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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to cutting devices or systems and, more particularly, to a cutting device or system operable for repeatedly cutting drill pipe, tubing, coiled tubing, and/or wireline so as to be especially suitable for use in a lightweight intervention package and/or in substitutions for replacing at least one BOP in an intervention package.
Background of the Invention
Blowout Preventer (B.O.P.) stacks are frequently utilized in oilfield well bore Christmas trees and subsea intervention operations such as, for instance, lower riser packages in offshore wells. B.O.P. stacks may include a first set of rams for sealing off the wellbore and a second set of rams for cutting pipe such as tubing, wireline and/or intervention tools. However, B.O.P. stacks are quite bulky and heavy, which are undesirable features especially in lower riser packages for undersea operation where space is often at a premium. B.O.P. stacks tend to be expensive for installation and removal due to the need for heavy lifting equipment. Moreover, if maintenance is required, then the high maintenance costs for utilizing B.O.P. stacks for intervention purposes severely limits the wells that can be economically reworked. B.O.P. stacks may frequently require maintenance after cutting pipe. For instance, the cut pipe may become stuck within the B.O.P. stack blocking other operations.
Consequently, those skilled in the art will appreciate the present invention that addresses the above problems.
The following patents discuss background art related to the above discussed subject matter:
U.S. Pat. No. 6,601,650, issued Aug. 5, 2003, to A. Sundararajan, which is incorporated herein by reference, discloses apparatus and methods for replacing a BOP with a gate valve to thereby save space, initial costs, and maintenance costs that is especially beneficial for use in offshore subsea riser packages. The method provides a gate valve capable of reliably cutting tubing utilizing a cutting edge with an inclined surface that wedges the cut portion of the tubing out of the gate valve body. A method and apparatus is provided for determining the actuator force needed to cut the particular size tubing.
U.S. Pat. No. 8,353,338, issued Jan. 15, 2013, to J. Edwards, discloses a well bore control valve comprising a housing defining a throughbore, the throughbore adapted to receive a first tubular. The valve further comprises first and second gates located within the housing, the gates being movable in different directions transverse to the throughbore between the throughbore open position and the throughbore closed position. Movement of the gates from the throughbore open position to the throughbore closed position, in use, shares a tubular located between the gates. The valve also comprises a first seal seat performing a seal of one of the gates in the throughbore closed position to seal the throughbore.
U.S. Patent Application No. 20100218955 discloses an oil field system comprising a main body having a bore therethrough, the main body having a connection at one end of the bore for, in use, connecting the main body to an existing wellhead, tree or other oil field equipment, a transverse cavity through the bore, the cavity having at least one opening to the outside of the main body, a plurality of flow control systems for insertion, at different times, into the cavity in order to selectively control fluid flow through the bore, wherein the plurality of flow control systems includes a gate valve and drilling BOP rams.
The above prior art does not disclose the cutting system operable for cutting drill pipe while still being very lightweight as described in the present specification. Consequently, those skilled in the art will appreciate the present invention that addresses the above and/or other problems.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved cutting apparatus and/or system.
Another possible object of the present invention is to provide a non-sealing compact cutting device to cut drill pipe at least up to 3½ inches and allows use with a gate valve for sealing the wellbore with the combination to substitute for a much heavier BOP.
Yet another possible object of the present invention is to provide a compact cutting system with a short stroke length and/or piston rod assemblies and/or lesser fluid volumes at different vertical heights.
Accordingly, a compact cutting system is provided that is operable for cutting 4½ inch 16.60 lb/ft drill pipe, coiled tubing, wireline and sinker bar. The cutting system comprises a housing defining a throughbore, a first gate and a second gate mounted within the housing. The first gate and the second gate are moveable transversely with respect to the throughbore between an open position and a closed position. In one embodiment, the first and second gates comprise openings therein that prevent sealing of the throughbore in the closed position.
The compact cutting system may further comprise a gate valve wherein the compact cutting system is operable for substitution of at least one BOP.
In one possible embodiment, the system may comprise a first piston and a first piston rod operably connected to the first gate with a first stroke length. A second piston and a second piston rod is operably connected to the second gate with a second stroke length. The first and second stroke lengths are less than a diameter of the throughbore.
In one possible embodiment, the first gate and the second gate each comprise a gate bore therethrough, in the open position each gate bore is in surrounding relationship to or form a portion the throughbore. In one embodiment, the gate bore is elliptical.
In one possible embodiment, when the throughbore is oriented vertically then the first piston and first piston rod is mounted to the housing at a higher vertical position than the second piston and second piston rod.
In one embodiment, the first piston and the second piston each comprise a piston surface with a diameter between one and one-half and two and one-half times as large as a diameter of the throughbore.
The compact cutting system may further comprise a first piston chamber for the first piston and a second piston chamber for the second piston. The first piston and the second piston are mounted so that all of each piston surface is available for engagement with hydraulic fluid for use in closing the gates. The piston rod end of the piston may then be utilized for opening the gates.
In one possible embodiment, the cutting system may comprise a first seat mounted in the throughbore adjacent the first gate. The first seat has a first seat interior. The first seat interior decreases in diameter with distance away from the first gate. A second seat is mounted in the throughbore adjacent the second gate. In a similar manner, the second seat interior decreases in diameter with distance away from the second gate. In one embodiment, the interior of the seats may be elliptical.
In one possible embodiment, the compact cutting system may comprise a first seat mounted in the throughbore adjacent the first gate, a second seat mounted in the throughbore adjacent the second gate. The first gate and the second gate may comprise a passageway therethrough to prevent sealing between the first gate and the first seat and between the second gate and the second seat.
In one possible embodiment, the first piston rod and the second piston rod comprise a length less than two and one-quarter times as large as a diameter of the throughbore. The first piston and the second piston each comprise a piston surface with a diameter between one and one-half and two and one-half times as large as a diameter of the throughbore.
These and other objects, features, and advantages of the present invention will become clear from the figures and description given hereinafter. It is understood that the objects listed above are not all inclusive and are only intended to aid in more quickly understanding the present invention, not to limit the bounds of the present invention in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
The above general description and the following detailed description are merely illustrative of the generic invention, and additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:
FIG. 1 is a front elevational view, in section, of a compact cutting system in the open position in accord with one possible embodiment of the present invention.
FIG. 2 is a front elevational view, in section, of a compact cutting system in the closed position in accord with one possible embodiment of the present invention.
FIG. 3 is a side elevational view, in section, of a compact cutting system in accord with one possible embodiment of the present invention.
FIG. 4 is a top elevational view of a compact cutting system in accord with one possible embodiment of the present invention.
FIG. 5 is a front elevational view of a compact cutting system in accord with one possible embodiment of the present invention.
FIG. 6 is an exploded view of a compact cutting system in accord with one possible embodiment of the present invention.
FIG. 7A is an enlarged view of a gate in accord with one possible embodiment of the present invention.
FIG. 7B is an enlarged view of a gate oriented in a reversed position with respect to FIG. 7A in accord with one possible embodiment of the present invention.
FIG. 8 is a schematic view of a compact cutter and gate valve that may be utilized in a subsea installation is place of at least one BOP (blowout preventer) in accord with one possible embodiment of the present invention.
FIG. 9 is an elevational view of a cutter in accord with one possible embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
Abbreviations include the following:
API—American Petroleum Institute
DNV—Det Norske Veritas (The Norwegian Veritas)
ISO—International Standardization Organization
ROV—remotely operated vehicle
NACE—National Association of Corrosion Engineers
QTC—Qualification Test Coupon
The use of CCD 10 complies with codes and standards including:
API 6A, Specification for wellhead and Christmas tree equipment, 20th Edition, October 2010;
API 16A, Specification for Drill-through equipment, 3rd Edition, June 2004;
API 16D Control Systems for Drilling Well control Equipment, 2nd Edition, July 2004;
NORSOK D-002, Well intervention equipment, Revision 2, June 2013;
DNV-OS-E101, Drilling Plant, October 2013;
ISO 13533, Drilling and production equipment—Drill-through equipment, 1st Edition, December 2001;
API 17G, Recommended practice for completion/workover risers, 2 nd Edition, July 2006
NACE MR0175/ISO 15156, Petroleum and natural gas industries—materials for use in H2S-containing environments in oil and gas production, 2nd Edition, October 2009.
Referring now to the drawings and more particularly to FIG. 1 , there is shown one possible embodiment of a compact cutting device or system which may be referred to herein as CCD 10 . Housing 12 defines throughbore 14 with axis 16 . Flange connection 18 at the bottom end, which may comprise studs or the like, may be utilized for connection with well equipment such as subsea installations, well intervention equipment, and the like. Another flange connection at the top end may connect to other well equipment such as a gate valve or the like. One embodiment of CCD 10 comprises a 7⅜ inch throughbore, with a 10K psi pressure rating. The top and bottom connectors may comprise a 13⅝ inch 10K psi studded connectors and/or flange connections. In one embodiment, CCD 10 is operable to cut pipe 68 (see FIG. 9 ) which may comprise 3½ in 13.3 lb/ft Grade E 75 drill pipe (Table 18, API 16A/ISO 13533) without leaving any snag or slug after cutting. In one embodiment, CCD 10 operates very quickly and can cut the drill string in less than 2 seconds when using an accumulator. The tests to be conducted for CCD 10 for use in an intervention package include NORSOK D-002 (API 16A/ISO 13533 Annex C) in one possible embodiment for cutting only, without the need for sealing tests as explained hereinafter. Further in one embodiment, CCD 10 weighs less than 12,000 pounds. Combined with a gate valve, the combination is much less than the weight of a BOP, which provides an opportunity for a highly desirable substitution in an intervention package. The light weight makes possible reworking of wells much less expensive than using a BOP.
Cylinder housings 20 and 22 are utilized to house pistons 24 and 26 , respectively, which drive piston rods 28 and 30 to move gates 44 and 46 between an open position and a closed position. FIG. 1 , FIG. 3 , and FIG. 9 show gates in an open or open throughbore position. FIG. 2 shows the gates in a closed position. As discussed below, in one possible embodiment moving the gates to the closed position does not necessarily provide a seal but instead in one presently preferred embodiment fluid flow may occur past the gates. However, if desired, the gates could also be made to provide a seal when closed.
In one embodiment, stroke length 32 and 34 of the pistons is relatively short so as to be less than the diameter of throughbore 14 . In one embodiment of a 7⅜ inch throughbore, the stroke length may be in the range of 5 inches. However, larger and smaller stroke lengths could be utilized. In one embodiment, compact cutting system CCD 10 advantageously utilizes considerably less volume of hydraulic fluid to operate in comparison to other units with cutting capability, e.g. a BOP. In one embodiment, the present invention utilizes less than 12 liters of hydraulic fluid for opening or closing the gates.
It will be noted that when CCD 10 is vertically oriented that piston 24 , rod 28 , gate 44 , and the axis of movement 36 of rod 28 is vertically higher than piston 26 , rod 30 , gate 46 and axis 38 of rod 30 . Likewise, piston housing 20 with associated bolts is vertically higher than piston housing 22 as shown in FIG. 1 , FIG. 2 , FIG. 5 , and FIG. 9 . The applied force is therefore directed along axis 36 and 38 of the pistons, piston rods and gates, which reduces bending forces acting on the piston rods 28 and 30 due to cutting forces applied by the gates, which are at different vertical heights.
In FIG. 2 , valve cavity 98 can be irregularly shaped due to the different vertical heights of the components. In one embodiment, the diameter of the opening into housing 12 for the components used with each cylinder is almost the same diameter of the pistons and may be used for inserting the seats, gates, and other components.
FIG. 4 shows the top elevational view whereby it can be seen that from an external view, cylinders 20 and 22 are aligned in top view, which may be considered the x-y plane. Accordingly, their associated pistons, piston rods, gates, piston axes are also aligned from this view. This is in contrast to FIG. 5 , which shows that cylinder 20 is vertically higher than cylinder 22 , which might be considered along a z-axis.
Referring again to FIG. 1 , upper seat 40 and lower seat 42 are mounted in throughbore 14 in respective recesses in housing 12 . Seats 40 and 42 may or may not seal with gates 44 and 46 when in the closed or closed throughbore position. In one embodiment, referring to FIG. 2 that shows CCD 10 in the closed position, openings are formed in gates 44 and 46 that positively prevent sealing when in the closed position as indicated by flowpath 56 through the gates 44 and 46 , which allows for fluid flow even in the closed or closed throughbore position. For example, slots may be milled into gates 44 and 46 as shown in FIG. 7A and FIG. 7B at 65 and 67 . In another embodiment additional openings, passageways, or the like may be formed with in the gates.
In another embodiment, if desired, and which is not necessarily a preferred embodiment, one or both gates could be made to seal with seats 40 and 42 , with a metal to metal seal.
FIG. 2 also shows hydraulic fluid volumes 52 and 54 that are filled with pressurized hydraulic fluid to move the gates to the closed position. It will be appreciated that the entirety of piston surfaces 58 and 60 can be utilized to create force to drive the cutters in the gates to cut drill pipe or the like within throughbore 14 . In one embodiment, diameter 62 of piston surfaces 58 and 60 may be in the range of 1½ to 2½ times the diameter of throughbore 14 . In another embodiment the diameter may be between 1½ to 2 times the diameter of throughbore 14 . In this way, a significant cutting force relative to pipe within throughbore 14 is produced, which allows the high speed powerful cutting. Use of surfaces 58 and 60 to create the force to drive the cutters takes advantage of the full surface of the pistons rather than using the side of the piston to which the piston rod is attached. Use of the piston rod side to drive the cutters would reduce the area on which the pressurized hydraulic fluid operates. Significant gate opening force is also available to open the gates by applying hydraulic fluid to the interior side of pistons 24 and 26 . The piston rods connected to the interior size limit the force to some extent and in this embodiment may result in interior piston surfaces in the range of 132 square inches. Accordingly somewhat less hydraulic fluid is required for opening.
In one embodiment, the use of a shorter piston rod also helps produce a compact size for CCD 10 . In one embodiment, piston rods 28 and 30 comprise a length less than 2¼ times the throughbore diameter and in another embodiment less than 2 times the throughbore diameter when measured from the inner surface of the piston to the end thereof.
As noted above, the cutting action is performed by moving the gates towards the wellbore so the full hydraulic piston surface area is used (not the rod end). This allows maximization of the performance and utilization of the hydraulic pressure available.
Using two gates 44 , 46 causes the tool string to be centralized during the cut action rather than it being pushed to one side. The tool string is captured inside the two gate bores 64 , 66 to provide crushing action to yield and cut the string in an area away from the upper and lower seats 40 , 42 . Gate bores 64 , 66 , comprise a minimum diameter of the throughbore, which in one embodiment is 7⅜ inches.
In one embodiment, the gate bores 64 , 66 may be oval so that the minimum of 7⅜ is along one axis of the oval with the other axis of the oval being greater than the borehole diameter. Likewise, upper and lower seat 40 , 42 may comprise an oval interior to match that of the gates.
FIG. 6 shows an exploded view of CCD 10 , including piston seals 82 , 84 , piston rod seals 86 , 88 and cylinder housing bases 90 , 92 . Other components have already been discussed but are shown here in a perspective view. It will be noted that external shapes of upper seat 40 and lower seat 42 as well as that of other components is shown.
FIG. 7A and FIG. 7B show enlarged views of gates 44 and 46 as well as cutter inserts 94 and 96 . Gates 44 and 46 may or may not utilize cutter inserts such as cutter inserts 94 and 96 . Utilizing cutter inserts 94 , 96 allows the cutting surfaces to be changed out. Cutting face or surface 76 is shown in FIG. 7A . As discussed hereinbefore, gate openings or bores 64 and 66 preferably encircle throughbore 14 and drill pipe or the like within the throughbore when in the open position. In one embodiment openings or bores 64 and 66 , with the corresponding cutter inserts 94 , 96 are preferably circular or as shown in this embodiment, are oval. Openings 65 , 67 and/or other openings can be milled into the gates and utilized to provide that the gates do not seal with the seats and allow fluid flow through the throughbore in the closed position as discussed hereinbefore. However, if desired, the openings may not be used and the gates could seal with the seats, although that is not the presently preferred embodiment. It will be noted that a T-slot connection can be used on the ends of the gate with corresponding T connector on the piston rods if desire.
In one embodiment, the taper angle at the cutting edge of the gates is unique. Cutting inserts may or may not be used. If desired, hard facing or case hardening process may not be used on the gates.
FIG. 8 shows a schematic of intervention package 100 that comprises CCD 10 , which may be utilized with gate valve 102 in conjunction with subsea installation 104 in substitutions for a much heavier BOP in accord with one embodiment of the invention. CCD 10 may be utilized to cut 3½ in. 13.3 lb/ft Grade E-75 drill pipe without leaving any snag after cutting in accord with Table 18, API 16A/ISO 13533 and may be utilized to cut up to 4½ IN 16.60 lb/ft drill pipe. The use of CCD 10 in place of the much heavier BOP for use in an intervention package complies with codes and standards including:
API 6A, Specification for wellhead and Christmas tree equipment, 20th Edition, October 2010;
API 16A, Specification for Drill-through equipment, 3rd Edition, June 2004;
API 16D Control Systems for Drilling Well control Equipment, 2nd Edition, July 2004;
NORSOK D-002, Well intervention equipment, Revision 2, June 2013;
DNV-OS-E101, Drilling Plant, October 2013;
ISO 13533, Drilling and production equipment—Drill-through equipment, 1st Edition, December 2001;
API 17G, Recommended practice for completion/workover risers, 2nd edition, July 2006
NACE MR0175/ISO 15156, Petroleum and natural gas industries—materials for use in H2S-containing environments in oil and gas production, 2nd Edition, October 2009.
FIG. 9 , which is another embodiment of a cutting system, namely cutting system 10 A, shows openings 64 and 66 in gates 44 , 46 which surround throughbore 12 and pipe 68 . Cutting system 10 A utilizes longer cylinder rods and housing.
It will also be seen that gate opening 64 decreases in inner diameter with distance away from seat 40 as indicated by interior surface profile 52 until coming to cutting face 74 at the bottom of upper gate 44 . Likewise, the inner diameter of gate opening 66 decreases with distance away from seat 42 as indicated by interior surface profile 55 until coming to a cutting face 76 at the top of lower gate 46 . The changes in inner diameter of the openings 64 , 66 through the gate can also be seen in FIG. 1 , FIG. 2 , and FIG. 3 .
In this embodiment, the interior or inner diameter of upper seat 40 decreases in diameter with distance away from gate 44 as indicated by interior surface profile 48 . The interior of lower seat 42 also decreases in diameter with distance away from lower gate 46 as indicated by interior surface profile 50 . The decrease in diameter of the upper and lower seats discussed above leads to the throughbore diameter at about the midpoint of the seats, which in one embodiment may be 7⅜ inches. In other words, both the seats and the gates comprise openings which are larger than the throughbore diameter in some regions and then either approach or are at the throughbore diameter, e.g. at the cutting faces and at the upper portion of upper seat 40 and the lower portion of lower seat 42 . The minimum diameter is the throughbore diameter. As discussed above, both the interior of the seats and the gates may be oval.
Upper seat seal surface 70 is recessed into housing 12 and seals with upper seat 40 . Lower seat seal surface 72 is recessed into housing 12 and seals with lower seat 42 . Face 78 is provided between first gate 44 and seat 40 . Face 80 is provided between second gate 46 and seat 42 . As discussed hereinbefore, in one embodiment the seats do not seal off throughbore 12 even when the gates are in the closed position. However, if desired, a metal to metal seal could be provided at face 78 , 80 to seal off throughbore 12 with the gates in the closed position.
In one embodiment, CCD 10 is operable to cut pipe 68 which may comprise 3½ in 13.3 lb/ft Grade E 75 drill pipe (Table 18, API 16A/ISO 13533) or 4½ IN 16.60 lb/ft drill pipe.
In summary, the present invention provides a compact cutting system or device. In one embodiment to provide a 7⅜ throughbore, the compact cutting system or device may be in the range of 40 to 50 inches in height, in the range of 65 to 75 inches at maximum width, and with a diameter in the range of 20-25 inches, with a weight in the range of 11,000 to 12,000 pounds. In one embodiment, a relatively short stroke is utilized. In one embodiment, the piston rods are at different vertical heights. The openings in the gates preferably surround the throughbore or form part of the throughbore in the open position. In the closed position, the gates may be modified to provide that they do not seal with the seats.
The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive nor to limit the invention to the precise form disclosed; and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. | As compared to a BOP, a compact lightweight cutting system may have two gates with cutters moveable in opposite directions to cut drill pipe. The system utilizes a relatively short stroke and relatively less hydraulic oil for subsea operation. An opening through the gates surrounds the wellbore in the open position. The cutting elements are mounted within the openings. The piston rods and pistons are vertically offset with respect to each other. The compact cutting system with a gate valve can be used to substitute for a BOP to significantly reduce the size and weight required in an intervention system. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a textile treating composition containing amino-modified silicone oils.
Linear polysiloxanes, so-called silicone oil, have been broadly employed in textile treating compositions for acrylic fibers which are processed into clothings or applied as the precursor in carbon fiber production, because of the water repellency, detachability, heat resistance, peculiar handle, i.e., smoothness or slickness, which are imparted to fiber by silicone oil. Particularly, the linear amino-modified polysiloxanes having amino groups in their molecules have proved superior performance as a component of textile treating compositions for acrylic fibers for clothing or for the precursors of carbon fibers. Because the linear amino-modified polysiloxanes can be dispersed into fine globules with suitable emulsifiers.
Amino-modified polysiloxanes have also proved superior performance as a textile treating agent for preventing the fusion or adhesion of organic and inorganic fibers in heat treatment, because of their detachability and heat resistance. The fusion or adhesion of fibers results in poor fiber quality.
Many processes for applying textile treating compositions containing amino-modified polysiloxanes to fibers have been proposed in literature, such as Japanese Patent KOKOKU (Publication for opposition) No. Sho. 52-24136, Japanese Patent KOKAI (Provisional Publication) No. Sho. 62-45786 and No. Sho. 62-45787, Japanese Patent KOKAI No. Hei. 6-220722 and No. Hei. 6-220723 and others.
Amino-modified polysiloxanes can be dispersed into fine globules of 0.1 micrometer or less in diameter in an aqueous emulsion with the aid of an emulsifier having acidic groups. The fine globules are attained by the hydrophilic amino salts generated from the reaction of basic amino groups in the amino-modified polysiloxanes and acidic groups in the emulsifiers blended with the amino-modified polysiloxanes. The above aqueous emulsion is almost transparent, and thus the amino-modified polysiloxanes seem to have been dissolved. Actually, however, they are dispersed into fine globules of approximately several decades of milimicrometer giving high transmittance to the resultant emulsion.
Such fine globules of textile treating composition dispersed in aqueous emulsion are preferable for applying the textile treating compositions uniformly on fiber surface.
Such fine globules are indispensable for applying textile treating compositions rapidly to the surface of monofilaments located at the inside of tows or multifilament yarns.
