils) 120 which pass substantially longitudinally through the bed. The tubes 120 may, if desired, be used to generate steam from water supplied thereto from steam/water supply source 122. Alternatively, tubes 120 may be used to superheat steam furnished by source 122 thereto. The resulting steam exiting tubes 120 may be collected or recovered in steam collection chamber 124 and optionally be directed into inlet plenum chamber 102 to comprise all or a part of the steam supply to the gasifier-combustor. By pre-determining the rate of flow of water or steam through the bed, localized temperatures within the bed are readily controlled. It is recommended to control the temperature of the bed in such a manner that carbon-water gasification reaction temperatures of at least about 1800° F. are maintained in at least portions of the bed.
INDUSTRIAL APPLICABILITY
The rotating fluidized bed gasifier of the present invention has broad applicability but is particularly useful as a gasifier-combustor incorporated in conventional powerplants such as compound engines. When operating in this capacity the fluidized bed portion 106 preferably rotates about the same axis, shaft assembly 14, on which compressor and expander elements are mounted, and rotation is motivated by suitable gearing to other conventional engine functions. Upon rotation of the shaft assembly 14, the compressor means 20 draws air, preferably heated air, into housing 100, compresses the air, and directs the air flow into inlet plenum chamber 102. Steam is also fed via inlets 105 to inlet planum chamber 102. Powdered coal fuel is fed through entry port 104 into the heated compressed air stream and is conveyed with the air stream and steam flow via inlet plenum chamber 102 through perforated outer wall 108 into fluidization chamber 112. Inasmuch as the rotation of fluidized bed portion 106 causes the particles 114 within chamber 112, which are an admixture of carbon and inert materials, to gravitate toward outer wall 108, the opposing flow of the compressed air stream and steam into the chamber 112 fluidizes the particles. Combustion occurs within fluidizing chamber 112 between the compressed air and the powdered coal fuel to produce hot combustion gases and thermal energy within the bed. This raises the temperature of the bed to the approximately 1800° F. range desired for the endothermic gasification reaction between the carbon particles in the bed and the steam. The gasification reactions which take place produce hot reaction product gases which are swept out of the bed together with the hot combustion gases and the unreacted air and steam through inner perforated wall 110 by the flow of fluidizing compressed air and steam through the bed. The unreacted compressed air, unreacted steam and the hot combustion and reaction product gases pass through outlet plenum chamber 116 into core 118 and are directed through positive displacement reciprocating expander 22 and then through the vanes of turbine 24 to drive the expander-turbine combination and, through shaft 14, to drive compressor means 20 as well. Temperatures within the bed portion 106 may be controlled and steam for feeding to the gasifier-combustor may be produced by directing water or steam through tubes 120 which extend longitudinally through bed portion 106.
Various configuration compound engines are contempated. For example, the compressor means 20 may advantageously consist of two centrifugal stages, each having, e.g., a 3.5:1 compression ratio followed by a positive displacement stage capable of handling higher pressures, e.g., about 5-6:1 compression ratio, to produce a final pressure of about 1000 psig. The compressors may be of any type, e.g., reciprocating, rotary, etc.. Intercoolers may be advantageously used between compressor stages. Reciprocating compressors and expanders may be logically incorporated into a single engine block with half the cylinders running as compressors and the other half operating as expanders. The two centrifugal compressors may also usefully operate on the same shaft as two turbines, all coupled to the crank, or, in some situations, even running free as a turbocharger. An exhaust gas boiler can generate steam which is directed to the tubes 120 of the gasifier-combustor to become superheated and/or to act as a temperature control in the bed.
Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims. | PCT No. PCT/US79/00929 Sec. 371 Date Nov. 1, 1979 Sec. 102(e) date Nov. 1, 1979 PCT Filed Nov. 1, 1979 PCT Pub. No. WO81/01295 PCT Pub. Date May 14, 1981
A rotating fluidized bed gasifier system especially useful in compound engines comprising an annular fluidization chamber containing a bed of carbon containing pulverulent solid materials. The chamber, which is defined by inner and outer spaced apart coaxial, cylindrical, perforated walls, rotates about the longitudinal axis of the cylinders. Steam enters the bed, which is maintained at about 1800° F., through the outer perforated wall and fluidizes the particles. The steam reacts endothermically with the carbon to produce reaction product gas which exits the bed, together with unreacted steam, through the inner perforated wall. In a preferred form of the invention the bed is maintained at approximately 1800° F. by combining a rotating fluidized bed combustor with the gasifier. In this embodiment compressed air and powdered coal enter the bed with the steam through the outer perforated wall. The air reacts exothermically with the fuel within the bed to generate heat for the endothermic steam-carbon reaction and to produce hot combustion gas which exit the bed, together with the reaction product gas, unreacted steam and compressed air, through the inner perforated wall. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to machines and methods of loading pallets, and specifically to machines and methods of palletizing cylindrical articles such as rolled sheet material or the like.