The finish film on fiber attained by a textile treating composition dispersed in fine globules in aqueous emulsion is much more uniform than that attained by the textile treating compositions dispersed in coarse globules to give milky emulsion. Uniform finish film minimizes the decrease or variation of water repellency, detachability, heat resistance, and peculiar handle of fiber, i.e., smoothness and slickness.
Japanese Patent KOKAI No. Hei. 6-220722 and No. Hei. 6-220723 disclose that amino-modified polysiloxanes applied on fiber gradually degrade into smaller molecules during storage, due to the breakage of the molecular chain of the amino-modified polysiloxanes, when the amino-modified polysiloxanes are prepared into emulsion with the emulsifiers having acidic groups disclosed in Japanese Patent KOKOKU No. Sho. 52-24136, and Japanese Patent KOKAI No. Sho. 62-45786 and No. Sho. 62-45787. And the above KOKAI No. Hei. 6-220722 and No. Hei. 6-220723, also disclose that the heat durability, detachability, and peculiar handle imparted by the amino-modified polysiloxanes are gradually reduced due to the degradation.
The methods for solving the above problem are proposed in Japanese Patent KOKAI No. Hei. 6-220722 and No. Hei. 6-220723, in which amino-modified polysiloxanes are emulsified with nonionic emulsifiers and weak carboxylic acids instead of strongly acidic emulsifiers.
The inventors of the present invention found that the textile treating compositions disclosed in the prior art mentioned above are apt to fall from fiber to stick on the surface of guides and rolls employed in yarn-spinning or textile dyeing processes of acrylic fibers, and in the conversion processes of polyacrylonitrile precursors into carbon fibers.
The textile treating compositions sticking on the guides or rolls change into varnish type residue to cause the wrap of monofilaments of tows during long-time continuous processing. Further, the dusts in a workplace stick on the varnish type residue on the guides or rolls, causing monofilament breakage and fluffs.
A method for preventing the guides and rolls from the adhesion of textile treating compositions by adding various antioxidants has been proposed in Japanese Patent KOKAI No. Hei. 2-91225. The method may often result in the reduction of the durability of the water repellency, detachability, heat resistance, and peculiar handle imparted to fiber, though the method may prevent the varnish type residue on the guides or rolls. The antioxidants proposed in the above method are estimated to decompose amino-modified polysiloxanes into smaller molecules so as to reduce the chemical stability of the amino-modified polysiloxanes, though the antioxidants prevent the gelling of the amino-modified polysiloxanes. The function of the antioxidants, the acceleration of the decomposition of dimethylpolysiloxane into smaller molecules is described in Zh. Prikl. Khim. Vol. 49, No. 4, p 839-844 (1976).
The proper level of the gelling of amino-modified polysiloxane is preferable for attaining durable water repellency, detachability, heat resistance, and peculiar handle of the fiber. Some of the textile treating compositions comprising amino-modified polysiloxanes emulsified with phosphoric esters and blended with antioxidants cannot attain durable water repellency, detachability, heat resistance, and peculiar handle on fiber.
Antioxidants, strongly acidic substances, and basic substances, all of which minimizes the gelling of amino-modified polysiloxanes, may decompose amino-modified polysiloxanes into smaller molecules during long-term storage or heat treatment leading to the reduction of heat resistance of amino-modified polysiloxane.
SUMMARY OF THE INVENTION
An object of the invention is to provide a textile treating composition imparting water repellency, detachability, heat resistance, and peculiar handle, i.e., smoothness and slickness, all of which are durable, to acrylic fibers or polyacrylonitrile precursors for carbon fiber production.
Another object of the invention is to minimize the varnish type residue of textile treating compositions processing operation.
The textile treating composition of the present invention comprises a silicone oil (A) containing at least 50 percent by weight of an amino-modified polysiloxane having a viscosity of 50 cSt or more at 25° C. an emulsifier (B) containing monoesters of dicarboxylic acids 10 to 100 percent by weight and nonionic surfactants 90 to 10 percent by weight, and aminocarboxylic acids (C) formulated in the said textile treating composition in 0.2 to 10 parts by weight to the 100 parts by weight of the total of (A) and (B).
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a novel textile treating composition, which is dispersed into fine globules in its aqueous emulsion for achieving uniform application on fiber, forms low-viscous aqueous emulsion, gives minimum stain on guides or rolls in fiber processing, and maintains heat stability on fiber for long-term storage; and the production method thereof.
The present invention relates to a textile treating composition comprising a silicone oil (A) containing at least 50 percent by weight of amino-modified polysiloxanes having a viscosity of 50 cSt or more at 25° C.; an emulsifier (B) containing monoesters of dicarboxylic acids 10 to 100 percent by weight and nonionic surfactants 90 to 10 percent by weight, and aminocarboxylic acids (C) formulated in the said textile treating composition in 0.2 to 10 parts by weight to the 100 parts by weight of the total of (A) and (B).
The preferable nitrogen content, which represents the amine content in the amino-modified polysiloxanes of the present inventions is from 0.05 to 2.0 percent. The amino-modified polysiloxanes containing nitrogen less than 0.05 percent cannot be easily dispersed into fine globules in aqueous emulsion. The amino-modified polysiloxanes containing nitrogen 2.0 percent or more have poor heat resistance and are not applicable to the fibers to be heated at high temperature, though such polysiloxanes can be easily dispersed into fine globules in aqueous emulsion.
The amino groups contained in an amino-modified polysiloxane may be any amines of primary, secondary, tertiary, and quaternary; a mixture of amines different in the class; or combined amines of primary and secondary amines. Amines having an amino group at the terminal position may also be used.
The preferable viscosity of the amino-modified polysiloxane for obtaining satisfiable results is 50 cSt or more at 25° C.
The maximum viscosity of the amino-modified polysiloxanes is not limited, though the viscosity of less than 10,000 cSt is preferable for blending the amino-modified polysiloxanes and emulsifiers with conventional blenders. The amino-modified polysiloxanes, of which viscosity is 10,000 or more, can be blended with emulsifiers with high-performance blenders.
The silicone oil (A) of the present invention preferably consist of amino-modified polysiloxanes alone. Dimethyl polysiloxane, methylphenyl polysiloxane, and modified-polysiloxanes, such as polyether- or epoxy-modified polysiloxanes can be blended in the silicone oil (A), provided that the blended silicone oil can be dispersed into globules of which mean diameter is below 0.1 micrometer in the aqueous emulsion, and can give 20 weight percent emulsion of which transmittance is above 60 percent. Amino-modified polysiloxanes must be contained in the silicone oil (A) 50 weight percent or more for giving sufficient globule size and transmittance of the textile treating composition of the present invention. And the polyether-modified silicone in the silicone oil (A) must be restricted below 50 weight percent not to reduce the heat resistance of the resultant textile treating composition, though the globule size and transmittance of the emulsion are satisfiable even when the polyether-modified silicone is blended more than 50 weight percent.
The emulsifier (B) applicable to the present invention comprises monoesters of dicarboxylic acids and other nonionic surfactants. As the monoesters of dicarboxylic acids, any compounds represented by the following formula may include:
R.sup.1 --O--(AO).sub.m OCQCOOH I
wherein R 1 is a hydrocarbon group having the carbon number of 6-22 (hereinafter referred as C 6 -C 22 ), e.g., an alkyl group, aralkyl group, or aryl group having one or more substituents; and any alkyl group of these groups may have one or more unsaturated bonds and/or one or more branches; A is one of the C 2 -C 4 alkylene groups which may have a branch, or is the mixture. thereof, e.g., ethylene, propylene, trimethylene, butylene, and isobutylene, tert-butylene, preferably ethylene or the mixture of ethylene and propylene; m is 0 to 20, preferably 5 to 15; and Q is a dicarboxylic acid residue, e.g., a C 1 -C 8 hydrocarbon group, such as malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebatic acid, maleic acid, fumaric acid, citraconic acid, mesaconic acid, isophtharic acid, and terephtharic acid, preferably a succinic acid residue;
{H(OA).sub.n O}.sub.x XO(AO).sub.n OCQCOOH II
wherein X is a polyol residue, such as ethylene glycol, propylene glycol, glycerol, pentaerythritol, trimethylol propane, and sorbitan, preferably ethylene glycol residue; A and Q are the same as in the formula I; n is 0 to 20, preferably 5 to 15; and x is 1 to 6, preferably 2 to 4;
R.sup.1 COO(AO).sub.m OCQCOOH III
wherein R 1 , A, Q, and m are the same as in the formula II;
R.sup.1 NH(AO).sub.m OCQCOOH IV
wherein R 1 , A, Q, and m are the same as in the formula II;
R.sup.1 CONH(AO).sub.m OCQCOOH V
wherein R 1 , A, Q, and m are the same as in the formula II.
The most preferable monoesters of dicarboxylic acids among those represented by the formulae I to V is the monoesters represented by the formula I:
R.sup.1 --O--(AO).sub.m OCQCOOH I
particularly, the compounds in which R 1 is 7 to 12 and Q is ethylene. Such compounds can sufficiently emulsify the silicone oil (A) of the present invention.
The above-mentioned monoesters of dicarboxylic acids, represented by the formulae I to V, can be applied by blending two or more of them. But it is preferable to use at least one of the monoesters I. Mono- or polyesters of polycarboxylic acids, of which one or more carboxyl groups among three or more carboxyl groups in one molecule are remained without substituted by alkyl groups, can be applied in combination with the above monoesters of dicarboxylic acid, though such mono- or polyesters do not have higher performance than the monoesters of dicarboxylic acid. In addition, such mono- or polyesters cannot be easily obtained in a homogeneous state from polycarboxylic acids.
The silicone oil (A) of the present invention is emulsified with the emulsifier (B) of the present invention, which comprises 10 to 100 weight percent of the monoesters of dicarboxylic acids represented by the above formulae, I, II, III, IV, and V, and 90 to 0 weight percent of other nonionic surfactants.
The nonionic surfactants are not strictly defined, and any nonionic surfactants available in market can be applied. The preferable nonionic surfactants are polyoxyalkylene higher fatty alcohols, polyoxyalkylene alkylphenols, polyoxyethylene phenylphenols, polyoxyethylene stylenized phenols, polyalkylene glycol higher fatty acid esters, polyoxyalkylene alkyl- or alkylphenylamines, polyoxyalkylene amides, higher fatty acid esters of polyfunctional alcohols, and polyalkylene oxide addition products thereof. The preferable alkylene oxides in the above nonionic surfactants are ethylene oxide, the random or block copolymers of ethylene oxide, and also propylene oxide.
The ratio of the monoesters of dicarboxylic acids in the emulsifier (B) of the present invention should be at least 10 weight percent or more of the emulsifier (B), i.e. the total of the monoester and nonionic surfactant, and preferably be 30 weight percent or more, for satisfiable emulsification of the silicone oil of the present invention.
The emulsifier (B) of the present invention dominates the emulsification level of amino-modified polysiloxanes. And the emulsifier (B) should be formulated to neutralize amino-modified polysiloxanes so as to control the pH of the resultant textile treating composition from 4 to 8. Low pH of the textile treating composition, 4 or less, must be modified by increasing nonionic surfactants other than the monoesters of dicarboxylic acid, and the high pH, 8 or more must be modified by increasing the monoesters of dicarboxylic acids represented by the formulae from I to V. The resultant textile treating composition, of which pH is controlled within the optimum range, from 4 to 8, is stable and gives transparent emulsion.
The textile treating composition which gives transparent emulsion must be formulated by blending the silicone oil (A) and the emulsifier (B) first, then diluting the blend with water into a given concentration, and adding the amino carboxylic acids (C).
The 20 percent emulsion of the textile treating composition prepared in the above procedure should have the transmittance of 60 percent or higher at 660 nm determined with a spectrophotometer in a 1 cm cell employing water as blank.
The emulsion prepared by dissolving the emulsifier (B) and the carboxylic acids (C) in water before adding the silicone oil (A) is not sufficiently transparent due to the coarse globules of the silicone oil dispersed.
The preferable ratio between the silicone oil (A) and the emulsifier (B) of the present invention is 100 to 10-50 weight percent, more preferably 100 to 20-50 weight percent. The preferable ratio of water for preparing the textile treating composition of the present invention is from 60 to 90 weight percent, more preferably from 75 to 80 weight percent of the total of the silicone oil (A) and the emulsifier (B).
The amino carboxylic acids (C) of the present invention include the compounds having one or more amino groups and one or more carboxyl groups in the same molecules, such as amine salts of carboxylic acid, and amino or betaine compounds. And the amino carboxylic acids of poor solubility in water, 0.2 g or less in 100 g of water, cannot be applied.
The carboxylic acids containing amino groups in their molecules include primary, secondary, tertiary, and quaternary amines. Hydroxy amino having hydroxyl groups in their molecules are also applicable.
In addition, aminoethers, which are obtained by reacting ethylene oxide with amino groups, such as the carboxylic acid salt of alkylamine; the carboxylic acid salt of arylamine; and the carboxylic acid salt, amino acid compounds, or betaine compounds of alkylaryl amine. The preferable blend ratio of those amino carboxylic acids is from 0.2 to 10 parts by weight, more preferably from 3 to 5 parts by weight to 100 parts by weight of the total of the silicone oil (A) and the emulsifier (B). Those amino carboxylic acid salts drastically decrease the viscosity of the emulsion of the textile treating composition of the present invention. Such low-viscosity emulsion easily and rapidly spread on the monofilament surface of filament bundles, such as tows, even on the monofilaments locating inside of the filament bundles.
Insufficient ratio of those amino carboxylic acids below 0.2 parts by weight, will fail to decrease the viscosity of the 20 percent emulsion of the textile treating composition down to 10 cSt or less. Excessive ratio of those amino carboxylic acid salts, 10 parts by weight is not practical, as the viscosity of the 20 percent emulsion of the textile treating composition is not decreased correlating to the increase of the ratio of the amino carboxylic acids beyond the 10 parts by weight level.
The aminocarboxylic acids do not cause poor transparency of the resultant emulsion, i.e., coarse globule size of emulsified silicone oil, nor reduce the water repellency, detachability, heat resistance, and peculiar handle imparted to fiber by the textile treating composition.
The aminocarboxylic acids function to decrease the varnish type residue of textile treating composition on dryer rolls in fiber production processes. The low viscosity of the textile treating composition and its aqueous emulsion given by the aminocarboxylic acids is estimated to contribute to the decrease of the varnish type residue.
Japanese Patent KOKAI No. Hei. 6-220722 and No. Hei. 6-220723 disclose the emulsifying method for silicone oils only with conventional nonionic emulsifiers, where lower fatty monocarboxylic acids were required as the emulsifying promoter.
The inventors of the present invention tested the 20 percent aqueous emulsions of the textile treating compositions disclosed in the above two prior arts in the following procedure. The emulsion samples were placed in laboratory dishes respectively, and heated gradually as in the same manner of the fiber-drying processes up to 150° C. so as to the water in the emulsion samples was vaporized completely. Then the samples were cooled down to the room temperature, and observed. The dried textile treating compositions separated into two layers of silicone oils and emulsifiers. The lower fatty monocarboxylic acids added as the emulsifying promoter partially vaporized, and thus the ratio of the components differed from that before the heating.
The above test result suggests that the separation of the components of textile treating compositions causes the falling off of textile treating composition from fiber surface in the drying processes of fiber production or processing. In drying processes, textile treating compositions partially vaporize resulting in the change of components ratio. The components separate into layers lose sufficient affinity to fiber, and thus textile treating compositions fall off from fiber.
The weakly acidic monoesters of dicarboxylic acids employed in the emulsifier (B) of the present invention do not cause the above-mentioned separation of the compositions, contrary to the lower fatty monocarboxylic acids employed in the textile treating compositions disclosed in the prior art.
The textile treating composition of the present invention seldom resulted in such separation of components after heated in the same manner as in the above test, owing to the performance of the weakly acidic monoesters of dicarboxylic acids. And the ratio of the components of the textile treading composition rarely changed after the heating, as the monoesters of dicarboxylic acids do not vaporize in the heating owing to their higher boiling point than that of the lower fatty monocarboxylic acids.
The textile treating composition of the present invention rarely falls off from fiber to the surface of guides or rolls in fiber processing, so as to minimize or eliminate the filament breakage or fluffs due to filament wrap on guides or rolls even in continuous production.
Other components applicable to the textile treating composition of the present invention are cationic or anionic antistats, fatty acid soaps, and lubricants.
The textile treating composition of the present invention should preferably be prepared into 20 percent aqueous emulsion and diluted into 2 percent concentration. The preferable application device is a kiss roll, and the preferable application level is from 1.0 to 1.5 percent (in active content) of fiber weight.
The invention will now be further described in the following specific examples which are to be regarded solely as illustrative and not as restricting the scope of the invention. The percentage mentioned in the following examples refers weight percent unless otherwise specified.
The quantity of the textile treating composition applied on fiber, the globule size of the emulsion, transmittance of the emulsion, the insoluble matter in MEK15 (methyl ethyl keton), and the stain on rolls, of which data are given in the examples, were determined in the following method.
(1) Determination of the quantity of the textile treating composition on fiber
A fiber sample was fused with the mixture of potassium hydroxide and sodium butylate solutions. Then the fused sample was dissolved in water, and the pH of the solution was controlled into 1 with hydrogen chloride. The solution was colored with sodium sulfite and ammonium molybdate to determine the silicon content in the colorimetric determination (at 815 micrometer wave length), of silicon molybdenum blue. The silicon content obtained in this method was calculated into the quantity of textile treating compositions on the fiber sample according to the silicon ratio in the textile treating compositions previously determined in the same manner.
(2) Determination of the globule size
The mean globule size and the size distribution in the 20 percent aqueous emulsion of the textile treating compositions were determined with a laser scattering particle size distribution analyzer (LA-910, by Horiba Ltd.).
(3) Determination of transmittance
The transmittance of the 20 percent aqueous emulsion of the textile treating compositions was determined in 1 cm cell at 660 micrometer wave length, applying water as the blank, with a spectrophotometer (100-10, by Hitachi Co., Ltd.).
(4) Determination of insoluble matter in MEK
The 20 percent aqueous emulsion of a textile treating composition was weighed in approx. 5 g in an aluminum dish (6 cm in diameter, 1.5 cm deep), heated in an oven at 150° C. for one hour, and weighed (A g). Then the sample was further heated in an oven at 230° C. for one hour. The heated sample was dissolved in 50 ml of MEK and transferred in a beaker, and agitated for 5 minutes at room temperature. The solution was then filtrated through a glass filter of know weight. The residue was rinsed with 50 ml of MEK two times to remove the soluble matter in MEK. The residue on the filter was dried in an oven at 105° C. for 30 minutes, and weighed (B g).
The weight of the insoluble matter in MEK was obtained by the following formula. ##EQU1##
The insoluble matter in MEK indicates the gelling of the heated textile treating compositions. More gelling of textile treating composition is preferable for attaining durable water repellency, detachability, heat resistance and peculiar fiber handle. The desirable level of the insoluble matter in MEK is 30 percent or more for attaining satisfiable durability of the above properties.
(5) Stain on rolls
The varnish type residue (stain) stuck on the surface of rolls (mirror-finished chromium-plated rolls) employed in a continuous fiber processing operation was visually inspected, and ranked into five groups as shown in Table 1.
TABLE 1______________________________________grade of stain state of stain on rolls______________________________________1 no stain after 8 hrs. processing2 slight stain after 8 hrs. processing, and no stain after 4 hrs. processing3 slight stain after 4 hrs. processing4 stain after 4 hrs. processing, and no stain after 1 hr. processing5 stain after 1 hr. processing______________________________________
EXAMPLE 1
Copolymer of acrylonitrile 92 percent and methylacrylate 8 percent was spun in wet spinning process, rinsed with water, and drawn. The resultant wet fiber was applied with four variants of textile treating composition and dried to be prepared into four different tow samples. The monofilament thickness was 2.0 denier, and the single tow was 100,000 denier. The amount of amino-modified polysiloxane on each of the tow samples applied with the textile treating compositions 1, 2, 3, and 4 was 1.16 percent, 1.19 percent, 1.11 percent, and 1.17 percent respectively.
The stain on rolls given by the above four tow samples was observed as shown in Table 2. The textile treating compositions applied to the tow had the following formulae.
______________________________________Textile treating composition 1 (of the present invention)The major components and their blend ratio are as follows.______________________________________amino-modified polysiloxane*.sup.1 : 66.7POE(12)*.sup.2 nonylphenyl succinic monoester: 13.3POE(12) nonylphenyl ether: 10POE(7) nonylphenyl ether: 10______________________________________ *.sup.1 : aminomodified polysiloxane, wherein a primary amine and a secondary amines were contained at the amount represented by 0.8% nitrogen, of which viscosity was 1,500 cSt *.sup.2 : POE represents polyoxyethylene residue, and the figures in the parentheses represent the number of ethylene oxide.
The textile treating composition 1 was prepared by blending 100 parts by weight of the above major components with 3 parts by weight of β-alanine, applicable as the aminocarboxylic acids (C) of the present invention.
______________________________________Textile treating composition 2 (of the present invention)The major components and their blend ratio are as follows.______________________________________amino-modified polysiloxane*.sup.1 : 65POE(12) nonylphenyl maleic monoester: 15POE(12) nonylphenyl ether: 10POE(7) nonylphenyl ether: 10______________________________________ *.sup.1 : the same polysiloxane as in the composition 1.
The textile treating composition 2 was prepared by blending 100 parts by weight of the above major components with 4.5 parts by weight of dibutylethanolamine acetate, applicable as the aminocarboxylic acids (C) of the present invention.
______________________________________Textile treating composition 3 (comparative example)The major components and their blend ratio are as follows______________________________________amino-modified polysiloxane*.sup.1 : 66.7POE(9) nonylphenyl phosphate (monophosphate): 6.6POE(9) nonylphenyl ether: 26.7______________________________________Textile treating composition 4 (comparative example)The major components and their blend ratio are as follows______________________________________amino-modified polysiloxane*.sup.1 : 66.7POE(9) nonylphenyl ether: 33.3______________________________________ *.sup.1 : the same polysiloxane as in the composition 1.
The textile treating composition 4 was prepared by blending 100 parts by weight of the above major component with 4.5 parts by weight of dibutylethanolamine acetate, as the aminocarboxylic acids.
As apparent in Table 2, the textile treating compositions 1 and 2 of the present invention gave slight stain on rolls, while the textile treating composition 4, the comparative example, gave considerable stain on rolls for 1 hr. operation.
The textile treating composition 3 was found to have generated a lot of siloxane oligomer (300 to 600 M.W.), approximately ten times of those generated from the other textile treating compositions, through the analysis with gel-permeation chromatography on the textile compositions extracted with MEK from the fiber stored for one year after applied with the textile treating compositions 1, 2, 3, and 4. The strong acid groups in the monophosphate blended as the emulsifier in the textile treating composition 3 is estimated to have facilitated the degradation of the amino-modified polysiloxane into smaller molecules.
TABLE 2______________________________________Composition 1 2 3 4Testing Ex. Ex. Comp. Comp.______________________________________Stain on rolls 1 1 1 5pH (20% aq. emul.) 6.0 5.2 6.4 4.9Viscosity (cSt) 2.4 2.5 2.6 2.7(20% aq. emul.)Transmittance (%) 93 92 98 93(20% aq. emul.)Insoluble matter 85 87 12 81in MEK (%)______________________________________
EXAMPLE 2
A textile treating composition was formulated by blending 0.1 to 10 parts by weight of glycine with 100 parts by weight of the following major component.
______________________________________amino-modified polysiloxane*.sup.1 : 70POE(12) nonylphenyl succinic monoester: 10POE(12) nonylphenyl ether: 10POE(7) nonylphenyl ether: 10______________________________________ *.sup.1 : aminomodified polysiloxane, containing a primary amine of which amount is represented by 0.4% nitrogen, of which viscosity was 1,700 cSt
The resultant textile treating composition was prepared into 20 percent aqueous emulsion, and tested on transmittance and viscosity. The result was shown on Table 3.
As apparent from Table 3, the textile treating composition blended with 0.2 percent or more of glycine gave low-viscous aqueous emulsion, which could be easily prepared.
TABLE 3______________________________________glycine content 0 0.1 0.2 1.0 3.0 5.0 10.0Transmittance 98 98 98 98 98 97 95(20% aq. emul.)Viscosity (cSt) 26 14 8 4.2 2.8 2.4 2.3(20% aq. emul.)______________________________________
EXAMPLE 3
Six variants of textile treating compositions were prepared by blending 100 parts by weight of the major components, in which the ratio of the emulsifiers was varied as shown in Table 4, with 3 parts by weight of β-alanine. The textile treating compositions were tested on transmittance and pH as also shown in Table 4.
______________________________________amino-modified polysiloxane*.sup.1 : 70Emulsifier: 30X: POE(12)*.sup.2 nonylphenyl succinic monoesterY: POE(12) nonylphenyl etherZ: POE(7) nonylphenyl ether______________________________________ *.sup.1 : aminomodified polysiloxane, containing a primary amine of which amount if represented by 0.4% nitrogen, of which viscosity was 1,700 cSt *.sup.2 : POE represents polyoxyethylene residue, and the figures in the parentheses represent the number of ethylene oxide.
TABLE 4______________________________________Emulsifier ratio Transmittance (%) pH______________________________________X/Y/Z - 100/0/0 96 4.1X/Y/Z - 70/15/15 93 5.2X/Y/Z - 40/30/30 93 5.7X/Y/Z - 20/40/40 88 5.8X/Y/Z - 10/45/45 72 6.4X/Y/Z - 0/50/50 0.1 7.1______________________________________
EXAMPLE 4
Copolymer of acrylonitrile 98 percent and methaacrylate 2 percent was spun, rinsed with water, and drawn. The resultant wet fiber was applied with four variants of textile treating composition described below and dried to be prepared into four different multifilament yarn sample, of which monofilament thickness was 1.0 denier.
The amount of the silicon oil on each of the yarn samples applied with the textile treating compositions 5, 6, 7, and 8 was 1.4 percent, 1.2 percent, 1.5 percent, and 1.3 percent respectively. And the yarn samples were tested on the stain on roll. The data is shown in Table 5 with the data of the 20 percent emulsion of the textile treating compositions from 5 to 8.
______________________________________Textile treating composition 5 (of the present invention)The major components and their blend ratio are as follows.______________________________________amino-modified polysiloxane*.sup.1 : 65POE(12) nonylphenyl maleic monoester: 15POE(12) nonylphenyl ether: 10POE(7) nonylphenyl ether: 10______________________________________ *.sup.1 : aminomodified polysiloxane, containing a primary amine of which amount is represented by 0.5% nitrogen, of which viscosity was 1,700 cSt
The textile treating composition 5 was prepared by blending 100 parts by weight of the above major components with 2 parts by weight of β-alanine.
______________________________________Textile treating composition 6 (of the present invention)The major components and their blend ratio are as follows.______________________________________amino-modified polysiloxane*.sup.1 : 50ether-modified polysiloxane*.sup.2 : 20POE(12) nonylphenyl succinic monoester: 10POE(12) nonylphenyl ether: 10POE(7) nonylphenyl ether: 10______________________________________ *.sup.1 : aminomodified polysiloxane, containing a primary amine of which amount is represented by 0.5% nitrogen, of which viscosity was 1,700 cSt *.sup.2 : ethermodified polysiloxane, having approx. 50% POE in the molecules, of which viscosity was 4,000 cSt, soluble in water
The textile treating composition 6 was prepared by blending 100 parts by weight of the above major components with 5 parts by weight of POE (2) laurylamino ether acetate.
______________________________________Textile treating composition 7 (of the present invention)The major components and their blend ratio are as follows.______________________________________amino-modified polysiloxane*.sup.1 : 65POE(12) nonylphenyl maleic monoester: 15POE(12) nonylphenyl ether: 10POE(5) laurylamide ether: 10______________________________________ *.sup.1 : aminomodified polysiloxane, containing a primary amine of which amount is represented by 0.5% nitrogen, of which viscosity was 1,700 cSt
The textile treating composition 7 was prepared by blending 100 parts by weight of the above major components with 3 parts by weight of β-alanine, and 3 parts by weight of the antioxidant, ADEKASTAB AO-23, available from Adeka Argus Chemical Co., Ltd.
______________________________________Textile treating composition 8 (of the present invention)The major components and their blend ratio are as follows.______________________________________amino-modified polysiloxane*.sup.1 : 70POE(9) nonylphenyl ether: 30______________________________________ *.sup.1 : aminomodified polysiloxane, containing a primary amine of which amount is represented by 0.5% nitrogen, of which viscosity was 1,700 cSt
The textile treating composition 8 was prepared by blending 100 parts by weight of the above major components with 3 parts by weight of L-glutamic acid, and 3 parts by weight of the antioxidant, ADEKASTAB AO-23, available from Adeka Argus Chemical Co., Ltd.
TABLE 5______________________________________Composition 5 6 7 8Testing Ex. Ex. Ex. Comp.______________________________________Stain on rolls 1 1 1 5pH (20% aq. emul.) 5.0 5.2 5.7 4.4Viscosity (cSt) 2.7 2.5 3.3 8.3(20% aq. emul.)Transmittance (%) 93 92 98 94(20% aq. emul.)Insoluble matter 86 87 60 45in MEK (%)______________________________________
The textile treating composition of the present invention minimizes stain on rolls in fiber processing to improve the efficiency of continuous fiber processing. And the water repellency, detachability, heat resistance, and peculiar handle imparted to fiber last for a long time as the amino-modified polysiloxane in the textile treating composition is not degraded into smaller molecules. | A textile treating composition imparting durable water repellency, detachability, heat resistance, and smooth and slick handle to acrylic fiber and polyacrylo- nitril precursors for carbon fiber; and minimizing stain on guides or rolls in fiber processing is disclosed. The composition comprises amino-modified polysiloxanes, monoesters of dicarboxylic acids, nonionic surfactants, and amino carboxylic acids. | 3 |
The present invention relates to luminaires and particularly to locating and retaining means for the lamp within a luminaire.
BACKGROUND OF THE INVENTION
High intensity lamps such as mercury, metal halide or high pressure sodium lamps commonly used in lighting fixtures are usually single-ended and have a screw base. While the socket into which the lamp is screwed will locate it and hold it in place, it is desirable to have some additional means to positively locate the lamp in the desired attitude or location relative to the luminaire's design light center. Also in installations subject to vibration it is desirable to have some additional means to counter the effects thereof and prevent the lamp for loosening and possibly fracturing at the socket and falling out. This is particularly desirable in outdoor luminaires, especially street or highway lighting fixtures which are subject to roadway vibration and pole sway caused by wind.
In U.S. Pat. No. 3,694,649--Thompson, Lamp Support Device, a retaining device for countering the effects of vibration is described. It takes the form of a pair of elongated stiff wire members secured to an adjustable lamp socket bracket. These members extend axially to the neck portion of the lamp and have curved end portions which engage the neck while encircling it. In addition to protecting the lamp against vibration-loosening under service conditions, the support device also facilitates relamping. By providing support adequate to retain the lamp in the fixture even after the base is fully disengaged from the socket, the possibility of the lamp being accidentally dropped by the electrician and resultant breakage is greatly reduced.
SUMMARY OF THE INVENTION
The object of our invention is to provide an improved retaining means for a lamp within a luminaire which adapts to variations in lamp stem diameters, and provides structural support and positive positioning of the lamp in relation to the reflector together with ease of lamp replacement. A retaining means is desired which is cheaper to make than what has been used heretofore and which is easily installed while the luminaire is being assembled.
In accordance with our invention we provide a resilient wire retaining means formed to a four-sided parallelogram shape with four outboard reverting projections between sides or segments. Conveniently one pair of diametrically opposed projections may be curved to encircle fixing means such as bolts which hold the retainer relative to the luminaire's optical assembly. The other pair are not restrained and provide extra material for flexing in accommodating to variations in lamp diameter.
In a preferred embodiment, the retaining means is made of a single length of spring wire extending from one terminal loop to a diametrically opposite reverting loop, and then back to a second terminal loop which is juxtaposed to the first on a common axis. The two juxtaposed terminal loops encircle one retaining bolt and the reverting loop encircles the other retaining bolt to hold the retainer in place relative to the optical assembly.
DESCRIPTION OF DRAWING
FIG. 1 is a side elevational view, partly sectioned and with parts broken away of a luminaire in which the invention is embodied.
FIG. 2 is a plan view of the spring wire retainer.
FIG. 3 is a cross-sectional view through the lamp neck in FIG. 1 showing the retainer in place.
DETAILED DESCRIPTION
Referring now to the drawing and particularly to FIG. 1, there is shown a luminaire 1 in which the lamp retaining means of the invention finds particular utility. The luminaire comprises an optical assembly which includes a dome-shaped housing 2 enclosing an inner polished reflector 3. The reflector has a configuration producing a desired distribution of reflected light when a lamp is properly located relative to the design light center. The reflector is engaged by the domed housing at the rim 4. The entire optical assembly depends from and is fastened by bolts 5 or the like to the rim of a generally cylindrical socket compartment 6 which forms part of a ballast housing 7. The ballast housing including the socket compartment may be an aluminum casting. The open end of domed housing 2 may be closed by a light-transmitting closure or window 2a in known fashion, for instance as described in U.S. Pat. No. 3,694,649--Thompson, whose disclosure is incorporated herein by reference.
A conventional single-ended lamp socket 8 is accommodated within compartment 6, being fastened to its inner end wall 9. Within the ballast housing 7 are mounted electrical operating components such as a ballast transformer (not shown) for operating a discharge lamp 10 shown screwed into socket 8. The illustrated lamp, a 1000 watt metal halide lamp such as those sold under the registered trademark Multi-Vapor, is but one example of a high intensity lamp which may be used in the luminaire.
In accordance with the present invention a lamp retaining means is constructed and arranged in the luminaire to clamp resiliently about the neck 10' of the lamp. The retaining means must permit easy lamp replacement yet provide sufficient restraint to positively locate the lamp on axis at the design light center and also retain the lamp when it is unscrewed from the socket. Also it must accommodate variations in lamp diameter due to manufacturing tolerances, securely holding smaller diameter lamps but without fracturing together diameter ones. Referring to FIGS. 2 and 3, this is accomplished by a flexible wire retainer 11 made of spring wire formed to a four-sided parallelogram shape with outboard reverting projections between sides or segments. The retainer is held in place, transverse to the lamp axis across the mouth or rim of socket compartment 6 by two of the four bolts which fasten the optical assembly to the ballast housing at the rim of the socket compartment. These bolts 5' and 5" engage one opposed pair or set of reverting projections.
In the preferred construction best seen in FIG. 2 the retainer 11 is made of a single length of resilient wire, suitably 1/16" diameter steel spring wire. The wire is bent or formed as follows: beginning with a terminal loop 12, there follows a straight segment 13, then a cusp-like outboard projection 14, a straight segment 15, a reverting loop 16, a straight segment 17, a cusp-like outboard projection 18, a straight segment 19 and finally a terminal loop 20. The retainer is preferably sheathed by a cushioning material capable of withstanding the lamp's operating temperature, suitably glass cloth sleeving 21 as shown in FIG. 3, to prevent metal-to-glass contact.
When the retainer is installed in the luminaire, the two terminal loops 12 and 20 are juxtaposed, that is superposed on behind the other under one of the retaining bolts 5', while the reverting loop 16 is engaged by the other retaining bolt 5". The retaining bolts 5',5" are shouldered so as to clamp the optical assembly tightly against the rim of socket compartment 6 but leaving the loops of the retainer 11 free to flex. Our retainer design thus provides for quick and easy installation in the process of assembling the luminaire components.
In use, a lamp 10 is inserted into the socket compartment, the straight segments 13,15 and 17,19 are forced out and bent slightly, thus exerting pressure against the neck 10' of the lamp. The cusp-like projections or outboard ribs 14 and 18 tend to close in flexing while the reverting loop 16 tends to open. The terminal loops 12 and 20 have an action similar to that of the reverting loop 16. The arrangement according to the invention thus assures adequate flexibility to accommodate expected variations in lamp neck diameter without fracturing the lamp, while exerting sufficient pressure on the lamp neck to hold the lamp securely in place.
The particular embodiment which has been illustrated and described in detail will accommodate 1000 and 1500 watt metal halide lamps, 1000 and 1500 watt mercury lamps, and 1000 watt high pressure sodium lamps. Such lamps have a nominal neck diameter of 2.250" with a permissible manufacturing tolerance of +0.250" and -0.062". Of course such embodiment is intended only as an illustrative example and the appended claims are intended to cover modifications that those skilled in the art may make without departing from the spirit and scope of the invention. | A retaining means for a lamp within a luminaire provides structural support and positive positioning. It comprises a resilient wire formed to a four-sided parallelogram shape with four outboard reverting projections between segments. One pair of diametrically opposed projections encircle bolts which hold the retainer transversely to the lamp axis at the rim of the socket compartment. Another pair of projections are unrestrained and provide extra flexibility in accommodating to variations in lamp diameters. | 5 |
BACKGROUND
[0001] The present invention relates to testing of radio frequency (RF) wireless signal transceivers, and in particular, to testing such devices without a need for RF signal cables for conveyance of RF test signals.
[0002] Many of today's electronic devices use wireless technologies for both connectivity and communications purposes. Because wireless devices transmit and receive electromagnetic energy, and because two or more wireless devices have the potential of interfering with the operations of one another by virtue of their signal frequencies and power spectral densities, these devices and their wireless technologies must adhere to various wireless technology standard specifications.
[0003] When designing such devices, engineers take extraordinary care to ensure that such devices will meet or exceed each of their included wireless technology prescribed standard-based specifications. Furthermore, when these devices are later being manufactured in quantity, they are tested to ensure that manufacturing defects will not cause improper operation, including their adherence to the included wireless technology standard-based specifications.
[0004] For testing these devices following their manufacture and assembly, current wireless device test systems (“testers”) employ a subsystem for analyzing signals received from each device. Such subsystems typically include at least a vector signal generator (VSG) for providing the source signals to be transmitted to the device, and a vector signal analyzer (VSA) for analyzing signals produced by the device. The production of test signals by the VSG and signal analyses performed by the VSA are generally programmable so as to allow each to be used for testing a variety of devices for adherence to a variety of wireless technology standards with differing frequency ranges, bandwidths and signal modulation characteristics.
[0005] Calibration and performance verification testing of a device under test (DUT) are typically done using electrically conductive signal paths, such as RF cables, rather than wireless signal paths, by which a DUT and tester communicate via electromagnetic radiation. Accordingly, the signals between the tester and DUT are conveyed via the conductive signal path rather than being radiated through ambient space. Using such conductive signal paths helps to ensure repeatability and consistency of measurements, and eliminates positioning and orientation of the DUT as a factor in signal conveyance (transmission and reception).
[0006] In the case of a multiple input, multiple output (MIMO) DUT, a signal path must be provided, in some form, for each input/output connection of the DUT. For example, for a MIMO device intended to operate with three antennas, three conductive signal paths, e.g., cables and connections, must be provided for testing.
[0007] However, using conductive signal paths significantly impacts the time needed for testing each DUT due to the need for physically connecting and disconnecting the cables between the DUT and tester. Further, in the case of a MIMO DUT, multiple such connecting and disconnecting actions must be performed, both at the beginning and termination of testing. Further, since the signals being conveyed during testing are not radiated via the ambient space, as they would be in the normally intended use, and the antenna assemblies for the DUT are not in use during such testing, such testing does not simulate real world operation and any performance characteristics attributable to the antennas are not reflected in the test results.
[0008] As an alternative, testing could be done using test signals conveyed via electromagnetic radiation rather than electrical conduction via cables. This would have the benefit of requiring no connecting and disconnecting of test cables, thereby reducing the test time associated with such connections and disconnections. However, the “channel” in which the radiated signals and receiver antennas exist, i.e., the ambient space through which the test signals are radiated and received, is inherently prone to signal interference and errors due to other electromagnetic signals originating elsewhere and permeating the ambient space. Such signals will be received by the DUT antennas and can include multipath signals from each interfering signal source due to signal reflections. Accordingly, the “condition” of the “channel” will typically be poor compared to using individual conductive signal paths, e.g., cables, for each antenna connection.
[0009] One way to prevent, or at least significantly reduce, interference from such extraneous signals, is to isolate the radiated signal interface for the DUT and tester using a shielded enclosure. However, such enclosures have typically not produced comparable measurement accuracy and repeatability. This is particularly true for enclosures that are smaller than the smallest anechoic chambers. Additionally, such enclosures tend to be sensitive to the positioning and orientation of the DUT, as well as to constructive and destructive interference of multipath signals produced within such enclosures.
[0010] Accordingly, it would be desirable to have systems and methods for testing wireless signal transceivers, and particularly wireless MIMO signal transceivers, in which radiated electromagnetic test signals can be used, thereby simulating real world system operation as well as avoiding test time otherwise necessary for connecting and disconnecting test cabling, while maintaining test repeatability and accuracy by avoiding interfering signals due to externally generated signals and multipath signal effects.
SUMMARY
[0011] In accordance with the presently claimed invention, a system and method to facilitate wireless testing of a radio frequency (RF) signal transceiver device under test (DUT). With the DUT operating in a controlled electromagnetic environment, the tester exchanges multiple test signals wirelessly with the DUT. Signal phases of the respective test signals are controlled in accordance with feedback signals from the DUT and test equipment. Magnitudes of the respective test signals can also be controlled in accordance with such feedback signals, thereby enabling minimizing of apparent signal path loss between the tester and DUT to effectively simulate an electrically conductive signal path.
[0012] In accordance with one embodiment of the presently claimed invention, a system to facilitate wireless testing of a radio frequency (RF) signal transceiver device under test (DUT) includes a structure, an electrically conductive signal path, a plurality of antennas and RF signal control circuitry. The structure defines interior and exterior regions with the interior region substantially isolated from electromagnetic radiation originating from the exterior region, with the interior region including: a first interior location configured to allow placement of a DUT; a second interior location distal from the first interior location, and one or more RF absorbent materials disposed substantially lateral to a defined volume between the first and second interior locations. The electrically conductive signal path is to couple to the DUT and convey one or more electrical signals between the interior and exterior regions. The plurality of antennas is disposed at least partially at the second interior location to radiate a plurality of phase-controlled RF test signals. The RF signal control circuitry is coupled to the electrically conductive signal path and the plurality of antennas, and responsive to a plurality of signal data from the DUT related to the plurality of phase-controlled RF test signals and conveyed via the one or more electrical signals, and to a RF test signal by: replicating the RF test signal to provide a plurality of replica RF test signals; and controlling, in accordance with the plurality of signal data, respective phases of at least a portion of the plurality of replica RF test signals to provide the plurality of phase-controlled RF test signals.
[0013] In accordance with another embodiment of the presently claimed invention, a method of facilitating wireless testing of a radio frequency (RF) multiple-input, multiple-output (MIMO) signal transceiver device under test (DUT) includes providing a structure, an electrically conductive signal path and a plurality of antennas. The structure defines interior and exterior regions with the interior region substantially isolated from electromagnetic radiation originating from the exterior region, with the interior region including: a first interior location configured to allow placement of a DUT; a second interior location distal from the first interior location; and one or more RF absorbent materials disposed substantially lateral to a defined volume between the first and second interior locations. The electrically conductive signal path is to couple to the DUT and convey one or more electrical signals between the interior and exterior regions. The plurality of antennas is disposed at least partially at the second interior location to radiate a plurality of phase-controlled RF test signals. Further included is responding to a plurality of signal data from the DUT related to the plurality of phase-controlled RF test signals and conveyed via the one or more electrical signals, and to a RF test signal by: replicating the RF test signal to provide a plurality of replica RF test signals; and controlling, in accordance with the plurality of signal data, respective phases of at least a portion of the plurality of replica RF test signals to provide the plurality of phase-controlled RF test signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 depicts a typical operating and possible testing environment for a wireless signal transceiver.
[0015] FIG. 2 depicts a testing environment for a wireless signal transceiver using a conductive test signal path.
[0016] FIG. 3 depicts a testing environment for a MIMO wireless signal transceiver using conductive signal paths and a channel model for such testing environment.
[0017] FIG. 4 depicts a testing environment for a MIMO wireless signal transceiver using radiated electromagnetic signals a channel model for such testing environment.
[0018] FIG. 5 depicts a testing environment in accordance with exemplary embodiments in which a MIMO DUT can be tested using radiated electromagnetic test signals.
[0019] FIG. 6 depicts a testing environment in which a DUT is tested using radiated electromagnetic test signals within a shielded enclosure.
[0020] FIGS. 7 and 8 depict exemplary embodiments of testing environments in which a wireless DUT is tested using radiated electromagnetic test signals in a shielded enclosure with reduced multipath signal effects.
[0021] FIG. 9 depicts a physical representation of a shielded enclosure in accordance with an exemplary embodiment for use in the testing environments of FIGS. 7 and 8 .
DETAILED DESCRIPTION
[0022] The following detailed description is of example embodiments of the presently claimed invention with references to the accompanying drawings. Such description is intended to be illustrative and not limiting with respect to the scope of the present invention. Such embodiments are described in sufficient detail to enable one of ordinary skill in the art to practice the subject invention, and it will be understood that other embodiments may be practiced with some variations without departing from the spirit or scope of the subject invention.