As exemplified by the machines shown in U.S. Pat. Nos. 2,977,002, 3,111,233 and 3,844,422, machines have heretofore been developed for loading pallets with various types of articles. Where the load consists only of flat or block shaped articles such as boxes and crates, the palletizing task is relatively simple. In such cases, loading the pallet with efficiency, compactness, and with proper alignment of individual load articles to pallet are the primary concerns.
With cylindrical articles such as rolled sheet roofing material or the like, the problem of palletizing becomes more difficult and has conventionally been accomplished with manual labor. Where the cylindrical articles are loaded in a horizontal configuration they often tend to roll off the pallet. Where the cylindrical articles are loaded in an upright position, they tend to tip and knock over adjacent cylindrical articles during the loading operation. Even when an array of cylindrical articles is successfully loaded onto a pallet, the load possesses little stability.
Accordingly, it is a general object of the present invention to provide an improved machine and method for palletizing cylindrical articles.
More specifically, it is an object of the invention to provide improved means and methods for accumulating a plurality of cylindrical articles and for grouping them together in a stack.
Other objects of the invention are to provide a machine and method for palletizing cylindrical articles with speed, accuracy, operational efficiency and resultant load stability and security.
SUMMARY OF THE INVENTION
In one preferred form of the invention a machine is provided for palletizing cylindrical articles which has means for accumulating a plurality of cylindrical articles and for grouping them together in a stack with each cylindrical article oriented horizontally. The machine also has means for placing an end of the stack formed by adjacent ends of the cylindrical articles aside a vertically oriented pallet. The machine further includes means for bringing the pallet to a horizontal position and concurrently bringing the stack to an upright position with adjacent ends of the cylindrical articles supported upon the pallet.
Stated somewhat more specifically, the apparatus of the present invention comprises conveyor means for sequentially conveying cylindrical articles upwardly along a first incline and for sequentially dumping the articles into cradle means positionable adjacent the top of the first incline. Trough-shaped cradle means are mounted adjacent the conveyor means for receiving cylindrical articles dumped from the conveyor means and for collecting the articles in rows. The apparatus also includes index means for indexing the cradle means downwardly along a second incline aside the first incline in steps as successive rows of cylindrical articles are collected in the cradle means.
In another preferred form of the invention, a method is provided for palletizing cylindrical articles. The method, in general terms, includes the steps of grouping a plurality of cylindrical articles together in a stack with each cylindrical article oriented horizontally, placing an end of the stack formed by adjacent ends of the cylindrical articles aside a generally vertically oriented pallet, and together bringing the pallet to a horizontal position with adjacent ends of the cylindrical articles supported upon the pallet.
Stated in somewhat more specific terms, the method comprises the steps of sequentially conveying individual cylindrical articles to a dump point and there sequentially dumping individual cylindrical articles into a trough-shaped cradle having two inclined support members joined together at an angle. The methed also includes the step of indexing the trough-shaped cradle downwardly along the incline of one of the flat cradle floors in steps as successive rows of cylindrical articles are collected in the cradle.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic plan view of a machine embodying principles of the invention in one preferred form which may be used in practicing a method of the invention.
FIG. 2 is a schematic front side view of the conveyor and cradle components of the machine shown in FIG. 1.
FIG. 3 is a schematic right side view of the pallet and load reorienting components of the machine shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in more detail in the drawing, there is schematically illustrated generally at 8 a machine for palletizing cylindrical articles which articles, in the illustrated example, consists of rolls of roofing material 10. The rolls 10 arrive at the machine 8 by any suitable device, such as the sloping ramp 12 straddled by a jogger 14 which horizontally align the rolls. The ramp 12 terminates adjacent an inclined conveyor comprising a pair of parallel endless conveyor belts 18a and 18b from which a number of spaced-apart lugs 20 project in parallel alignment. A rigid support 22 underlays the belt along a loaded portion of their path of travel to limit belt flexing. The belts 18a and 18b are looped over a lower wheel 24 and over a motor driven upper wheel 26 at a load dump point 28.
A trough-shaped cradle indicated generally at 30 is provided adjacent the upper end of the inclined conveyor, and the cradle is supported for reciprocal movement along an inclined path of travel 31 which is beneath the conveyor and which parallels the conveyor path of travel. The cradle comprises a first pair of idler rollers 32a and 32b mutally supported at a normal angle to define an upwardly-facing V formation. The cradle 30 also comprises a second set of idler rollers 33a and 33b parallel to and laterally spaced apart from the corresponding idler rollers 32a and 32b, and an idler roller 34 which is interpositioned between the idler rollers 32a and 33a. The idler rollers 32a, 33b, 32a, 33b, and 34 are carried by suitable support structure (omitted from the drawing for clairty) which selectably moves the rollers in unison along the inclined path 31 by operation of an actuator as fluid-powered cylinder 35 or the like. At the top of the cradle path 31 the upper surfaces of the idler rollers 32a and 33a are positioned closely adjacent and tangential to the conveyor wheel 26. The actuating cylinder 35 or the like operates to step the cradle 30 downwardly successively from the depicted initial roll-receiving position to the lower roll-receiving positions 36, 37, 38 and 39, and thence to the lowermost position 39', and then to return the cradle to its raised initial position. A pair of upper joggers and top guides 40 is rigidly mounted above the upper most reach of the cradle.