[0023] Throughout the present disclosure, absent a clear indication to the contrary from the context, it will be understood that individual circuit elements as described may be singular or plural in number. For example, the terms “circuit” and “circuitry” may include either a single component or a plurality of components, which are either active and/or passive and are connected or otherwise coupled together (e.g., as one or more integrated circuit chips) to provide the described function. Additionally, the term “signal” may refer to one or more currents, one or more voltages, or a data signal. Within the drawings, like or related elements will have like or related alpha, numeric or alphanumeric designators. Further, while the present invention has been discussed in the context of implementations using discrete electronic circuitry (preferably in the form of one or more integrated circuit chips), the functions of any part of such circuitry may alternatively be implemented using one or more appropriately programmed processors, depending upon the signal frequencies or data rates to be processed. Moreover, to the extent that the figures illustrate diagrams of the functional blocks of various embodiments, the functional blocks are not necessarily indicative of the division between hardware circuitry.
[0024] Referring to FIG. 1 , a typical operating environment, and ideal testing environment for a wireless signal transceiver (at least in terms of simulating real world operation), would have the tester 100 and DUT 200 communicate wirelessly. Typically, some form of test controller 10 , (e.g., a personal computer) will also be used to exchange testing commands and data via wired signal interfaces 11 a , 11 b with the tester 100 and DUT 200 . The tester 100 and DUT 200 each have one (or more for MIMO devices) respective antennas 102 , 202 , which connect by way of conductive signal connectors 104 , 204 (e.g., coaxial cable connections, many types of which are well known in the art). Test signals (source and response) are conveyed wirelessly between the tester 100 and DUT 200 via the antennas 102 , 202 . For example, during a transmit (TX) test of the DUT 200 , electromagnetic signals 203 are radiated from the DUT antenna 202 . Depending upon the directivity of the antenna emission pattern, this signal 203 will radiate in numerous directions, resulting in an incident signal component 203 i and reflected signal components 203 r being received by the tester antenna 102 . As discussed above, these reflected signal components 203 r , often the products of multipath signal effects as well as other electromagnetic signals originating elsewhere (not shown), result in constructive and destructive signal interference, thereby preventing reliable and repeatable signal reception and testing results.
[0025] Referring to FIG. 2 , to avoid such unreliable testing results, a conductive signal path, such as a RF coaxial cable 106 , is used to connect the antenna connectors 104 , 204 of the tester 100 and DUT 200 to provide a consistent, reliable and repeatable electrically conductive signal path for conveyance of the test signals between the tester 100 and DUT 200 . As discussed above, however, this increases the overall test time due to the time needed for connecting and disconnecting the cable 106 before and after testing.
[0026] Referring to FIG. 3 , the additional test time for connecting and disconnecting test cabling becomes even longer when testing a MIMO DUT 200 a . In such cases, multiple test cables 106 are needed to connect corresponding tester 104 and DUT 204 connectors to enable conveyance of the RF test signals from the RF signal sources 110 (e.g., VSGs) within the tester 100 a for reception by the RF signal receivers 210 within the DUT 200 a . For example, in a typical testing environment, the tester for testing MIMO devices will have one or more VSGs 110 a , 110 b , . . . , 110 n providing corresponding one or more RF test signals 111 a , 111 b , . . . , 111 n (e.g., packet data signals having variable signal power, packet contents and data rates). Their corresponding test cables 106 a , 106 b , . . . , 106 n , connected via respective tester 104 a , 104 b , . . . , 104 n and DUT 204 a , 204 b , . . . , 204 n connectors, convey these signals to provide the received RF test signals 211 a , 211 b , . . . , 211 n for the corresponding RF signal receivers 210 a , 210 b , . . . , 210 n within the DUT 200 a . Accordingly, the additional test time required for connecting and disconnecting these test cables 106 can be increased by a factor n corresponding to the number of test cables 106 .
[0027] As discussed above, using test cables for connecting the tester 100 a and DUT 200 a does have the advantage of providing consistent, reliable, and repeatable test connections. As is well known in the art, these test connections 107 can be modeled as a signal channel H characterized by a diagonal matrix 20 , where the diagonal matrix elements 22 correspond to the coefficients h 11 , h 22 , . . . , h nn , for the respective signal channel characteristics (e.g., signal path conductivities or losses for the respective test cables 106 ).
[0028] Referring to FIG. 4 , in accordance with one or more exemplary embodiments, the conductive, or wired, channel 107 ( FIG. 3 ) is replaced by a wireless channel 107 a corresponding to a wireless signal interface 106 a between the tester 100 a and DUT 200 a . As discussed above, the tester 100 a and DUT 200 a communicate test signals 111 , 211 via respective arrays of antennas 102 , 202 . In this type of test environment, the signal channel 107 a is no longer represented by a diagonal matrix 20 , but is instead represented by a matrix 20 a having one or more non-zero coefficients 24 a , 24 b off of the diagonal 22 . As will be readily understood by one skilled in the art, this is due to the multiple wireless signal paths available in the channel 107 a . For example, unlike a cabled signal environment in which, ideally, each DUT connector 204 receives only the signal from its corresponding tester connector 104 . In this wireless channel 107 a , the first DUT antenna 202 a receives test signals radiated by all of the tester antennas 102 a , 102 b , . . . , 102 n , e.g., corresponding to channel H matrix coefficients h 11 , h 12 , . . . , and h 1n .
[0029] In accordance with well known principles, the coefficients h of the channel matrix H correspond to characteristics of the channel 107 a affecting transmission and reception of the RF test signals. Collectively, these coefficients h define the channel condition number k(H), which is the product of the norm of the H matrix and the norm of the inverse of the H matrix, as represented by the following equation:
[0000] k ( H )=∥ H∥*∥H −1 ∥
[0030] The factors affecting these coefficients can alter the channel condition number in ways that can create measurement errors. For example, in a poorly conditioned channel, small errors can cause large errors in the testing results. Where the channel number is low, small errors in the channel can produce small measurements at the receive (RX) antenna. However, where the channel number is high, small errors in the channel can cause large measurement errors at the receive antenna. This channel condition number k(H) is also sensitive to the physical positioning and orientation of the DUT within its testing environment (e.g., a shielded enclosure) and the orientation of its various antennas 204 . Accordingly, even if with no extraneous interfering signals originating elsewhere or arriving via reflections and impinging on the receive antennas 204 , the likelihood of repeatable accurate test results will be low.
[0031] Referring to FIG. 5 , in accordance with one or more exemplary embodiments, the test signal interface between the tester 100 a and DUT 200 a can be wireless. The DUT 200 a is placed within the interior 301 of a shielded enclosure 300 . Such shielded enclosure 300 can be implemented as a metallic enclosure, e.g., similar in construction or at least in effect to a Faraday cage. This isolates the DUT 200 a from radiated signals originating from the exterior region 302 of the enclosure 300 . In accordance with exemplary embodiments, the geometry of the enclosure 300 is such that it functions as a closed-ended waveguide.
[0032] Elsewhere, e.g., disposed within or on an opposing interior surface 302 of the enclosure 300 , are multiple (n) antennas arrays 102 a , 102 b , . . . , 102 n , each of which radiates multiple phase-controlled RF test signals 103 a , 103 b , . . . , 103 n (discussed in more detail below) originating from the test signal sources 110 a , 110 b , . . . , 110 n within the tester 100 a . Each antenna array includes multiple (M) antenna elements. For example, the first antenna array 102 a includes m antenna elements 102 aa , 102 ab , . . . 102 am . Each of these antenna elements 102 aa , 102 ab , . . . , 102 am is driven by a respective phase-controlled RF test signal 131 aa , 131 ab , . . . , 131 am provided by respective RF signal control circuitry 130 a.
[0033] As depicted in the example of the first RF signal control circuitry 130 a , the RF test signal 111 a from the first RF test signal source 110 a has its magnitude increased (e.g., amplified) or decreased (e.g., attenuated) by signal magnitude control circuitry 132 . The resulting magnitude-controlled test signal 133 is replicated by signal replication circuitry 134 (e.g., a signal divider). The resulting magnitude-controlled, replicated RF test signals 135 a , 135 b , . . . , 135 m have their respective signal phases controlled (e.g., shifted) by respective phase control circuits 136 a , 136 b , . . . , 136 m to produce magnitude- and phase-controlled signals 131 aa , 131 ab , . . . , 131 am to drive the antenna elements 102 aa , 102 ab , . . . , 102 am of the antenna array 102 a.
[0034] The remaining antenna arrays 102 b , . . . , 102 n and their respective antenna elements are driven in a similar manner by corresponding RF signal control circuits 130 b , . . . , 130 m . This produces corresponding numbers of composite radiated signals 103 a , 103 b , . . . , 103 n for conveyance to and reception by the antennas 202 a , 202 b , . . . , 202 n of the DUT 200 a in accordance with the channel H matrix, as discussed above. The DUT 200 a processes its corresponding received test signals 211 a , 211 b , . . . , 211 m and provides one or more feedback signals 201 a indicative of the characteristics (e.g., magnitudes, relative phases, etc.) of these received signals. These feedback signals 201 a are provided to control circuitry 138 within the RF signal control circuits 130 . This control circuitry 138 provides control signals 137 , 139 a , 139 b , . . . , 139 m for the magnitude control circuitry 132 and phase control circuitry 136 . Accordingly, a closed loop control path is provided, thereby enabling gain and phase control of the individual radiated signals from the tester 100 a for reception by the DUT 200 a . (Alternatively, this control circuitry 130 can be included as part of the tester 100 a .)
[0035] In accordance with well-known channel optimization techniques, the control circuitry 138 uses this feedback data 201 a from the DUT 200 a to achieve optimal channel conditions by altering the magnitudes and phases of the radiated signals in such a manner as to minimize the channel condition number k(H), and produce received signals, as measured at each DUT antenna 202 , having approximately equal magnitudes. This will create a communication channel through which the radiated signals produce test results substantially comparable to those produced using conductive signal paths (e.g., RF signal cables).
[0036] This operation by the control circuitry 138 of the RF signal control circuitry 130 , following successive transmissions and channel condition feedback events, will vary the signal magnitude and phase for each antenna array 102 a , 102 b , . . . , 102 n to iteratively achieve an optimized channel condition number k(H). Once such an optimized channel condition number k(H) has been achieved, the corresponding magnitude and phase settings can be retained and the tester 100 a and DUT 200 a can continue thereafter in a sequence of tests, just as would be done in a cabled testing environment.
[0037] In practice, a reference DUT can be placed in a test fixture within the shielded enclosure 300 for use in optimizing the channel conditions through the iterative process discussed above. Thereafter, further DUTs of the same design can be successively tested without having to execute channel optimization in every instance, since differences in path loss experienced in the controlled channel environment of the enclosure 300 should be well within normal testing tolerances.
[0038] Referring still to FIG. 5 , for example, an initial transmission was modeled to produce a channel condition number of 13.8 db, and the magnitudes of the h 11 and h 22 coefficients were −28 db and −28.5 db, respectively. The magnitude matrix for the channel H would be represented as follows:
[0000]
H
dB
=
[
-
28
-
34.2
-
29.8
-
28.5
]
k
(
H
)
=
13.8
dB
[0039] After iterative adjustments of magnitude and phase, as discussed above, the channel condition number k(H) was reduced to 2.27 db, and the amplitudes of the h 11 and h 22 coefficients were −0.12 db and −0.18 db, respectively, producing a channel magnitude matrix as follows:
[0000]
H
dB
=
[
-
0.12
-
13.68
-
15.62
-
0.18
]
k
(
H
)
=
2.27
dB
[0040] These results are comparable to those of a cabled testing environment, thereby indicating that such a wireless testing environment can provide test results of comparable accuracy. By eliminating time for connecting and disconnecting cabled signal paths, and factoring in the reduced time for gain and phase adjustments, the overall received signal test time is significantly reduced.
[0041] Referring to FIG. 6 , influences of multipath signal effects upon the channel condition can be better understood. As discussed above, once disposed within the interior 301 of the enclosure 300 , the DUT 200 a , during transmit testing, radiates an electromagnetic signal 203 a from each antenna 202 a . This signal 203 a includes components 203 b , 203 c that radiate outwardly and away from the antenna 102 a of the tester 100 a . However, these signal components 203 b , 203 c are reflected off of interior surfaces 304 , 306 of the enclosure 300 and arrive as reflected signal components 203 br , 203 cr to combine, constructively or destructively, depending upon the multipath signal conditions, with the main incident signal component 203 ai . As discussed above, depending upon the constructive and destructive nature of the interference, test results will generally tend to be unreliable and inaccurate for use in proper calibration and performance verification.
[0042] Referring to FIG. 7 , in accordance with an exemplary embodiment, RF absorbent materials 320 a , 320 b are disposed at the reflective surfaces 304 , 306 . As a result, the reflected signal components 203 br , 203 cr are attenuated significantly, thereby producing less interference, either constructively or destructively, with the incident primary signal component 203 ai.
[0043] Additional RF signal control circuitry 150 can be included for use between the antenna array 102 a mounted within the interior 301 or on the interior surface 302 of the enclosure 300 a and the tester 100 a . (Alternatively, this additional control circuitry 150 can be included as part of the tester 100 a .) The radiated signals impinging upon the antenna elements 102 aa , 102 ab , . . . , 102 am produce received signals 103 aa , 103 ab , . . . , 103 am with respective signal phases controlled (e.g., shifted) by phase control circuitry 152 having phase control elements 152 a , 152 b , . . . , 152 m controlled in accordance with one or more phase control signals 157 a , 157 b , . . . , 157 m provided by a control system 156 . The resulting phase-controlled signals 153 are combined in a signal combiner 154 to provide the received signal 155 a for the tester 100 a and a feedback signal 155 b for the control system 156 . The control system 156 processes this feedback signal 155 b , as part of a closed loop control network, to adjust, as needed, the respective phases of the composite receive signals 103 aa , 103 ab , . . . , 103 am to minimize the apparent signal path loss associated with the interior region 301 of the enclosure 300 a . This closed loop control network also allows the system to reconfigure the phased array enabled by these antennas 102 a and phase control circuitry 152 in the event that the positioning or orientation of the DUT 200 a changes within the enclosure 300 a . As a result, following minimization of the path loss using this feedback loop, accurate and repeatable conveyance of the DUT signal 203 a to the tester 100 a using the radiated signal environment within the enclosure 300 a can be achieved.
[0044] Referring to FIG. 8 , similar control and improvement in producing accurate and repeatable test results can be achieved for DUT receive signal testing. In this case, the test signal 111 a provided by the tester 100 a is replicated by the signal combiner/splitter 154 , and the respective phases of the replicated test signals 153 are adjusted as necessary by the phase control circuitry 152 before being radiated by the antenna elements 102 aa , 102 ab , . . . , 102 am . As in the previous case, the reflected signal components 103 br , 103 cr are significantly attenuated and result in reduced constructive and destructive interference with the primary incident signal component 103 ai . One or more feedback signals 203 a from the DUT 200 a provide the control system 156 with the information necessary for controlling the phases of the replicated test signals 153 to minimize the apparent signal path loss associated with the interior 301 of the enclosure 300 a , thereby establishing consistent and repeatable signal path loss conditions.
[0045] Referring to FIG. 9 , in accordance with one or more exemplary embodiments, the shielded enclosure 300 b can be implemented substantially as shown. As discussed above, the DUT can be positioned at one end 301 d of the interior 301 of the enclosure 300 b , opposite of the interior region 301 b containing or facing the interior surface 302 on which the tester antenna arrays 102 a , 102 b , . . . , 102 n ( FIG. 5 ) are located. In between is an interior region 301 a forming a waveguide cavity surrounded by the RF absorbent materials 320 .
[0046] Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and the spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. It is intended that the following claims define the scope of the present invention and that structures and methods within the scope of these claims and their equivalents be covered thereby. | A system and method to facilitate wireless testing of a radio frequency (RF) signal transceiver device under test (DUT). With the DUT operating in a controlled electromagnetic environment, the tester exchanges multiple test signals wirelessly with the DUT. Signal phases of the respective test signals are controlled in accordance with feedback signals from the DUT and test equipment. Magnitudes of the respective test signals can also be controlled in accordance with such feedback signals, thereby enabling minimizing of apparent signal path loss between the tester and DUT to effectively simulate an electrically conductive signal path. | 7 |
FIELD OF THE INVENTION
This invention relates to optically active pyridines which are useful as an electro-optical display material.
BACKGROUND OF THE INVENTION
In recent years, liquid crystal display cells of high multiplexing driving systems have been gradually increased in size, leading to an increasing demand as displays for computer terminals, TV sets and so forth. With this increase in demand, liquid crystal materials having high level multiplexibility have been more needed.
High level multiplexing driving systems are depending on change in environmental temperature and a cross-talk phenomenon will easily occur. In order to prevent the formation of the cross-talk phenomenon due to changes in the environmental temperature, the following have been known; (1) a method in which a temperature compensation circuit is provided in the liquid crystal display equipment; and (2) a method in which the temperature dependency of threshold voltage of liquid crystal material is decreased by adding a chiral substance the molecular orientation of which is twisted right and a chiral substance the molecular orientation of which is twisted left, to the liquid crystal material. The method (1), however, has a disadvantage in that the equipment becomes expensive. Also the method (2) has a disadvantage in that the amount of the substances added is limited because if the amount of the substances added is increased, the response time is decreased, although the substances are necessary to add in large amounts in order to sufficiently obtain the desired effect; therefore the desired effect cannot be obtained sufficiently.
SUMMARY OF THE INVENTION
An object of this invention is to efficiently prevent the cross-talk phenomenon due to changes in environmental temperature in high level multiplexing driving systems.
Another object of this invention is to provide novel pyridine derivatives which when added to various practical nematic liquid crystal compositions, are able to sufficiently decrease the temperature dependency of threshold voltage of the compositions even in small amounts.
It has been found that the objects can be attained by using compounds represented by the general formula (I) as described hereinafter.
This invention provides optically active pyridines represented by the general formula (I): ##STR3## (wherein R represents a straight chain alkyl group having from 2 to 12 carbon atoms; R' represents a straight chain alkyl or alkoxy group having from 1 to 20 carbon atoms; represents an asymmetric carbon atom; A represents ##STR4## and X and Y each represents a hydrogen atom or a fluorine atom, provided that X and Y do not simultaneously represent a fluorine atom).
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
FIG. 1 shows a temperature dependence of the threshold voltage for each of the host liquid crystal (A) and a mixed liquid crystal comprising said host liquid crystal (A) and 0.84% by weight of the optically active compound No. 1 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The compound represented by formula (I) can be prepared by reacting a compound represented by formula (II): ##STR5## wherein R', A, X and Y are defined above, with an optically active tosylate represented by formula (III): ##STR6## wherein R and are as defined above, in a solvent, such as dimethyl sulfoxide, in the presence of a base, such as potassium t-butoxide.
Typical compounds represented by formula (I) are shown in Table 1 below together with their transition temperatures and optical rotations. In Table 1, C means a crystal phase; Sc * means a chiral smectic phase; S A means a smectic A phase; N * means a chiral nematic phase; I means an isotropic liquid phase; S 4 means a high-order smectic phase; and S B means a smectic B phase.
TABLE 1__________________________________________________________________________ ##STR7## Transition OpticalCompound Temperature RotationNo. R R' A X Y (°C.) [α].sub.D.sup.25__________________________________________________________________________1 n-C.sub.6 H.sub.13 n-C.sub.5 H.sub.11 ##STR8## H H ##STR9## +3.50 ##STR10## ##STR11##2 n-C.sub.6 H.sub.13 n-C.sub.5 H.sub.11 ##STR12## H H ##STR13## +2.903 n-C.sub.10 H.sub.21 n-C.sub.5 H.sub.11 ##STR14## H H ##STR15## +11.104 n-C.sub.6 H.sub.13 n-C.sub.5 H.sub.11 O ##STR16## H H ##STR17## +5.80 ##STR18## ##STR19## ##STR20##5 n-C.sub.6 H.sub.13 n-C.sub.5 H.sub.11 ##STR21## F H ##STR22## +3.106 n-C.sub.6 H.sub.13 n-C.sub.5 H.sub.11 ##STR23## H F ##STR24## +3.00__________________________________________________________________________
By adding a small amount of the compound of formula (I) to a number of nematic liquid crystal compositions commonly employed at present, temperature dependence of the threshold voltage of the liquid crystal compositions can be reduced sufficiently.
FIG. 1 shows the temperature dependence of the threshold voltage for each of a host liquid crystal (A) having the following composition which is of present use as nematic liquid crystal material and a nematic liquid crystal composition comprising the host liquid crystal (A) having incorporated thereto 0.84% by weight of Compound 1 according to the present invention. This nemtaic liquid crystal composition has a pitch of 100 μm.
Composition of Host Liquid Crystal (A):
__________________________________________________________________________ Ratio (wt %)__________________________________________________________________________ ##STR25## 13 ##STR26## 9 ##STR27## 13 ##STR28## 10 ##STR29## 2 ##STR30## 7 ##STR31## 5 ##STR32## 5 ##STR33## 5 ##STR34## 9 ##STR35## 4 ##STR36## 4 ##STR37## 8 ##STR38## 7__________________________________________________________________________
Table 2 below shows a pitch and a difference between the threshold voltage at 0° C. and that at 40° C. for various mixed liquid crystal compositions prepared by mixing the host liquid crystal (A) and each of Compounds 1 to 6 according to this invention.
TABLE 2______________________________________ Difference in Amount of Compound ThresholdMixed Liquid (I) Added Pitch VoltageCrystal (wt %) (μm) (mV)______________________________________(A) -- 208(A) + Compound 1 0.840 100 108(A) + Compound 2 0.654 100 112(A) + Compound 3 0.681 100 111(A) + Compound 4 0.842 100 94(A) + Compound 5 0.410 100 103(A) + Compound 6 0.518 100 107______________________________________
It can be seen from Table 2 that addition of a small amount of the compound according to this invention to a nematic liquid crystal composition produces a sufficient effect to reduce temperature dependence of the threshold voltage of the composition.
The compounds of formula (I) are also applicable as liquid crystal material for ferroelectric liquid crystal display elements proposed by Clerk, et al. in Appl. Phys. Lett., Vol. 36, 899 (1980). Among the compounds of formula (I), Compound 1 is of particular advantage because it has a broad chiral smectic C phase and the series of phase transition is suited for orientation.
The optically active compounds in accordance with this present invention reduce a temperature dependence of the threshold voltage of a nematic liquid crystal composition when added thereto in a small amount. Therefore, the compounds can be effectively used in the preparation of liquid crystal materials which can be prevented effectively from suffering a cross-talk phenomenon due to change of environmental temperature in a high level multiplexing driving system.
The present invention is now illustrated in greater detail with reference to the following examples, but it should be understood that the present invention is not deemed to be limited thereto.
EXAMPLE 1
In 30 ml of dimethyl sufixide was dissolved 3.2 g (0.010 mol) of a compound of formula: ##STR39## and 1.5 g (0.013 mol) of potassium t-butoxide was added to the solution. After stirring the mixture at room temperature for 30 minutes, 2.9 g (0.010 mol) of (S) (+)-2-octyl tosylate was added thereto, followed by allowing the mixture to react at 50° C. for 5 hours. After completion of the reaction, the reaction mixture was poured into 100 ml of ice-water, followed by extraction with toluene. The extract was washed with water and dried. The solvent was removed by distillation under reduced pressure, and the residue was purified by recrystallization from ethanol to obtain 32. g (0.0075 mol) of compound represented by ##STR40## in a yield of 75%.
In the same manner as described above, compounds shown in Table 3 below were prepared.
TABLE 3______________________________________ ##STR41##R R'______________________________________C.sub.2 H.sub.5 NC.sub.3 H.sub.7n-C.sub.3 H.sub.7 On-C.sub.7 H.sub.15n-C.sub.4 H.sub.9 n-C.sub.12 H.sub.25n-C.sub.5 H.sub.11 On-C.sub.17 H.sub.35n-C.sub.6 H.sub.13 C.sub.2 H.sub.5n-C.sub.6 H.sub.13 OC.sub.2 H.sub.5n-C.sub.6 H.sub.13 On-C.sub.5 H.sub.11n-C.sub.6 H.sub.13 n-C.sub.8 H.sub.17n-C.sub.6 H.sub.13 On-C.sub.8 H.sub.17n-C.sub.6 H.sub.13 n-C.sub.10 H.sub.21n-C.sub.6 H.sub.13 On-C.sub.10 H.sub.21n-C.sub.6 H.sub.13 n-C.sub.13 H.sub.27n-C.sub.6 H.sub.13 On-C.sub.13 H.sub.27n-C.sub.6 H.sub.13 n-C.sub.19 H.sub.39n-C.sub. 6 H.sub.13 On-C.sub.19 H.sub.39n-C.sub.7 H.sub.15 n-C.sub.4 H.sub.9n-C.sub.8 H.sub.17 On-C.sub.6 H.sub.13n-C.sub.9 H.sub.19 n-C.sub.15 H.sub.31n-C.sub.10 H.sub.21 On-C.sub.5 H.sub.11n-C.sub.11 H.sub.23 n-C.sub.14 H.sub.29n-C.sub.12 H.sub.25 On-C.sub.18 H.sub.37______________________________________
EXAMPLE 2
In the same manner as in Example 1, except for replacing the compound of formula: ##STR42## with a compound of formula ##STR43## to obtain a compound of ##STR44## in a yield of 67%.
EXAMPLE 3
A compound of ##STR45## was prepared in the same manner as in Example 2, in a yield of 56%.
EXAMPLE 4
A compound of ##STR46## was prepared in the same manner as in Example 2. Yield: 58%.
Table 4 below shows compounds which can be prepared in the same manner as in Example 2.
TABLE 4______________________________________ ##STR47##R R'______________________________________C.sub.2 H.sub.5 C.sub.2 H.sub.5n-C.sub.3 H.sub.7 On-C.sub.6 H.sub.13n-C.sub.4 H.sub.9 n-C.sub.11 H.sub.23n-C.sub.5 H.sub.11 On-C.sub.16 H.sub.33n-C.sub.6 H.sub.13 n-C.sub.3 H.sub.7n-C.sub.6 H.sub.13 On-C.sub.3 H.sub.7n-C.sub.6 H.sub.13 n-C.sub.6 H.sub.13n-C.sub.6 H.sub.13 On-C.sub.6 H.sub.13n-C.sub.6 H.sub.13 n-C.sub.8 H.sub.17n-C.sub.6 H.sub.13 On-C.sub.8 H.sub.17n-C.sub.6 H.sub.13 n-C.sub.10 H.sub.21n-C.sub.6 H.sub.13 On-C.sub.10 H.sub.21n-C.sub.6 H.sub.13 n-C.sub.12 H.sub.25n-C.sub.6 H.sub.13 On-C.sub.12 H.sub.25n-C.sub.7 H.sub.15 n-C.sub.3 H.sub.7n-C.sub.8 H.sub.17 On-C.sub.8 H.sub.17n-C.sub.9 H.sub.19 n-C.sub.14 H.sub.29n-C.sub.11 H.sub.23 On-C.sub.10 H.sub.21n-C.sub.12 H.sub.25 n-C.sub.20 H.sub.41______________________________________
EXAMPLE 5
In the same manner as in Example 1, except for replacing the compound of formula: ##STR48## with a compound of formula: ##STR49## to obtain a compound of ##STR50## in a yield of 71%.
EXAMPLE 6
In the same manner as in Example 1, except for replacing the compound of formula: ##STR51## with a compound of formula: ##STR52## to obtain a compound of ##STR53## in a yield of 68%.
Table 5 below shows compounds which can be prepared in the same manner as in Example 5 or 6.
TABLE 5______________________________________ ##STR54##R X Y R'______________________________________C.sub.2 H.sub.5 H F n-C.sub.4 H.sub.9n-C.sub.3 H.sub.7 H F On-C.sub.8 H.sub.17n-C.sub.4 H.sub.9 F H n-C.sub.14 H.sub.29n-C.sub.5 H.sub.11 F H On-C.sub.18 H.sub.37n-C.sub.6 H.sub.13 H F C.sub.2 H.sub.5n-C.sub.6 H.sub.13 H F OC.sub.2 H.sub.5n-C.sub.6 H.sub.13 F H On-C.sub.5 H.sub.11n-C.sub.6 H.sub.13 H F On-C.sub.5 H.sub.11n-C.sub.6 H.sub.13 H F n-C.sub.7 H.sub.15n-C.sub.6 H.sub.13 H F On-C.sub.7 H.sub.15n-C.sub.6 H.sub.13 F H n-C.sub.8 H.sub. 17n-C.sub.6 H.sub.13 F H On-C.sub.8 H.sub.17n-C.sub.6 H.sub.13 H F n-C.sub.10 H.sub.21n-C.sub.6 H.sub.13 H F On-C.sub.10 H.sub.21n-C.sub.6 H.sub.13 F H OC.sub.11 H.sub.25n-C.sub.6 H.sub.13 F H On-C.sub.12 H.sub.25n-C.sub.7 H.sub.15 H F n-C.sub.4 H.sub.9n-C.sub.8 H.sub.17 H F On-C.sub.10 H.sub.21n-C.sub.9 H.sub.19 F H n-C.sub.11 H.sub.23n-C.sub.10 H.sub.21 F H On-C.sub.6 H.sub.13n-C.sub.11 H.sub.23 H F n-C.sub.11 H.sub.23n-C.sub.12 H.sub.25 H F On-C.sub.16 H.sub.33______________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | An optically active compound represented by formula (I): ##STR1## wherein R represents a straight chain alkyl group having from 2 to 12 carbon atoms; R' represents a straight chain alkyl or alkoxy group having from 1 to 20 carbon atoms; C represents an asymmetric carbon atom; A represents ##STR2## and X and Y each represents a hydrogen atom or a fluorine atom, provided that X and Y do not simultaneously represent a fluorine atom. The compound (I) reduces a temperature dependence of the threshold voltage of a nematic liquid crystal composition when added thereto in a small amount. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to amplitude modulated carrier signals and more specifically to the demodulation of these signals.
2. Description of the Prior Art
The well-known process of using amplitude modulation to recover a baseband signal is the usual method utilized to recover modulated information such as gyroscopic output information. The demodulation of sensor signals can be extended to include quadrature detection demodulation so as to output the sine and cosine components as referenced to the case coordinate system of the sensor.
There are several prior art techniques available for performing in-phase and quadrature demodulation of an amplitude modulated double sideband suppressed carrier signal. The requirement exists, however, for an apparatus that not only addresses the need to demodulate a sinusoidal signal, but also the need to convert this demodulated signal into digital format. All of the prior art techniques, however, require analog circuitry to perform the demodulation process and then separately, the demodulated signal is digitized with an analog to digital converter.
Analog circuits are subject to many error sources including temperature sensitivity, noise, and induced error voltages from EMI. These error sources can be addressed in traditional ways, but in applications that have a small scale factor of the output signals, any additional noise presents major problems and such sources must be carefully scrutinized.
Temperature compensation can be performed to minimize temperature related errors such as bias drifts but any compensation requires knowledge of the system that is often acquired from empirical testing Such testing is time consuming and therefore expensive.
Noise encountered in analog circuits can generally be classified into a few specific categories such as Johnson noise, flicker or 1/f noise, shot (or Schottky) noise or popcorn noise. The error contribution of each type of noise must be studied and weighed to determine a correct method of reduction. This analysis adds cost and time delays to the final product.
The requirement still exists for an accurate yet inexpensive method for demodulation of a sinusoidal signal into in-phase and quadrature components digital data.
SUMMARY OF THE INVENTION
In accordance with the present invention an amplitude modulated double sideband suppressed carrier signal containing unknown amplitude and phase information for in-phase and quadrature components is demodulated. This invention uses voltage to frequency converters, digital counters and a computer to combine the demodulation and analog to digital converter (ADC) process into one step thus providing for a simpler and less costly method of demodulation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a hardware block diagram of the present invention.
FIG. 2 illustrates a sine waveform.
FIG. 3 illustrates a multisensor counter timing diagram.
FIG. 4 illustrates Group 1 data samples.
FIG. 5 illustrates Group 2 data samples.
FIG. 6 illustrates cosine, sine counts versus VAC input for VIN=COS (WT).
FIG. 7 illustrates Group 3 data samples.
FIG. 8 illustrates Group 4 data samples.
FIG. 9 illustrates Group 5 data samples.
FIG. 10 illustrates Group 6 data samples.
FIG. 11 illustrates cosine, sine counts versus VAC input for VIN= - COS (WT).
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a digital in-phase and quadrature demodulator. Embodiments of this invention can be used in a wide variety of applications where sinusoidal signals containing unknown amplitude and phase information are desired to be demodulated. For purposes of this discussion, an application involving an acceleration sensor, having one output sinusoidal signal, will be used to illustrate one embodiment of the present invention.
FIG. 1 illustrates sensor 11, VFC and counter board 12 and interface board 13 residing within computer 14. A PC-XT will be used as the computer for this discussion. As can be seen, sensor 11 is outputting 2 signals, an acceleration sinusoidal signal (Vl) 15 and a phase reference pulse (PRP) 16. These signals are input to VFC and counter board 12 and then to computer 14 where they are demodulated using a digital demodulation scheme. The following is a description of the signals that are output from sensor 11 and an overview of the digital demodulation process of the present invention.
As stated above, the outputs of sensor 11 consist of one acceleration sinusoidal signal 15 and one phase reference pulse 16. The acceleration signal is a sinusoidal wave whose amplitude is proportional to the applied external specific force of acceleration and whose phase is related to the position of the input acceleration vector to a fixed point on the case of the unit. The frequency of the sinusoidal is the spin frequency of the rotating sensing platform. A spin frequency of 50 HZ will be used for this example. The PRP 16 is an analog pulse that is output by sensor 11 one time per revolution of the rotating head assembly. The purpose of this pulse is to indicate the phase position of the rotating platform with respect to a fixed position on the case of the sensor.
The purpose of the present invention is to implement a digital demodulation scheme to measure the amplitude and phase of the sinusoidal signal. The approach to be taken to perform this demodulation process is to convert the acceleration sinusoidal signal 15 into digital pulses which are accumulated by digital counters. The phase reference pulse 16 is used to enable counter and latch 18 to latch the state of the counters at specific times and to inform the computer 14 to sample the state of the counters. By sampling the state of the counters at these appropriate times, software is able to measure the input sinusoidal signals. The amplitude is then directly proportional to the magnitude of the acceleration being experienced by sensor 11.
The mathematical representation of the acceleration sinusoidal signal (VI) 15 that is output from the sensor is as follows:
Vl=Ax cos(Ws*t)+Ay sin(Ws*t)
Where Ax and Ay are the input specific forces of acceleration as referenced to the sensor's case and Ws is the spin frequency of the rotating elements of the sensor. Although this technique will work for a wide range of Ws frequencies, Ws will be assumed to be 50 Hz for the discussion of this embodiment of the invention.
This signal is then sent through the demodulator where it is resolved into the x case 23 and y case 24 coordinate systems i.e. the in-phase and quadrature components. The mathematical expression of the signal which is output from the demodulator is as follows:
Vx(case)=Ax cos(Ws*t)
Vy(case)=Ay sin(Ws*t)
The symbol indicates that this is a measurement.
This demodulation, in part, is implemented digitally by integrating (counting) the pulses from the voltage to frequency converter (VFC) 17. This count information is accumulated in four subcounts for each 50 Hz cycle. Assume for the moment that the incoming voltage is represented by "sin (Ws*t)". The counter is cleared out at the beginning of the 50 Hz sinusoid and the count is read as the waveform passes through the 90 degree position. This constitutes the first subcount. Subcounts are acquired for the 90 to 180, 180 to 270, and 270 to 360 degree positions. These 4 subcounts are named A1, A2, A3 and A4 respectively.
Using the calculus integral operation, Al is the integral of Vl over the interval from 0 to 90 degrees. Therefore Aj is the delta count information as computed by reading the count at the t0 point and again at the t90 point. Then Al equals the count at t90 minus the count at t0. So for the sine wave as shown in FIG. 2:
sin(Ws*t)=A1+A2-A3-A4
and likewise for a cosine wave
cos(Ws*t)=A1-A2-A3+A4
and so the complete demodulated outputs from the computer are:
Ax(case)=(A1-A2-A3+A4)
Ay(case)=(A1+A2-A3-A4)
The phase reference pulse is output one time per revolution of the rotating platform and therefore can be used to reference the phase of the output signals. This pulse is always lined up with the X case axis of the sensor and so this pulse is lined up with the peak amplitude of the Ax*cos(Ws*t) waveform.
FIG. 3 illustrates the relationship of the various timing signals. The PRP is output from the sensor and indicates the position of the spinning platform which contains the transducer elements. This small amplitude analog signal is run into a signal conditioner (19 of FIG. 1) which first uses a rate deriver to calculate the rate of change of the input signal. This derived signal is then passed to a comparator also within signal conditioner (19 of FIG. 1) that fires at a reference voltage, generating a sharp clock edge at the center of the PRP. This digitized version of the PRP which occurs at the spin frequency (Ws), is run into a Phase Locked Loop (PLL) (20 of FIG. 1) that is set up to generate a square wave clock (4 Ws) which is four times the frequency of the PRP. This 4 Ws pulse (21 of FIG. 1) is used to latch the contents of the counters at the 0, 90, 180, and 270 degree points of the input sinusoidal waveform.
The sinusoidal acceleration information is directed to a voltage to frequency converter (VFC) which outputs digital pulse trains proportional to the amplitude of that sine wave. These VFC's output a digital pulse train whose frequency is proportional to the amplitude of the input voltage. The VFC's are setup to output a frequency of about 900 KHZ when the input voltage is at +5 VDC, 500 Khz when the input voltage is at 0.0 VDC and about 100 KHZ for an input voltage of -5 VDC. Therefore when a sinusoidal wave that swings to +5 Vpeak to -5 Vpeak and is centered around zero volts is input to the VFC, the output looks like an FM signal. The digital pulses that are output are a 0 to +5 VDC pulse of 400 ns duration.
As indicated in FIG. 1 the VFC pulse trains are run into counter and latch 18 which has synchronous counters that accumulate the number of pulses occurring in a given time interval determined by the 4 Ws signal described above. At the rising edge of the 4 Ws signal a latch command is generated by a latch synchronization circuit within counter and latch 18 to store the present count in the latches. When the 4 Ws pulse latches the count it also sets certain bits in a status word. A polling scheme is employed whereby the computer tests this bit to know when to read the count data.
FIG. 3 illustrates the timing relationship of the various signals involved in generation of the latch command. The latching process is initiated by each rising edge of the 4 Ws data pulses. Since the VFC pulses and the PRP are asynchronous to each other, care must be taken to synchronize the latching of the data and the occurrence of a sensor data pulse so that the counters are given sufficient time to settle at the new count before their output is stored in the latches.
The accumulators, that is the digital counters, actually perform an integration of the input signal and by integrating over the correct Periods the sine and cosine information of the demodulation scheme can be derived. In order to determine the phase relationships of the input accelerations, the computer must read the accumulated pulses synchronously. Computer and accumulator synchronization is achieved by the Ws signal in conjunction with a computer issued synchronization reset. This allows the computer to know the start and end of a complete revolution of the spinning elements in the sensor.
The hardware used to interface the VFC 17 and counter and latch 18 to the computer 14 over the data bus, address bus and control lines 22 is located on an interface board 13 which resides in a prototype slot of the PC-XT. Standard buffers and discrete logic gates exist on interface board 13.
The following will describe the software organization of this preferred embodiment. The algorithm is implemented by a program called "IDHSOD". This stands for Integer Demod Heap Statistics Optionally store to Disk. This program reads the counter data at the appropriate times, and calculates the demodulation data. After the data collection process is accomplished the statistical mean and standard deviation of all the data is computed. As a user option, the data accumulated from the complete run which is accumulated in RAM can be stored in a disk.
Since, in this embodiment, the sensor is spinning at 50 Hz, the computer needs to read data 4 times per revolution. This means the computer must take a reading at a 200 hz rate (5 ms). The maximum VFC output frequency is about 900 KHZ so the maximum count that could be accumulated in a 200 HZ period is 900 KHZ/200 Hz=4500 or about 4096 (12 bits). This allows integer arithmetic to be used in many of the computations. The program flow for this IDHSOD program is described by way of the following pseudo code.
IDHSOD PSUDOCODE:
begin
initialize the screen;
determine the amount of data to be collected;
display free memory available in RAM;
initialize all data variables;
display beginning system time;
synchronize hardware and software to the sensor;
pulse done calc; ( * for code timing only); repeat
synchronize HW/SW
get a batch of data;
add a record to RAM;
until all batches of data have been collected;
display system time;
calculate the statistics;
optionally display the heap to the screen;
optionally store the RAM contents to the disk;
display free memory available in RAM; end IDHSOD;
The sets of data illustrated in the figures were taken by inputting a sinusoidal voltage at a specified phase, with respect to a phase reference pulse, into the VFC and counter board. For testing groups 1 to 4, each reading is the statistical mean of 1000 readings.
The Group 1 data as shown in FIG. 4 illustrates the basic functionality of the invention. A plot of the group 1 data as shown in FIG. 6 illustrates that the data measurement of voltage is quite linear. Also note that the data is not purely cosine but has some small component of a sine wave. The actual misalignment phase angle is constant for all readings in the set and calculates out to be about: ##EQU1##
Group 2 data as shown in FIG. 5, as opposed to Group 1 data, inputs a sine wave. Note that the counts of the sine are now much larger than the cosine but again there is some small pickup on the cosine axis.
Group 3 data as shown in FIG. 7 is similar to Group 1 data and is presented to show the ability to detect the inversion of the cosine wave. Plot 2 as shown in FIG. 11 is a plot of this data group.
Group 4 data as shown in FIG. 8 illustrates the ability of the demodulator of the present invention to accurately measure signals with varying phase angles.
Group 5 data as shown in FIG. 9 illustrates the ability of the demodulator of the present invention to extract data in the presence of various DC offsets. One major benefit of working with AC signals is their insensitivity to DC voltage offsets. Notice that performance in this area is quite good.
Group 6 data as shown in FIG. 10 demonstrates the convergence of the data for various sized data population samples with a constant input voltage.
Plots 1 and 2 as shown in FIGS. 6 and 11 indicate that the measurement technique is linear. The scale factor of the conversion scheme works out to be: ##EQU2## The LSB weighting is 462 micro volts per LSB of count.
This technique can be used in all applications where a requirement exists to Perform in-phase and quadrature demodulation of a sinusoidal signal to determine the amplitude and phase of two orthogonal sets of input signals. This technique can reduce the cost, weight, and volume of the apparatus required to perform this demodulation and digitization process. An example of this invention would be sensors that output measured body rates or accelerations in the form of sinusoidal data.
It is not intended that this invention be limited to the hardware or software arrangement, or operational procedures shown disclosed. This invention includes all of the alterations and variations thereto as encompassed within the scope of the claims as follows. | A digital demodulator utilizes voltage to frequency converters, digital counters and a computer to combine demodulation and analog to digital conversion into one step, therefore providing for in-phase and quadrature demodulation of amplitude modulated double sideband suppressed carrier signals. Accleration sinusoidal signals and phase reference pulses are input to a voltage to frequency converter and counter board which interfaces to a computer where the signals are demodulated using a digital demodulation scheme. | 7 |
BACKGROUND
[0001] The present invention pertains to rechargeable electric vehicle batteries, and in particular a battery management system to prolong the operational life of battery cells in electric vehicles. One object of the present invention is to protect battery systems misuse from the failure of adjacent systems external to the battery system's control domain. Further objects of the invention are to control cell voltage, pack voltage and temperature, and measure cell and/or package (cycle count), capacity (a function of Coulomb counting), individual cell or string internal resistance (a function of loaded vs. unloaded bi-directional power performance, vehicle speed, energy data or commands, regenerative energy data or commands, brake blending data or commands, charger data or commands and any other control oriented data.
[0002] Battery management systems may be designed as active, passive, or a combination thereof, and may be designed to implement control algorithms internally or accept control inputs from an external source. In certain cases, external commands can be accepted and evaluated to determine a battery's ability to respond to the command.
[0003] In applications using a large number of cells, data communication with other systems generally occurs via established industry-standard protocols, such as RS232, RS485, J1850, CAN, LIN, MOST, FlexRay, etc. However, for lower cell count applications, it is possible to operate a highly simplified system without the use of these protocols, having a few discrete signals, typically 0-5 Volt “discrete I/O” which can serve to maintain control function “communication” with one or a few external systems. Such simplified communication has several advantages low cost hardware, reduce or eliminated programming requirements and comparatively simple and reliable operation.
[0004] Monitoring Cell and Pack Voltage:
[0005] By far, the safest method of control and protection involves measuring individual cell voltages. With proper control functionality, this data ensures that the operation of the pack, which is limited by the “weakest” cell in the pack, does not result in detrimental effects to any individual cell. The term ‘weakest’ refers to an individual cell's ability to provide or accept current and is closely related to a cells internal resistance.
[0006] The performance of a cell within a pack depends on relatively equal values of internal resistance and voltage compared to other cells in the pack. Internal resistance has been shown to strongly correlate to anode and/or cathode condition which typically deteriorates with a cell's cycle life. Individual cell voltage performance “softens” with this deterioration, meaning that the affected cell voltage drops readily as power is drawn.
[0007] Historically, measurement of pack voltage has typically been used to establish a pack “state-of-charge” (SOC), however, as is the case in lithium polymer (LiPol) electrochemistry, a relatively flat voltage profile makes for a highly uncertain SOC estimation when based solely on pack voltage. Rather, complex SOC algorithms must be implemented to accurately assess LiPol SOC. Pack voltage data can be used effectively as data for timely arbitration, for example, of a current command from a DC/DC converter, a propulsion controller, a charger controller or other applications.