With continued reference to the drawing the palletizing machine is further seen to include a stack push-off plate 42 adapted to be reciprocally driven along a horizontal path by an actuator such as a cylinder 44. A pair of stationary idler rollers 45a and 45b in V formation, best seen in FIG. 1, are located alongside the cradle on the side opposite the push-off plate 42, and two pairs of tiltable idler rollers 48a and 48b, compositely arranged in V-shaped formations, are located alongside and in parallel alignment with the stationary idler rollers 45a and 45b. The stationary idler rollers 45a, 45b and the pairs of tiltable idler rolers 48a and 48b are positioned so that such idler rollers and the idler rollers 32a, 32b, 33a, 33b, and 34 of the cradle 30 are in mutual parallel alignment when the cradle is at its lowermost position 39. A conventional stack banding device 52 having a banding track 52a is located over and between the stationary idler rollers 45a, 45b and the tiltable idler rollers 48a, 48b for placing a band 53 around a stack of articles 10 which are supported on such idler rollers.
The tiltable idler rollers 48a and 48b are mounted on appropriate support structure (omitted from the drawing for clarity) including a tilt control motor T which enables such rollers to be tilted 90° about the axis of rotation 47 between the raised position shown, in solid line in FIG. 3, and the lower position, shown in phantom in FIG. 3. A suitable support 49 is provided to hold a conventional pallet 50 in a vertical position alongside the upright idler rollers 48a, 48b. A gravity conveyor 56 is positioned beneath the lowered position of the tiltable idler rollers. A pallet retaining clamp 58 is provided adjacent the upper end of the gravity conveyor, and a back stop 60 is located adjacent the lower end of the gravity conveyor.
In operation, cylindrical rolls of roofing material 10 are fed down the input ramp 12 through jogger 14 and are sequentially engaged by the lugs 20 of the conveyor belts 18. The rolls are there lifted to the dump point 28 where they are dumped off the conveyor belts and onto the idler rollers 32a, 33a, and 34 of the crade 30, which is positioned at the top of its path of travel. One by one the rolls roll down the idler rollers of the cradle and accumulate into a row, with the leading roll resting at the juncture of the V formed by the cradle idler rollers and with the other rolls resting against each other in succession. When a row consisting of a predetermined number of rolls has been accumulated on the idler rollers 32a, 33a, and 34, an appropriate sensing means such as the last-roll sensing switch 60 signals the cradle actuating cylinder 35 which then steps or indexes the cradle down to position 36. The next roll arriving at the dump point 28 then rolls down over the first row of rolls already accumulated in the cradle, and contacts the cradle idler rollers 32b, 33b. Other rolls follow to form a complete second row in the cradle, whereupon the cradle is again indexed downwardly to position 37. The jogger and top guide 40 assures that the rolls which form each row in the cradle are horizontally aligned. This same procedure is repeated until five rows (for example) have been formed with the cradle now located at position 39.
Once a full stack of rolls in horizontal position has been formed in the cradle 30, the full conveyor is stopped and the cradle is lowered to its lowermost position 39', so that the final row of rolls is lowered beneath the jogger and top guide 40. The cylinder 44 is now actuated to urge push-off plate 42 against the stack of cylindrical rolls 10 supported in the cradle; the plate 42 pushes the stack laterally off the cradle, over the stationary idler rollers 45a and 45b, onto the tilting idler rollers 48a and 48b, and against a vertically oriented pallet 50. The conventional banding device 52 is now operated by means of the band track 52a to place a band 53 snugly around the horizontal stack of rolls. Once banding is completed, the tilt control motor T is actuated and the tiltable idlers along with the banded stack of rolls and the pallet 50 are tilted 90° to the lowered position, as shown in FIG. 3. The pallet 50 is brought to rest atop the gravity conveyor 56 and, upon release of the pallet retaining clamp 58, the loaded pallets slides down the conveyor 56 to backstop 60, thereby completing the operation.
The push-off plate 42 can be returned to its initial position (as shown in FIG. 1) immediately after the stack of rolls has been transferred to the tiltable idlers. The cradle 30 can then be returned to its initial roll-receiving position, so that the roll conveyor can again be operated to commence feeding rolls to the cradle.
It should be understood that the foregoing described embodiment merely illustrates principles of the invention in selected, preferred forms. Many modifications, deletions and additions may, of course, be made thereto without departure from the spirit and scope of the invention as set forth in the following claims. | A machine and method for palletizing cylindrical articles by which a plurality of cylindrical articles are grouped together in a stack with each cylindrical article oriented horizontally, the formed stack placed aside a vertically oriented pallet, and the pallet brought to a horizontal position and the stack simultaneously uprighted thereon. The machine includes a trough-shaped cradle which is moved downwardly in steps along an inclined path relative to a conveyor on which the cylindrical articles are elevated, for collecting and forming the cylindrical articles into a stack. | 8 |
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