[0008] Pack Current Measurement:
[0009] The measurement of current being processed through a pack of cells is used to assess performance to a command. Source current, providing energy to an external load (propulsion or housekeeping) is typically controlled by limits enforced by an operating strategy for propulsion and “housekeeping” loads. Often, the primary limiting parameter is a prescribed lower voltage limit. However cell or pack temperature factors should also be used to enforce such current limits.
[0010] Temperature:
[0011] Critical to the performance of a battery system is operation within safety and performance defined temperature limits. Performance limiting and shut-down algorithms based on a temperature profile assists in preventing conditions which could lead to a variety of problems such as cell deterioration due to under or over temperature conditions, and in particular, over temperature exothermic runaway (potentially leading to a fire).
[0012] It is therefore an object of the BMS of the present invention to protect cells from over charging, which might lead to an exothermal runaway reaction; and also to prevent cell damage from discharge below established limits. It is another object of the BMS to extend battery life, and extend the range of an electric vehicle using a cell array. These and other objects will become apparent from the following summary, description and claims.
SUMMARY
[0013] The Battery Management System of the present invention employs the following functions; voltage sensing, temperature sensing, voltage limit sensing, and current limit sensing. Charge control is employed for optimal system operation, and to ensure proper cell balancing control during charging. A main charge prolongs battery charge time. The invention also comprises a SOC look-up table for monitoring and diagnosis. The SOC function monitors the voltage, current and temperature of the cells. It also performs data storage and diagnosis function, and an alarm/error message to provide warnings. Finally, a user interface is provided for communication to the electric vehicle propulsion controller and communication to the intelligent main charger.
[0014] Balancing individual cell voltages while charging can occur by charge depletion. With charge depletion, the energy contained in the higher voltage cells is converted to heat to achieve an equal uniform voltage among the pack cells. Although this method is the least efficient in terms of energy retention, this is outweighed by its simplicity and low cost of implementation. In a preferred embodiment of the present invention, the following controller boards are used to implement the various battery management activities: a system controller board, a controller area network (CAN) interface and a battery management board (BMS).
FIGURES
[0015] FIG. 1 is a diagram of the overall system of the present invention, including the system controller board, CAN bus and battery management box comprising a BMS board and battery cells.
[0016] FIG. 2 is a diagram of the BMS battery box of the present invention comprising temperature inputs and circuit shunting circuitry.
[0017] FIG. 3 , is a diagram of the system controller board and associated interfaces of the present invention, including the connection of the system controller board to the BMS.
DESCRIPTION
[0018] Referring to FIG. 1 , a system for managing the battery power in an electrically powered vehicle is shown. The system comprises a system controller board 1 connected via a controller area network (CAN) bus 4 to a battery management system (BMS) board 2 and battery array 3 . The BMS board monitors the charge of individual batteries and governs the flow of electricity to individual batteries in the array; in a manner that charges less highly charged cells first, allowing them to “catch up” to more highly charged cells. In this manner, the cells are always charged evenly. prolonging the life of the cells.
[0019] Specifically, the BMS board reads the voltages of a group of cells, and shunts a portion, including all, charging power to the lowest charged cell or cells in the group. When the lowest charged cell or cells in the group obtain a charge higher than the formerly second lowest charged cell or cells, the EMS board shunts power to these cells. By repeating this operation, an entire array of cells may be charged evenly.
[0020] Referring to FIG. 2 , in one preferred embodiment, an array of battery cells comprises an 8-cell stack, wherein each stack is associated with its own BMS board. Each cell stack and associated EMS board is contained in a battery box for protection of the cells and BMS board, and to serve as containment means in the event of a malfunction. The BMS board contains eight channels of analog input to measure cell temperature, and current shunt circuitry accomplishes charge balancing. Additionally a solid state temperature sensor measures heat sink temperature and provides a board ID.
[0021] In a further preferred embodiment, each local 8-cell stack is connected to its corresponding BMS board's analog ground in the middle of the stack to minimize common mode error. An RC circuit low pass filter at the output of each amplifier reduces high frequency noise, and a microcontroller on the system controller board controls the 12V CAN interface power on/off.
[0022] Still referring to FIG. 2 , the CAN interface is optically isolated to compensate for the high voltage difference between a 12V battery on the vehicle and the voltage from the cell stack. A 120 Ω terminating resistor is connected externally at the last battery node on the CAN bus. In an alternate embodiment, the terminating resistor is externally connected. In one preferred embodiment, the total current drawn from the CAN bus does not exceed 1.2 amps. In another preferred embodiment, a standard vehicle CAN bus is used.
[0023] To measure cell voltages, high voltage unity-gain difference amplifiers, channels 1 - 96 , are used. To minimize the potential for common mode error, each local eight-cell stack is connected to the BMS board's analog ground in the middle of the stack. A resistor-capacitor filter at each amplifier's output reduces high frequency noise. Cell voltages are then read using the BMS processor's internal 10-bit analog-to-digital converter (0-Vdd range). By reading a precision 4.096V voltage on another analog-to-digital channel, the cells' absolute voltages can be interpreted.
[0024] For data communications, the software in the BMS maps the cell voltage readings into a single byte expressing a voltage value. In one preferred embodiment, the voltage value range is 2.50V to 5.05V with a resolution of 10 mV. However, the maximum voltage that can be measured is the Vdd supply voltage. Vdd supply voltage is nominally 5V, varying according to voltage regulator tolerance. In this manner, for example, one board may be able to measure up to 5.50V, while another board may max out at 4.97V.
[0025] To monitor and maintain the temperature of each battery box, a system of thermistor inputs monitor battery cell temperature. In one embodiment the thermistors are disposed between individual cells in an array. A precision pull-up resistor forms a voltage divider between thermistors in an array. The voltage divider ratio is accurately determined by an internal analog-to-digital converter on the BMS processor. Since the reference voltage of the analog-to-digital converter and the pull-up resistor voltage are the same, the conversion is inherently ratiometric. The voltage divider ratio allows the thermistor resistance to be determined, and a look-up table yields the temperature.
[0026] Each battery box further comprises a solid state temperature sensor, measuring the temperature of a heat sink in the box. Each of the temperature sensors contains a unique identifier, in one embodiment a serial number, which can be used to uniquely identify each BMS board and the battery box with which it is associated.
[0027] The BMS board further comprises charge balancing heat sink circuitry comprising cell management channels for each of the cells in an array, including the preferred embodiment of 8 cells. A constant-current circuit controlled by a processor can draw approximately 200 mA away from its corresponding cell. This current sink circuit allows lower charged cells to “catch up” to higher charged cells.
[0028] For all cells, when the processor turns on the optoisolator, a darlington power transistor also turns on and forces current through a resistor and diode; wherein the diode provides temperature compensation to the current control loop since its forward voltage drop temperature coefficient is close to that of the transistor base-emitter on voltage. The current sink circuit is adjusted up or down by changing the value of the resistors, or by controlling the on/off duty cycle of the circuit. Most of the energy associated with the diversion of current from individual cells is conducted to a power resistor. For any cell, the power dissipation will be proportional to the cell voltage, and the overall power dissipation will increase with the number of cells balancing.
[0029] Referring to FIG. 3 , the system controller board is shown and described. The system controller board comprises an means for providing a CAN interface to the battery management board, and an interface to the driver interface computer. The driver interface computer governs the vehicles instrumentation controls and provides an interface to other subsystems of the vehicle. Subsystems of the vehicle include power control of the computer; current measurement for current provided by an external battery charging means, motor drive and solar provided current; vehicle speed and distance measurement; fuel gauge control; shutdown relay; and outputs to drive auxiliary devices.
[0030] IN a preferred embodiment, the system controller board is powered by the vehicles on-board 12V battery, and comprises means for self-resetting, current overage, and voltage/reverse voltage protection.
[0031] The system controller board powers on whenever the vehicle key switch is on. In other embodiments, the board powers on if the battery charger is connected, if current is delivered from an external source, for instance a solar array, and in another embodiment, the system controller board remains on.
[0032] Auxiliary devices may be driven by high current MOSFET switch outputs. In one embodiment, two switch outputs are used. Communication with the driver interface computer is accomplished with an RS2322 serial interface. Fuel gauge control comprises programmable voltage output digital to analog conversion. A serial interface is provided on the system controller board, and in a further embodiment, two bidirectional RS232 serial interface channels are available, with a standard 9-pin D-type connector. Power, including low voltage power, and control of the power functions of the driver interface computer are also governed by the system controller board. In one embodiment, the maximum current provided by the system controller board is 1.2 amps.
[0033] The system controller board further comprises current measurement means, including current sensing functions. Current sensors may include two Hall-effect current sensor measurement channels powered by a DC-DC converter supplies power to the current sensors. The current measurement channels may be identical, and the controller board can activate and deactivate the converter to conserve power. The current measurement functions further include resistors and capacitors that form a filter that attenuates common mode and differential mode RF interference in the channels. In a preferred embodiment, the sensors comprise a difference amplifier, and gain is programmed according to the formula:
[0000] G =1+((180 K )/( R 21+20 K )).
[0034] To address high frequency noise on the signal coming from the amplifier, and the signal is read using the system controller board's internal analog-to-digital converter.
[0035] The system controller board comprises a vehicle speed sensor interface using a differential amplifier to detect signal from a wheel speed sensor. The differential amplifier detects pulses from the transmission output shaft sensor, and lower value resistors are used to detect a decrease in amplitude input signal. Logic level signals are applied directly to the Vss+ input on the system controller board in instances where a jumper is installed, and speed signal integrity is displayed on an LED array.
[0036] The vehicle fuel gauge is driven by a digital-to-analog (DAC) converter associated with the system controller board. A 12-bit DAC is used with a programmable output voltage ranging from 0 to 4.095 volts.
[0037] In addition to subsystems, the system controller board controls the vehicle's main power. Control is obtained using a relay with both normally open and normally closed contacts. Two 10 amp, 60 volt open-drain MOSFET outputs are installed on the system controller board to control external devices.
[0038] All features disclosed in this specification, including any accompanying claims, abstract, and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0039] Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. § 112, paragraph 6. In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. § 112, paragraph 6.
[0040] Although preferred embodiments of the present invention have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, is to be understood that the present invention has been described by way of illustration and not limitation. | A battery management system for the propulsion batteries of an electric vehicle comprises means for voltage sensing, temperature sensing, voltage limit sensing, and current limit sensing. Charge control is employed for optimal system operation and ensures cell balancing by detecting the lowest charged cells in a cell stack and charging those cells first, thereby ensuring that all cells charge uniformly. Charge control is accomplished on a battery management circuit board associated with battery cells in a battery box, while control of the battery management board is governed by a system controller board through a controller area network interface. The system controller board uses data from the battery management board to govern charge characteristics of the batteries, and supply data and control functions to a driver interface computer. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
BACKGROUND
[0003] The present disclosure relates to roadway snow and ice control and more particularly to a system that employs a six-bit hydraulic manifold onboard a dump truck and in a stationary brine control assembly.
[0004] A variety of commercial proposals involve spreading granular salt, brine, or brined salt on roadways for snow and ice control. Such proposals include, for example, U.S. Patents Nos. Re 33,835, U.S. Pat. Nos. 5,318,226, 5,988,535, 6,446,879, and 7,108,196. A related proposal for making brine is found in U.S. Pat. No. 6,736,153.
[0005] Despite such advances in this art, inconsistence in salt spreader output from the dump truck, auger bypass, and inaccurate reporting of salt usage still exist. Considering that in a moderately severe winter, salt usage by the State of Ohio, for example, could exceed $100,000,000 annually, there is a strong drive to improve such salt roadway distribution.
[0006] One method to decrease salt usage would be to enable salt spreader trucks to place light loads (say, 100 to 200 pounds/mile). Right now minimum accurate salt usage ranges from about 400 pounds/mile on up to 1,000 pounds/mile or more.
[0007] Of course, additional improvements in the salt spreading operation could save additional governmental funds, as well as more reliably spread salt and brined salt on roadways for ice and snow control.
[0008] It is to such improvements that the present disclosure is addressed.
BRIEF SUMMARY
[0009] Disclosed is a system for precisely controlling distribution of saline, which employs a 6-bit manifold employing 6 solenoid valves for controlling the flow of hydraulic fluid therethrough. The manifold is in hydraulic fluid communication with motor valves. A mathematical formula or a lookup table determines the amount of saline distributed. The system is devoid of feedback. The 6-bit manifold can be employed on a salt spreader vehicle for controlling an improved flighted auger assembly for distributing granular salt from the rear of a salt spreader vehicle. The auger assembly has 3-stages of increasing diameter flights. The largest flight is at a discharge end of the auger assembly. A choke surrounds the ultimate auger flight at the auger assembly discharge end. The space between the choke and the ultimate flight is between about ⅛ and ¼ inch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a fuller understanding of the nature and advantages of the present method and process, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:
[0011] FIG. 1 is an overhead layout of salt, brine, and brined salt generation station; and a salt truck loading/washing operation;
[0012] FIG. 2 is piping schematic for the layout in FIG. 1 ;
[0013] FIG. 3 is an overhead schematic for the brine making and brine storage tanks and associated piping;
[0014] FIG. 4 is an overhead schematic of the wastewater recycling tank and associated piping;
[0015] FIG. 5 is an overhead schematic of the blend tank and associated piping;
[0016] FIG. 6 is an overhead schematic of the calcium chloride (CaCl) tank and associated piping;
[0017] FIG. 7 is an overhead schematic of the BEET tank and associated piping;
[0018] FIG. 8 is schematic hydraulic diagram showing the components employed in the new 6-bit hydraulic manifold for the brine station;
[0019] FIG. 9 is block diagram illustrating the operation of the truck fill by the end user using the operator key fob;
[0020] FIG. 10 is a block diagram illustrating the operation of the recipe setup by the station manager;
[0021] FIG. 11 is the control panel used by the end user for selecting the desired truck fill;
[0022] FIG. 12 is a perspective view of a key fob;
[0023] FIG. 13 is the control panel;
[0024] FIG. 14 is the control pad on the control panel used by the station manager of FIG. 13 ;
[0025] FIG. 15 is left elevational view of a truck outfitted with the six-bit hydraulic manifold and other features disclosed herein;
[0026] FIG. 16 is the rear elevational view of the truck of FIG. 15 ;
[0027] FIG. 17 is side sectional view of the 3-stage auger with tight choke, as carried by the rear of the truck of FIG. 16 ;
[0028] FIG. 18 is a sectional view through line 18 - 18 of FIG. 17 ;
[0029] FIG. 19 is schematic hydraulic diagram showing the components employed in the new 6-bit hydraulic manifold for the salt spreader on the truck of FIG. 16 ;
[0030] FIG. 20 graphically plots steps versus gallons per minute of salt in tests of the disclosed apparatus;
[0031] FIG. 21 is the salt truck control panel;
[0032] FIG. 22 is an exemplary table of the disclosed six-bit manifold valve positions for its 63 steps; and
[0033] FIG. 23 is a block diagram of a control circuit that may be employed for the salt truck.
[0034] The drawings will be described in greater detail below.
DETAILED DESCRIPTION
[0035] As disclosed above, the ability to dispense salt in finer quantities is one way to reduce unnecessary use/consumption of salt in connection with the formation of brine and the dispensing on roadways of salt, brine, and brined salt. The six-bit manifold disclosed herein is a component that achieves such reduced salt consumption, along with additional features disclosed herein.
[0036] Referring initially to FIG. 1 , an overhead layout of salt, brine, and brined salt generation station; and a salt truck loading/washing operation is depicted. A brine truck, 10 , is seen in a wash bay, 12 , by while a salt spreader truck, 14 , loaded with granular salt is seen in its salt loading position. A control room, 16 , also is seen within the building complex along with an equipment room, 18 . Wash bay 12 has a power washer control panel, 20 , located along one of the walls common with equipment room 18 . A key fob sensor panel, 22 , is located on one of the outside walls of control room 16 . A recipe control panel, 24 , is located on one of the inside walls of control room 16 .
[0037] Housed within building area, 26 , as indicated by the dashed line, is the brining complex, such as is described in U.S. Pat. No. 6,736,153. Components include a brine/vegetable matter tank, 28 (BEET), recycle tank (RECYC), 30 , calcium chloride tank, 32 (CaCl), blend tank, 34 (BLEND), a first brine tank, 36 (BRINE), a second brine tank, 38 (BRINE), a brine maker, 40 , a semi fill hose, 42 , and truck fill hose, 44 . Each of the tanks 28 - 38 are 10,000 gallon tanks made of and/or lined with material resistant to corrosion by salt and brine.
[0038] Referring now to the piping schematic in FIG. 2 , each brine tank 36 and 38 is in fluid connection with a positive displacement pump, 46 and 48 , respectively, which pumps are powered by hydraulic motors, 50 and 52 , respectively. The output from the brine tank pumps 46 and 48 runs to bypass valve, 54 , one branch recycling to positive displacement pumps 44 and 48 and the other branch running through a check valve, 56 , and into a mixer tube, 58 .
[0039] BEET tank 28 also has a positive displacement pump, 60 , powered by a hydraulic motor, 62 , running to a bypass valve, 64 , having a recirculation line indicated by the dotted line and also running through a check valve, 66 , into mixer tube 58 . In similar fashion, CaCl tank 32 also has a positive displacement pump, 68 , powered by a hydraulic motor, 70 , running to a bypass valve, 72 , having a recirculation line indicated by the dotted line and also running through a check valve, 74 , into mixer tube 58 .
[0040] The flow exiting mixer tube 58 runs through a valve, 76 , which has a flow back through a check valve, 78 , into blend tank 34 and a flow running through a check valve, 80 , to another tee, 82 , and into truck fill hose 44 . The material in blend tank 34 flows through a check valve, 84 , into tee 82 and onward to truck fill hose 44 .
[0041] Material in brine tank 38 can be pumped by a pump, 86 , through a check valve, 88 , and into a tee, 90 , to truck fill hose 44 . Alternatively, material in brine tank 38 can be pumped by a high volume pump, 92 , and into semi fill hose 42 .
[0042] Referring now to FIG. 3 , brine tanks 36 and 38 are seen. As mentioned earlier, each tank has a maximum capacity of 10,000 gallons. Brine tank 36 is connected to brine tank 38 through a line 47 . A sensor, such as a float sensor, 94 , indicates that brine tank 38 is filled to capacity, which causes any brine flow into brine tank 36 and 38 to cease. Brine tank 36 / 38 can be filled from brine maker 40 , which receives material from RECYC tank 30 and/or domestic water, which flows using a centrifugal pump, 95 , and into brine maker 40 . A recirculation loop, 96 , uses another centrifugal pump, 98 . A centrifugal pump, 100 , pumps brine from brine maker 40 into brine tanks 36 and 38 .
[0043] Referring now to FIG. 4 , RECYC tank 30 is fitted with a float sensor, 102 , indicates that RECYC tank 30 is filled to capacity, which causes any flow into RECYC tank 30 to cease. Material used in wash bay 12 is collected and recycled into RECYC tank 30 , through a heater, 104 , which keeps RECYC tank from freezing.
[0044] Referring now to FIG. 5 , a sensor, such as a float sensor, 106 , indicates that BLEND tank 34 is filled to capacity, which causes any flow into BLEND tank 34 to cease. Material from mixing tube 58 can flow into a recirculation loop, 108 , powered by a pump, 110 , for causing a circulation flow inside BLEND tank 34 with provision to divert the recirculation loop flow to fill hose 44 .
[0045] Referring to FIG. 6 , CaCl tank 32 is shown with provision of its contents, 30% aqueous calcium chloride, to calcium chloride pump, 68 , in FIG. 2 . Again, the capacity of CaCl tank 32 is 10,000 gallons.
[0046] Referring to FIG. 7 , BEET tank 28 is shown with a recirculation loop, 112 , for causing a recirculation flow thereinside using another centrifugal pump, 114 . While this tank often will be filled with byproduct from sugar beet production, other vegetable material may be used alone and/or in addition to the indicated sugar beet byproduct. Such vegetable material further depresses the freezing point of brine.
[0047] Referring now to FIG. 8 whereat a schematic hydraulic diagram showing the components employed in the new 6-bit hydraulic manifold for the brine station is set forth. Important in using such 6-bit hydraulic manifold is that no feedback loop is required. Simply, such 6-bit hydraulic manifold provides 63 steps in controlling flow, which yields an error of about 2% at most and often less than about 1%. In particular, such manifold relies simply on 6 precise orifices that can be used in any combination, yielding the noted 63 steps. Only one of the three 6-bit manifolds will be described in detail, as the other two shows 6-bit hydraulic manifolds operate in precisely the same fashion. General operation of a similar 4-bit device is disclosed in U.S. Pat. No. 7,108,196 ( FIG. 6 ). The present 6-bit manifold operates in similar fashion.
[0048] Referring now to a 6-bit hydraulic manifold, 116 , six-solenoid controlled orifices of different size are shown. In particular, a solenoid, 118 , uses a suitably sized orifice for a 0.25 gpm (gallon per minute) flow; a solenoid, 120 , uses a suitably sized orifice for a 0.5 gpm (gallon per minute) flow; a solenoid, 122 , uses a suitably sized orifice for a 1.0 gpm (gallon per minute) flow; a solenoid, 124 , uses a suitably sized orifice for a 2.0 gpm (gallon per minute) flow; a solenoid, 126 , uses a suitably sized orifice for a 4.0 gpm (gallon per minute) flow; and a solenoid, 128 , uses a suitably sized orifice for a 8.0 gpm (gallon per minute) flow. Manifolds 130 and 132 are identical to manifold 116 . Manifold 116 controls the BEET tank; manifold 130 controls the CaCl tank; and manifold 132 controls the Brine tank 38 .
[0049] Associated with manifold 116 is a compensator, 134 , functioning to provide a constant speed or pressure drop for motor 62 BEET tank 28 . Compensators 136 and 138 generally provide the same function as compensator 134 for CaCl tank motor 70 and the brine tank motors 50 and 52 , respectively. Operator input for the mixing of concentration in BEET tank 28 is at pump 60 ; pump 58 for CaCl tank 32 , and pumps 46 / 48 controlled by valve 140 and manifold 132 for brine tanks 36 , 38 . Operator input for motor 85 of pump 86 is through valve 142 (truck fill brine only) and motor 91 of pump 92 through valve 44 (semi fill), and motor 109 of pump 110 through valve 146 (stir blend tank or truck fill from blend tank) and motor 113 of pump 114 through valve 148 (stir BEET tank).
[0050] Referring now to FIGS. 9-12 , displayed is the block diagram illustrating the operation of the truck fill by the end user using an operator key fob, 158 (see FIG. 12 ), and key fob sensor panel 22 (see FIG. 1 ). Operation commences at START at block 160 with the truck operator scanning key fob 158 at block 162 by passing key fob 158 over sensor area, 168 of panel 22 (see FIG. 11 ). At block 164 , the operator rotates a knob, 170 on panel 22 (see FIG. 11 ), to select filling a semi, filling a truck with brine, or filling a truck with a mixed recipe. If the operator selects “Semi”, the operation proceeds to block 172 where the operator pulls a button, 174 on panel 22 ( FIG. 11 ). Operation then proceeds to block 176 where the computer selects semi fill pump. Operation next proceeds to block 178 where the pump 92 is activated to begin delivery of product into the semi. At block 180 , the operator pushes button 174 to stop pump delivery of product. Operation then ends at block 182 .
[0051] When the operator rotates knob 170 to select “mix”, operation proceeds to block 184 where the operator pulls knob 174 “on”. Operation proceeds to box 186 where the computer selects the current mix recipe. Operation then proceeds to box 188 where the pumps 46 , 48 , 60 , and 68 are activated to begin delivery of product. At box 190 , the operator pushes knob 174 in to stop delivery of product. Operation then ends at box 192 .
[0052] When the operator rotates knob 170 to select “brine”, operation proceeds to block 194 where the operator pulls knob 174 “on”. Operation proceeds to box 196 where the computer selects brine only pump 86 . Operation then proceeds to box 198 where pump 86 is activated to begin delivery of product. At box 200 , the operator pushes knob 174 in to stop delivery of product. Operation then ends at box 202 . Referring now to FIGS. 10-14 , control panel 24 is shown in FIG. 13 containing an interactive display, 204 , shown enlarged in FIG. 14 . The block diagram in FIG. 10 starts at box 206 with the plant operator at box 208 selecting values for flow rate for brine, CaCl, BEET or other agricultural agent, each by percentage. Such selection is made on control panel 204 as indicated by the numerical values of percent displayed thereon. The computer automatically calculates the flow rates for each tank based on the percentages inputted with an indicated delivery rate. Operation proceeds to block 210 where the operator saves the recipe by assigning a one or two character value using the lower number inputs on control panel 204 . At block 212 , the operator can recall any saved recipe by entering the correct assigned number. Operation ends at block 214 .
[0053] The computer retains a formula in memory for calculating/determining the combination of each aperture to be open/closed by their respective solenoid valves. As an example of such calculations for Brine and CaCl, the following is given:
[0000] AG_GPM=0.356*AG_SET
[0000] CALC_GPM=0.356*CALC_SET
[0000] BRINE_GPM=0.712*BRINE_SET
[0000] TOTAL_GPM=AG_GPM+CALC_GPM+BRINE_GPM
[0000] AG_%−(AG_GPM/TOTALGPM)*100
[0000] CALC_%=(CALC_GPM/TOTALGPM)*100
[0000] BRINE_%=(BRINE_GPM/TOTALGPM)*100
[0054] Referring now to FIGS. 15 and 16 , delivery truck 14 is illustrated. For a detailed description of it, reference is made to the description of truck 10 in U.S. Pat. No. 6,382,535. The '535 truck will be the same as the present truck, except for the use of the 6-bit manifold and modified auger disclosed herein.
[0055] Referring now to FIGS. 17 and 18 , an auger assembly, 216 , includes a housing, 218 , and auger 220 having 3-stages, 220 a, 220 b, and 220 c, each with increasing flight diameter, respectively. A motor, 221 , drives auger 220 . At the discharge end of the auger, a housing, 228 , houses auger 220 . A close fitting choke, 230 , fits around the end flight on auger 220 to ensure a reliable and consistent delivery of salt. A gap of around ⅛ to ¼ inch between the choke and auger flight is desired. The increasing diameter flights help resist cavitation and ensure the ability to delivery salt at the low rates discussed above. Additionally, an eccentric vibrator, 231 ( FIG. 15 ) was added to the bed of truck 14 to assist in urging salt to be moved from the bed to the auger when the salt was near exhaustion. A sensor activates the vibrator when the rate of salt feed to the auger diminishes through pressure switches 236 and 238 in FIG. 19 .
[0056] Referring to FIG. 19 where the 6-bit manifold for truck 14 is set forth, it is substantially similar to the 6-bit manifold described in FIG. 8 for the brine plant. In the present truck 6-bit manifold, the apertures are designed for ¼, %, 1, 2, 4, and 8 GPM (gallons per minute). Sixty-three steps, thus, are possible from such manifold design for enabling delivery from as little as 100 pounds/mile on up to 1,000 pounds/mile or greater with intermediate values of 200, 300, 400, 500 pounds/mile, etc., fully implementable.
[0057] Unlike the plant 6-bit manifold, the truck 6-bit manifold uses a lookup table, an example of which is given in FIG. 22 . Manifold 232 controls the auger/spreader and utilizes solenoid valves 234 a (0.25 gpm), 234 b (0.5 gpm), 234 c (1.0 gpm), 234 d (2.0 gpm), 234 e (4.0m gpm), and 234 f (8.0 gpm). A temperature sensor is seen at 242 . The main relief is seen at 244 . Item 245 is the auger compensator input. Manifold 246 controls the spinner and manifold 247 controls the wetting, as is described in U.S. Pat. No. 7,108,196, so a detailed description of these will not be given herein. The same is true for bed/plow sections 248 and 249 .
[0058] FIG. 20 graphically plots steps versus gallons per minute of brine in tests of the disclosed apparatus in FIG. 19 . The truck operator control panel is illustrated in FIG. 21 . Its operation is as described in U.S. Pat. No. 7,108,196.
[0059] Referring to FIG. 23 , a block diagrammatic representation of a microprocessor driven control function for vehicle 14 and it associated snow-ice control features is identified generally at 250 . The control function operates in conjunction with six sensor functions. In this regard, a hydraulic system low fluid sensor is provided as represented at block 252 . A hydraulic system temperature sensor function is provided as represented at block 253 . Hydraulic system low-pressure sensor function is provided as represented at block 254 , and a hydraulic system high-pressure sensor is provided as represented at block 255 . The functions represented at blocks 252 - 255 provide inputs as represented at respective lines 258 - 261 to the analog-to-digital function represented at sub-block 264 of a microprocessor represented at block 266 . Microprocessor 266 may be provided as a type 68HC11 marketed by Motorola Corporation. Device 266 is a high-density complimentary metal oxide semi-conductor with an eight-bit MCU with on-chip peripheral capabilities. These peripheral functions include an eight-channel analog-to-digital (NO) converter as noted above. An asynchronous serial communication interface is provided and a separate synchronous serial peripheral interface is included. Its main sixteen-bit, free-running timer system has three input capture lines, five-compare lines, and a real time interrupt function. An eight-bit pulse accumulator sub-system can count external events or measure external periods. Device 266 performs in conjunction with memory (EPROM) as represented at bi-directional bus 270 and block 272 . Communication also is provided via bus 270 with random access memory (RAM) as represented at 274 and function 274 may be provided, for example, as an OS 1644 non-volatile time-keeping RAM marketed by Dallas Semi-Conductor Corporation. The LCD display is represented at block 276 . A type DV-16100 S1FBLY assembly, which consists of an LCD display, a CMOS driver and a CMOS LSI controller marketed by Display International of Oviedo, Fla., may provide this function. Digital sensor inputs to the microprocessor function 266 are provided from a speed sensor represented at block 278 and line 280 . In general, the speed sensor will output 40,000 pulses per mile of vehicle travel, which equates to 7.5 pulses per foot. A two-speed sensor digital input is supplied to microprocessor 266 as represented at block 282 and line 284 .
[0060] The circuit power supply is represented at block 286 . This power supply, providing two levels of power, distributes such levels where required as represented at arrow 288 . Supply 286 is activated from the switch inputs of truck control panel ( FIG. 21 ) and represented in the instant figure at block 290 and arrow 292 . These various console and auxiliary console or control box switch inputs as represented at block 290 also are directed, as represented at arrow 294 to serial parallel loading shift registers as represented at block 296 . As represented by bus 298 , communication with the function at block 296 is provided with the microprocessor function represented at block 266 . Bus 298 also is seen directed to a 48 -channel driver function represented at block 300 . Function 300 may be implemented with a 48 -channel serial-to-parallel converter with high voltage push-pull outputs marketed as a type HV9308 by Supertex, Inc. The output of the driver function represented at block 300 is directed, as represented by arrow 302 , to an array of metal-oxide semiconductor field effect transistors (MOSFETS) as represented at block 304 . These devices may be provided as auto-protected MOSFETS type VNP10N07F1 marketed by SGS-Thomson Microelectronics, Inc. The outputs from the MOSFET array represented at block 304 are directed as represented by arrow 306 to solenoid actuators as represented at block 308 . An RS 232 port is provided within the control function 250 as represented at block 310 and arrow 312 communicating with microprocessor function 266 .
[0061] While the device and method have been described with reference to various embodiments, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope and essence of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed, but that the disclosure will include all embodiments falling within the scope of the appended claims. In this application all units are in the metric system and all amounts and percentages are by weight, unless otherwise expressly indicated. Also, all citations referred herein are expressly incorporated herein by reference. | Disclosed is a system for precisely controlling distribution of saline, which employs a 6-bit manifold employing 6 solenoid valves for controlling the flow of hydraulic fluid therethrough. The manifold is in hydraulic fluid communication with motor valves. A mathematical formula or a lookup table determines the amount of saline distributed. The system is devoid of feedback. The 6-bit manifold can be employed on a salt spreader vehicle for controlling an improved flighted auger assembly for distributing granular salt from the rear of a salt spreader vehicle. The auger assembly has 3-stages of increasing diameter flights. The largest flight is at a discharge end of the auger assembly. A choke surrounds the ultimate auger flight at the auger assembly discharge end. The space between the choke and the ultimate flight is between about ⅛ and ¼ inch. | 4 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with Government support under Contract DE-AC0676RLO1830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] Various types of micro-fabricated devices have been used in the fields of chemical separations and analysis including capillary electrophoresis, capillary isoelectric focusing and nano column separations (where both flow channel and stationary phase supporting particles can be directly fabricated on chip). As electrospray ionization mass spectrometry (ESI-MS) has become a widely used analytical technique, considerable efforts have been directed at the development of interfaces for chip-based devices with electrospray ionization mass spectrometers. Examples of the current available interfaces include an open channel interface. For example, Zhang, B.; Liu, H.; Karger, B. L.; Foret, F. Anal. Chem. 1999, 71, 3258-3264 shows an electrospray with modifications, while Ramsey, R. S.; Ramsey, J. M. Anal. Chem. 1997, 69, 1174-1178 and Xue, Q.; Foret, F.; Dunayevskiy, Y. M.; Zavracky, P. M.; Mcgruer, N. E.; Karger, B. L. Anal. Chem. 1997, 69, 426-430 show an electrospray without modifications, where an electrospray was generated directly from the open channel terminus, attaching a fused-silica capillary to the channel end where the joint was either sealed, as shown in Licklider, L.; Wang, X.; Desai, A.; Tai, Y.; Lee, T. D. Anal. Chem. 2000, 72, 367-375, Figeys, D.; Ning, Y.; Aebersold, R. Anal Chem. 1997, 69, 3153-3160, and Bings, N. H.; Wang, C.; Skinner, C. D.; Colyer, C. L.; Thibault, P.; Harrison, D. J. Anal. Chem. 1999, 71, 3292-3296, or made by a liquid junction, as shown in Forest, F.; Zhou, H.; Gangl, E.; Karger, B. L. Electrophoresis 2000, 21, 1363-1371 and Zhang, B.; Foret, F.; Karger, B. L. Anal. Chem. 2000, 72, 1015-1022. These, and all other references described herein, including without limitation patents, technical papers, or otherwise, are incorporated in their entirety by this reference.
[0004] Despite these advances, the reliability and/or ease of fabrication of these interfaces still presents significant problems for their broad applicability. Ideally the interface of a microfabricated device with a mass spectrometer should integrate the electrospray emitter with the device to form a complete separation and electrospray unit that can be readily replicated. As described in the paper “A Fully Integrated Monolithic Mircrochip Electrospray Device for Mass Spectrometry, Analytical Chemistry , Vol. 72, No. 17, Sep. 1, 2000, 4058-4063, Schultz and Corso recently described a concept for a microfabricated electrospray emitter array where photolithographic patterning and plasma etching were used to fabricate an array of electrospray emitters on a silicon wafer. The technique offered a potential solution to the problem of system integration for high-throughput applications where each spray nozzle can be connected to a different sample well and operated sequentially. A limitation associated with the use of silicon technology for electrospray emitter fabrication, as reported by Schultz and Corso, is that each spray nozzle array can only be used reliably for a little more than 1 h. Also, each nozzle in the array described by Schultz and Corso is designed to be interfaced with both the analyte source and the entrance to the mass spectrometer sequentially. As such, the device does not utilize the array to impact the analyte throughput, or the resulting signal strength, in the mass spectrometer. This is an important drawback, as generating a higher total ion current, given a liquid flow rate, is an important objective for enhancing the sensitivity of mass spectrometers.
[0005] Thus, there exists a need for improved interfaces between chip based separation and analysis devices with electrospray ionization mass spectrometers, and a particular need for improved devices which enhance the total ion current given a liquid flow rate.
BRIEF SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of the present invention to provide a method and apparatus that increases the total ion current introduced into an electrospray ionization mass spectrometer, given a liquid flow rate of a sample. This objective is accomplished by use of the surprising discovery that an array of spray emitters directed into a mass spectrometer produce a greater total ion current than a single emitter having the same liquid flow rate. Due to the small size of the emitters commonly deployed in mass spectrometry, the present invention is most conveniently constructed as an array of spray emitters fabricated on a single chip, however, the present invention should be understood to encompass any apparatus wherein two or more emitters are simultaneously utilized to form an electrospray of a sample that is then directed into a mass spectrometer.
[0007] When fabricated as a single chip, the array of spray emitters is interfaced with a liquid sample source, including but not limited to liquid separation devices, on one side of the chip. Suitable liquid separation devices include, but are not limited to capillary electrophoresis devices, capillary isoelectric focusing devices, and nano column separation devices. Typically, while not meant to be limiting, the liquid sample is interfaced with the chip by providing a single reservoir for the sample that is common to all of the spray emitters. However, in certain applications, it may be preferred to provide a separate reservoir for each emitter, or a plurality of reservoirs common, each feeding a portion of the emitters.
[0008] The other side of the chip is interfaced with the entrance to a mass spectrometer. Liquid samples are passed through the array, whereupon the samples are formed into an electrospray at each spray emitter within the array. The total electrospray formed at all of the spray emitters are then simultaneously introduced into a mass spectrometer. Preferably, while not meant to be limiting, the total electrospray is introduced into the mass spectrometer through a multi-capillary inlet, as more fully described in U.S. patent application Ser. No. 09/860,727 filed May 18, 2001, entitled “Improved Ionization Source Utilizing a Multi-Capillary Inlet and Method of Operation” by Smith et al. While not meant to be limiting, those skilled in the art will better understand the fabrication, operation, and advantages offered by the present invention, including its theory of operation, and the surprising increase in the total ion current generated by the device, through reference to the detailed description which follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0009] [0009]FIG. 1. is a schematic of an exemplary electrospray emitter array microfabricated to demonstrate a preferred embodiment of the present invention. FIG. 1( a ) shows an array of nine electrospray emitters arranged in a 3×3 configuration; FIG. 1( b ) shows the dimensions for each spray emitter in the array.
[0010] [0010]FIG. 2. is a schematic of the experimental setups used to demonstrate a preferred embodiment of the present invention. FIG. 2( a ) shows the experimental setup for the characterization of multielectrosprays generated from microfabricated emitter array and FIG. 2( b ) shows the experimental setup for the mass spectrometric evaluation of the microfabricated electrospray array.
[0011] [0011]FIG. 3. is a photograph of nine stable electrosprays generated from the nine-spray emitter array.
[0012] [0012]FIG. 4. is a graph showing the total spray ion current vs liquid flow rate for the single electrospray generated from a microfabricated single-spray emitter of the present invention and a fused-silica capillary for comparison using 50:50 methanol/water +1% acetic acid.
[0013] FIGS. 5 ( a ) and ( b ) are graphs showing the total spray ion current vs total liquid flow rate for (a) multielectrosprays generated from the microfabricated emitter arrays and (b) normalized by the number of electrosprays using 50:50 methanol/water +1% acetic acid.
[0014] FIGS. 6 ( a )( b )( c ) and ( d ) are mass spectrometric sensitivity comparisons between (a) single electrospray from fused-silica capillary and (b) three electro-sprays from microfabricated emitter array at flow rate of 1 íL/min, and between (c) single electrospray from fused-silica capillary and (d) four electrosprays from microfabricated emitter array at flow rate of 4 íL/min with 50 pg/íL reserpine in 50:50 methanol/water +1%acetic acid.
[0015] [0015]FIG. 7. is a graph showing the ESI-MS sensitivity improvement at different total liquid flow rates for a solution of 50 pg/íL reserpine in 50:50 methanol/water+1% acetic acid multielectrosprays as the ionization source.
DETAILED DESCRIPTION OF THE INVENTION
[0016] A prototype of the present invention was fabricated on a polycarbonate substrate using a laser etching technique, and a series of experiments were conducted with the prototype, to demonstrate the use and advantages of the present invention.
[0017] While the prototype was fabricated using a polycarbonate substrate and a laser etching technique, the present invention should in no way be viewed as limited to this embodiment. Accordingly, materials and techniques commonly used for the fabrication of microscale structures should be considered as within the scope of the present invention. Exemplary techniques would therefore include, but not limited to, laser etching, photolithographic patterning, wet chemical etching, laser ablation, plasma etching, casting, injection molding, and hot and cold stamping (embossing). Specific materials would include, but not be limited to, polycarbonate, plastic, glass, and silicon, as those materials are commonly used in the forgoing fabrication techniques. The products from these microfabrication techniques typically incorporate channels having micrometer range dimensions, and may further include valves for flow control and reservoirs for liquid storage. The use of such features also should be considered as within the contemplation of the present invention. Multiple layers of devices containing microfeatures can further be bonded together to form 3-D structures, and structures formed in this manner may be also be used to practice the present invention. While liquid flow in these structures is most often driven by the electroosmotic force induced by the electric field at the channel-liquid interface, the present invention should be understood to also include any motive force that directs liquid flow through an array of emitters, for example, pressure (e.g., using a syringe pump).
[0018] The prototype spray emitter arrays of the present invention were fabricated from a 1-mm-thick polycarbonate sheet using a laser etching method (Lumonics 848 excimer laser operating at 248 nm). FIG. 1 a shows a prototype where an array of nine electro-spray emitters were fabricated and arranged in a three by three configuration. The emitters were positioned 1.1 mm apart, and the spray emitter tip was ˜150 μm in diameter with a center channel 30 μm in diameter. The center through holes were first machined by laser ablation at a high demagnification factor (˜35×) using a small circular mask. The 450-μm-diameter and 250-μm-deep well around the each spray emitter was machined by reducing the laser beam demagnification factor to ˜5×. Because of the inherent taper of laser etching at low demagnification factors, the emitter tips produced in this way typically had a conical cross section, as illustrated in FIG. 1 b.
[0019] To enhance the hydrophobicity of the polycarbonate surface, the surface of the microchip was treated with a CF 4 rf plasma, or coated with a Teflon thin-film by sputtering coating technology after the spray emitter array was fabricated. The increased hydrophobicity of the treated polycarbonate surface prevented the sample solution from spreading over the edge of the emitter well and afforded stable electrosprays from each emitter.
[0020] To demonstrate multiple stable electrosprays using these prototype microfabricated emitter arrays, the arrays were mounted to a stainless steel block using the configuration shown in FIG. 2 a . The void behind the chip served as a liquid reservoir allowing a simultaneous supply of sample solution to each emitter. A syringe pump connected to the block through a standard LC fitting was used for sample infusion. The block assembly was mounted on an optical stand. A high-voltage dc power supply, connected to the metal block, was used to create the desired voltage difference relative to a metal counter electrode plate positioned ˜5 mm away. An electrometer was connected to the counter electrode for measurement of total electric current of multielectrosprays, which are refered to herein as the total ion current. Upon the establishment of stable multielectrosprays, further characterization of these “chip-based” electrosprays was also performed using this configuration. The solvent mixture of 50:50 methanol/water+1% acetic acid was used for all electrospray characterization experiments.
[0021] A stereo zoom microscope was used to monitor the electrospray in all the experiments and confirm spray stability. After the spray characterization, the microfabricated emitter array was further evaluated for its performance in electrospray ionization mass spectrometry, as shown in FIG. 2 b . A modified triple quadruple mass spectrometer (Sciex API 3000) was used in which the standard curtain gas-skimmer interface of the API 3000 was replaced with a heated multicapillary (7 — 500 ím) inlet and an electrodynamic ion funnel interface for improved spray desolvation and ion transmission efficiency, as described in U.S. patent application Ser. No. 09/860,727 filed May 18, 2001, entitled “Improved Ionization Source Utilizing a Multi-Capillary Inlet and Method of Operation” by Smith et al. and U.S. Pat. No. 6,107,628 entitled “Method and apparatus for directing ions and other charged particles generated at near atmospheric pressures into a region under vacuum” also issued to Smith et al.
[0022] The spray emitter array was positioned ˜5 mm away from the multicapillary inlet. The high-voltage dc power supply and syringe pump described in FIG. 2 a again provided electro-spray voltage and controlled liquid flow rate. Solutions of reserpine were used for evaluation of performance. The temperature of the heated multicapillary inlet was fixed at 200° C. A dc bias of 250 V was applied to the multicapillary block. The rf frequency and the amplitude applied to the ion funnel were 0.9 MHz and 130 Vp-p, respectively. The dc biases on the first ion funnel plate (25.4-mm i.d.) and the last ion funnel plate (2.3-mm i.d.) were 250 and 30 V, respectively, which resulted in an axial dc field of ˜20 V/cm in the ion funnel. The mass spectrometer was operated in the positive ESI mode, and the selected ion monitoring (SIM) mode was used for the evaluation of sensitivity.
[0023] [0023]FIG. 3 shows a photo of nine electrosprays generated from the nine-emitter array using the arrangement shown in FIG. 1. The emitter array was operated at a total infusion flow rate of 3 μL/min using a solvent mixture of 50:50 methanol/water +1% acetic acid. A stable electrospray was established from each emitter without the assistance of any nebulization gas, as demonstrated by the nine stable Taylor cones evident in FIG. 3. Interestingly, each electrospray showed a much smaller spray dispersion angle compared to that from a conventional single-capillary-plate configuration, which is ascribed to the significantly less divergent electric field between the electrospray emitter array and the counter plane electrode. The result is better focused electrosprays although a higher than typical voltage (˜7 kV for the electrode separation of ˜5 mm) is required to establish the stable electrosprays.
[0024] After stable electrosprays were established with the emitter array, the total spray ion current was measured at different liquid flow rates. To establish a baseline for all the comparisons, the total ion currents for single electrospray generated from both a conventional fused-silica capillary (100-im i.d. and 200-ím o.d. with the tip pulled down to 50 μm) and a microfabricated single-spray emitter were measured at different liquid flow rates. FIG. 4 shows the total ion currents measured at different flow rates.
[0025] The fact that the two sets of data in FIG. 4 correlate well indicates that the electrosprays had quite similar characteristics. It is also interesting to note from FIG. 4 that the total electrospray current fits a 0.44 power of liquid flow rate, very close to the theoretical prediction of de la Mora and Loscertales as described in De la Mora, J. F.; Loscertales, I. G. J Fluid Mech. 1994, 260, 155-184. Their analysis concluded that, for electrosprays of highly conductive liquids, the dependence of the total electrospray current on the liquid flow rate could be formulated as,
I s =f (ε)( QKy /ε) 1/2 (1)
[0026] where I s is the total spray current from single electrospray, K is the electric conductivity of the liquid, y is the surface tension of the liquid, ε is the dielectric constant of the liquid, and Q is the liquid flow rate. Equation 1 was derived through a detailed dimensional analysis of the charge transport process through the Taylor cone and was verified by the authors experimentally using variety of liquid mixtures. Good agreement between the experimental results shown in FIG. 4 and equation 1 supported the optical evaluation indicating that stable cone-jet mode electrosprays were obtained in the present studies.
[0027] Next, multielectrosprays were generated from the microfabricated chip using different numbers of emitters. The total ion currents of the multielectrosprays were measured at different liquid flow rates. The experimental data shown in FIG. 5 a clearly indicated that at each total liquid flow rate the total ion current increased as the number of the electrosprays increased. The results in FIG. 5 a also show that the total ion current from eight electrosprays was ˜3 times higher than from a single electrospray at the same total liquid flow rate. The reason for this is evident from equation 1. If one assumes that each electrospray in the array behaves identically to a single electrospray, then from eq 1,
I*=f (ε)( Q*Ky /ε) (2)
[0028] where I* and Q* are the ion current carried by each electrospray and the liquid flow rate supplied to each emitter in the array, respectively. It is apparent that Q* is smaller than the total liquid flow rate Q supplied to the emitter array. The total ion current of the multielectrosprays then becomes,
I Total = ∑ i = 1 n r i
[0029] where n is the total number of electrosprays generated from the emitter array.
[0030] If we further assume that the liquid flow is distributed uniformly into every emitter, i.e., Q*) Q/n, each electrospray in the array will then carry the same ion current. Equation 3 becomes
I Total =nI* (4)
[0031] Substituting eq 2 into eq 4, we have
I Total ={overscore (n)}f (ε)( Q*Ky /ε) 1/2 ={overscore (n)}I s (4)
[0032] total ion current from the multielectrosprays, compared to the ion current from single electrospray at a given total flow rate, is proportional to the square root of the number of electrosprays. To verify equation 5, the experimental data shown in FIG. 5 a were normalized by the number of electrosprays in FIG. 5 b . All the experimental data collapsed to provide a good fit by a single curve. These results support the assumptions used in the derivation of equation 5, i.e., that each electrospray carried approximately the same ion current in the multielectrospray and the liquid flow was distributed approximately equally to each spray emitter. Because of the higher ion current produced by the multielectrosprays, the potential of using multielectrosprays as an ionization source to enhance the sensitivity or dynamic range of mass spectrometry was further evaluated using the arrangement shown in FIG. 2 b . Sensitivity comparisons between a single electrospray using a fused-silica capillary and multielectrosprays from a microfabricated emitter array were performed using a solution of 50 pg/íL reserpine in 50:50 methanol/water +1% acetic acid introduced at different infusion flow rates. While all the MS parameter settings were held constant, the single electrospray and multielectrosprays sources were interchanged. FIG. 6 a and b shows the SIM mass spectra obtained for single electrospray and three electrosprays for a total sample infusion rate of 1 íL/min. A factor of 2 sensitivity enhancements was achieved using multielectrosprays as the ion source. Similar sensitivity enhancement was also achieved for four electrosprays at a sample flow rate of 2 íL/min compared to the single electrospray, as shown in FIG. 6 c and d . The experimental results are summarized in FIG. 7 where the number of electrosprays was varied from two to nine at liquid flow rates ranging from 1 to 8 íL/min. For comparison, the results from a single electrospray using a fused-silica capillary are also plotted in FIG. 7. A factor of 2-3 sensitivity enhancement was achieved using multielectrosprays at all the sample flow rates evaluated. It was also noted experimentally that stable multielectrospray could be generated at higher liquid flow rates compared to the fused-silica capillary single electrospray.
[0033] The sensitivity enhancements shown in FIG. 7 are consistent with the theoretical prediction of equation 5 if one assumes that the total electrospray current is the major parameter determining the ion intensity of the mass spectra.
[0034] It is particularly important to understand that the multiemitter ESI source can provide an even greater increase in dynamic range than suggested above. In many (or most) current ESI-MS applications (e.g., using liquid chromatography), much larger sample sizes or liquid flow rates are available than are of present practical utility with ESI. Thus, if all available ESI emitters were to be operated at a flow rate for maximum ion current production, the actual gain in total current would be approximately proportional to the number of emitters. For example, from FIG. 5 a , the eight-emitter array at 4 íL/min provides an ion current of 0.85 íA; that is more than 8 times greater than the ion current (˜0.1 íA) generated from a single capillary at 0.5 íL/min. Thus, a set of eight emitters each operating at 4 íL/min can potentially provide a current of more than 2 íA, much greater than that current achievable by any conventional ESI source used for mass spectrometry.
[0035] Closure
[0036] While a preferred embodiment of the present invention has been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. For example, while a preferred embodiment utilizing a 3×3 array arranged in a square pattern has been shown and described, it will be apparent to those having skill in the art that any arrangement of two or more emitters, which may further be arranged in a wide variety of geometrical arrangements, are possible, and will produce the enhanced sensitivity sought by the present invention. 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 method and apparatus that utilizes two or more emitters simultaneously to form an electrospray of a sample that is then directed into a mass spectrometer, thereby increasing the total ion current introduced into an electrospray ionization mass spectrometer, given a liquid flow rate of a sample. The method and apparatus are most conveniently constructed as an array of spray emitters fabricated on a single chip, however, the present invention encompasses any apparatus wherein two or more emitters are simultaneously utilized to form an electrospray of a sample that is then directed into a mass spectrometer. | 7 |
TECHNICAL FIELD
This invention relates to sighting devices for use with an archery bow, and, more particularly, to quick aiming sights for use in archery hunting.
BACKGROUND OF THE INVENTION
An archery sight for aiming the arrow or projectile is a virtual necessity for both competition shooting and for hunting. In general, such a sight consists of a plurality of horizontal, transversely extending pins in a vertical array, with the array affixed to the frame of the bow above the hand grip and arrow shelf. The free ends of the pins are beaded, in the manner of a rifle sight, to facilitate aiming. A peep-sight is mounted to the bowstring at the operator's eye level, and aiming is accomplished by aligning one of the beads with the target through the peep-sight. The horizontal pins are adjustable, both horizontally and vertically, for windage and elevation, respectively. Each of the pins can be set vertically for a specific range prior to actual use in hunting, for example, and in practice, the particular pin used will depend upon the archer's estimate of target range. Windage, i.e., horizontal adjustments of the pins generally must be done in the field, and where, for example, four pins set at different elevations or ranges are used, windage adjustment presents a delay where often speed is of the essence.
Where the peep-sight is affixed to the bowstring, as is generally the case, proper and consistent aiming requires that the bowstring be drawn in an absolutely consistent manner, with the same draw force and same finger location on the bowstring. These requirements are quite difficult to meet in hunting conditions.
In dim light it is difficult to sight through a peep hole at the appropriate bead and target. Efforts to alleviate the problems presented by dim light principally have been directed to providing some form of illumination for the bead, a solution that has not proven to be completely satisfactory for a number of reasons, among which are the difficulty in sighting on an illuminated bead through a peep-sight at an unilluminated target, and dependence upon an artificial source of illumination including a battery, which can fail at the most unpropitious moments.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned problems of the prior art in a first illustrative embodiment thereof wherein a longitudinal sight frame having front and rear end portions is adapted to be mounted to the frame of the bow in such a manner as to define a sighting direction. A front bracket is mounted to the sight frame at the front end portion and extends transversely thereto and to the sighting direction, and a rear bracket is mounted to the sight frame at the rear end portion thereof and extends parallel to the front bracket in the same direction. At least one sighting pin having a top end is mounted to the front bracket and extends vertically, parallel to the bow frame when the sight frame is mounted to the bow frame and normal to the sighting direction, and a notched sighting member is mounted to the rear bracket with the notch aligned with the top end of the sighting pin.
The sighting pin or pins are adjustable both laterally and vertically relative to the sight frame and the front bracket respectively, and a sight guard is mounted to the sight frame and substantially surrounds the sighting pins to protect them and their settings.
In another embodiment of the invention, for use with an overdraw attachment, the sight frame and front bracket are mounted to the bow frame, and the rear bracket is mounted to the rear of the overdraw attachment.
The various features and advantages of the present invention will be readily apparent from the following detailed description, read in conjunction with the accompanying drawing, in which:
DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a portion of a bow showing the sight attachment of the present invention mounted thereon.
FIG. 2 is a perspective view of the sight of the present invention for mounting on a bow.
FIG. 3 is an exploded perspective view of the sight of FIG. 2.
FIG. 3A is a partial elevation detail view showing the manner in which a sighting pin is mounted to the front bracket.
FIG. 4 is an elevation view of the sight attachment of the present invention as mounted on a bow and view from the archer's position.
FIG. 5 is a perspective view of a sight for use with an overdraw attachment and which embodies the principles of the present invention.
DETAILED DESCRIPTION
In FIG. 1 there is shown a bow frame 11 having upper and lower limbs 12 and 13 respectively, a hand grip 14 and an arrow shelf 16. Mounted to the bow frame 11 in a position above the hand grip 14 and arrow shelf 16, approximately level with the archer's eye, and defining a sighting direction as shown by the arrow, is a sighting attachment 17 embodying the principles of the present invention. For simplicity, the bowstring, which is connected between the free or distal ends of limbs 12 and 13, has not been shown.
FIGS. 2 and 3 depict the sighting attachment 17 in detail. Attachment 17 comprises a longitudinal sight frame 18 having a front end portion 19 and a rear end portion 21, with a central portion 22 joining the front and rear portions 19 and 21 and lying in a plane offset from the planes of portions 19 and 21 as shown. Portions 19 and 21 are preferably, although not necessarily, coplanar. Central portion 22 has a downwardly extending tang 23 having a slot 24 therein which is aligned with a slot 26 in portion 22 and mounting bolts, not shown, pass through slots 24 and 26 for mounting attachment 17 to frame 11, and afford a range of vertical adjustment of attachment 17 to accommodate the individual archer.
As best seen in FIG. 3, an L-shaped front bracket 27 is mounted to the front end portion 19 of frame 18 by suitable means such as bolts 28, 28. Bracket 27 extends normal to and out from portion 19, and, where attachment 17 is mounted on bow frame 11, transversely to the sighting direction. The normally extending leg of front bracket 27 has a longitudinal slot 29 therein for receiving first and second threaded sighting pins 31, 31 respectively, which pass therethrough. The top ends of pins 31 and 32 terminate in sighting beads 33 and 34, and the bottom ends terminate in knurled adjusting knobs 36 and 37. First and second indicator plates 38 and 39, through which pins 31 and 32 pass, rest on top of the leg of bracket 27 and are held in place by knurled nuts 41 and 42 threaded to pins 31 and 32 respectively. As best seen in FIG. 3A, nuts 41 and 42, only nut 41 being shown in FIG. 3A, each have a threaded lower portion 43 which passes through slot 29. Knurled nuts 44 and 46 having thread bores of a diameter sufficient to allow knurled knobs 36 and 37 to pass therethrough are screwed onto threaded portions 43 to hold the entire pin assembly in place, while leaving pins 31 and 32 free to turn in nuts 41 and 42 for any necessary adjustments. A sight or pin guard 47 which may take any of a number of forms, that shown here being a U-shaped rod, is bolted to portion 19 by means of nuts 48 and 49. Guard 47 protects pins 31 and 32 and their settings from being accidentally disturbed, and further protects against accidental snagging of the pins in heavy brush.
A rear L-shaped bracket 51 is mounted to rear end portions 21 by suitable means, such as bolts 52 and 53 passing through a slot 54 in end portion 21. The long leg 56 of bracket 51 extends outwardly from and normal to end portion 21, parallel to bracket 27, and across the line of sight when frame 17 is mounted on the bow. Leg 56 has a cut out portion 57 on its top edge over which a sighting plate 58 is mounted, as by bolts 59 and 61. Plate 58 has first and second notches 62 and 63 in its top edge which align with the top end beads 33 and 34 of pins 31 and 32, as best seen in FIG. 4.
The assembled sight is shown mounted on a bow in FIG. 4, as viewed from the archer's position. Windage corrections can be made by moving either or both of the pins 31 and 32 laterally, and range or elevation corrections can be made by moving them vertically. In addition, windage corrections can be had by sighting through either notch 62 or 63 at one of the pins, without the necessity of moving either pin laterally.
In FIG. 5 there is shown a modification of the sight of FIGS. 1 through 4 for use with a bow having an overdraw attachment, which has been shown in dashed lines. In the arrangement of FIG. 5, the front and rear brackets 27 and 51 are the same as in FIGS. 1 through 4, and will not be described further. Front bracket 27 is mounted to a sight frame 66 on a front portion 67 thereof, and frame 66 is mountable to the bow by means of a rear portion 68 having a slotted tang 69. Rear bracket 51 is mounted to the rear end of the overdraw attachment by means of a mounting bracket 71 and aligned with the front sight assembly as shown, for example, in FIG. 4.
It can be seen that the notch and bead arrangement of the present invention is less vulnerable to sighting problems resulting from dim light than is a peep-sight arrangement. Further, adjustment of the pins for both range and windage can be accomplished expeditiously in the field, thus making the sight readily adaptable to changing conditions. In addition, it is not always necessary to adjust the sight for windage inasmuch as the combination of two beads and two sighting notches constitutes a built-in windage compensator.
The numerous features and advantages of the present invention have been shown in first and second illustrative embodiments thereof. Various changes or modifications may occur to workers in the art without departure from the spirit and scope of the invention. | An archery sight for use with a bow has one or more adjustable beaded sighting pins extending vertically, parallel to the bow frame. A notched sighting plate is mounted remote from the pins with the notches aligned with the pins in the sighting direction. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application (under 35 U.S.C. §371) of PCT/DE2008/075004, filed Aug. 21, 2008, which claims benefit of German application 20 2008 002 233.9, filed Feb. 18, 2008.
DESCRIPTION
The present invention relates to a kitchen slicer comprising a slicer frame with a feed plate, a fixed plate and a blade, whereby the blade is arranged between the feed plate and the fixed plate, it is affixed to the fixed plate, and the front edge of the feed plate is offset with respect to the blade by a selectable cutting thickness.
BACKGROUND AND STATE OF THE ART
Such a kitchen slicer is previously known from German patent specification DE 103 28 506 B4. The problem of setting the cutting thickness is remedied by the solution presented there in that the kitchen slicer comes with several different feed plates that are interchangeable. Each individual feed plate establishes a specific cutting thickness so that a different cutting thickness can be achieved by changing a feed plate or by turning a feed plate.
Generally speaking, such kitchen slicers are used to process fruit and vegetables, a procedure in which sliding the food over a blade cuts the food into slices. For this purpose, a feed plate is provided on which the food is pushed towards the blade. The feed plate is positioned lower than the blade so that a gap that is the same size as the cutting thickness is created between the feed plate and the blade. The blade is arranged on a fixed plate on which the sliding movement of the food continues beyond the blade. In addition to the above-mentioned possibility of changing the cutting thickness, it is likewise a known procedure to configure the feed plate at a slant in such a way that a greater slant translates into a greater cutting thickness.
SUMMARY OF THE INVENTION
Before the backdrop of this state of the art, the present invention has an objective of putting forward a kitchen slicer that provides an alternative option for varying the cutting thickness.
According to one aspect of the invention, a kitchen slicer having a slicer frame is provided that allows the feed plate to be moved so as to remain parallel to the fixed plate. This parallel movement can allow the food to move straight towards the blade, which results in a more uniform cutting of the food. Moreover, this is particularly advantageous when a food holder is employed since the holder can always be held parallel to the two plates, which makes it easier to guide the food holder. Such a movement of the feed plate should especially be stepless so that the desired cutting thickness can be selected at will.
This can be done, for instance, by means of a height-adjustment guide provided in the slicer frame above the feed plate. In particular, the height-adjustment guides are configured in such a way that the feed plate can be repositioned in the height-adjustment guide perpendicular to the pushing direction of the food. Here, a guide in the form of grooves is provided which is arranged vertically in the slicer frame. The height-adjustment guides thus configured are closed off especially towards the blade (top), thereby defining the highest setting position for the feed plate. In the opposite direction, however, the height-adjustment guides are advantageously open, so that the feed plate can be removed, for instance, in order for the device to be cleaned. The feed plate has height-adjustment tabs so as to engage with the height-adjustment guides, thereby ensuring a reliable and uniform guidance.
The device is augmented in that a positioning slide is associated with the feed plate. Such a positioning slide has several sliding surfaces on which the feed plate is mounted so as to slide. Here, the sliding surfaces are positioned at a slant so that a lateral movement of the positioning slide relative to the feed plate also causes a movement of the latter. The feed plate has corresponding runners that can be placed onto the sliding surfaces. In a particularly advantageous manner, the sliding surfaces of the positioning slide are folded over and these folded-over edges run in matching grooves of the feed plate. As a result, the feed plate can be carried along upwards as well as downwards by the positioning slide.
Grooves are likewise associated with the positioning slide that runs in these grooves, but this is a lateral guide that is now arranged horizontally relative to the vertical height-adjustment guide of the feed plate. Therefore, if the positioning slide is moved along the lateral guide, then it presses against the feed plate, with the result that the feed plate—which is mounted so that only its height can be changed—can now only deflect upwards or downwards. Due to the runners or the sliding surfaces and the folded-over edges, a certain force is exerted onto the feed plate, so that a movement of the positioning slide in one direction raises the feed plate, while a movement in the opposite direction lowers the feed plate.
Accordingly, the positioning slide likewise has means in the form of lateral guide tabs that engage in the lateral guide. In contrast to the guide for the feed plate, the lateral guides, of course, cannot be open towards the bottom, which is why they have an insertion guide for inserting the lateral guide tabs into the lateral guides. It is via these lateral guides that the positioning slide can be returned to its original position after being cleaned.
In a particularly advantageous manner, the positioning slide can be attached to the feed plate by means of a bolt that can engage—for instance, by being screwed in or clamped on—with a bolt catch arranged on the feed plate. The bolt, which clamps the positioning slide against the feed plate, defines the relative position between the feed plate and the positioning slide, and thus, owing to the corresponding runners or rails, also establishes the position of the arrangement as a whole in the slicer frame. The cutting thickness can be varied by releasing the bolt and moving the positioning slide into another desired position. As an alternative to this, the bolt can be in the form of an adjustment screw that, when it is turned, moves the positioning slide in the appertaining direction.
By the same token, however, the feed plate can be connected to the positioning slide via an eccentric adjustment knob. For this purpose, an eccentric suspension is shaped on the feed plate and it goes through the positioning slide. Another suspension part is arranged directly on the positioning slide. Turning the eccentric adjustment knob—which is joined to both suspension parts—causes the two elements to move with respect to each other. The eccentric adjustment knob can have a graduated scale that provides information about the cutting thickness that is currently set.
In a special or alternative embodiment, the feed plate can be moved upwards to such an extent that said feed plate covers the blade. This is a preferred storage position since the blade is thus covered in such a way as to avoid accidental cutting with the blade, that is to say, for instance, injury to the user.
The kitchen slicer can advantageously be used with a food holder that has a food chamber to accommodate the food to be sliced. The holder provides a gripping surface so that the user does not move the food itself over the blade, but rather only the appertaining food holder. This has the advantage that the user's fingers do not move closer to the blade as some of the food is cut off upon contact with the blade since this would entail the risk that the user's fingers might touch the blade.
In this vein, at least on its side facing the blade, the food holder has a projection on the wall surface that constitutes a protective shield that protects the fingers from the blade.
In order to likewise achieve a uniform guidance of the food holder, especially in order to ensure that the food holder does not strike against the blade, the food holder also advantageously runs in a guide groove into which it can be inserted using a guide edge. In order to ensure that the food holder is always placed onto the slicer frame properly during use of the food holder—especially in order to make it clear that the food holder may only be used in the direction of the provided guide grooves—directional arrows that indicate the proper direction of movement can be printed or embossed onto the food holder.
Particularly when it comes to a food holder that is held in a guide groove, it is practical for the holder to have a removable lid. In this case, the food to be sliced can also be inserted via the removable lid into the food holder or into the food chamber so that it is not necessary to disengage the food holder from its guide every time a new piece of food is to be sliced. In an advantageous manner, holding means, especially a holding plate, are associated with the lid, and said means can be retracted into the food chamber from the lid side. By means of this holding plate, which advantageously has teeth, spikes or the like, the food can be held in place inside the food chamber, so that here as well, it is possible to achieve a well-defined cut. The holding plate is preferably pressed against the food by a pressure spring, so that the food likewise cannot slip upwards towards the space in the food chamber, said spacing becoming larger as more and more of the food is processed.
Moreover, the bottom of the food chamber can have a cutout that runs through the center point of the food chamber. This allows the food holder to be used for elongated types of food that are to be sliced, for instance, carrots, which otherwise cannot be inserted into a food holder that is, for example, round in shape. Therefore, thanks to the cutout, even such foods can be centered.
The food holder very advantageously has gripping surfaces along its circumference with which the user can more firmly grip the food holder. Appropriately shaped surfaces which, when properly handled, are situated in the area of the user's fingertips, prevent the fingers from slipping when the food holder is being moved, thus increasing the convenience of use.
It is likewise possible for the food chamber to be at least partially transparent, in other words, to be made of a transparent plastic, so that the user can see into it from the outside.
Advantageously, the bottom of the kitchen slicer has at least one support shoulder by means of which the kitchen slicer can be placed onto the edge of a bowl that is to be filled, whereby very advantageously, the support shoulder is configured so that it can be removed if so desired.
DESCRIPTION OF THE DRAWINGS
The invention described above will be explained in greater detail below on the basis of embodiments and with reference to the accompanying drawings in which:
FIG. 1 —a kitchen slicer having a slicer frame and a food holder, in a perspective view at a slant from above;
FIG. 2 —the kitchen slicer according to FIG. 1 , in a plan side view;
FIG. 3 —the kitchen slicer according to FIG. 1 , in an exploded perspective view at a slant from below;
FIG. 4 —the kitchen slicer according to FIG. 1 , in a plan view from the bottom;
FIG. 5 —a food holder in a perspective view, at a slant from the front; and
FIG. 6 —an alternative food holder in a exploded perspective view, at a slant from above.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 1 shows a kitchen slicer 1 consisting of a slicer frame 10 and a food holder 20 . In order for a piece of food to be processed, the food is placed into the food holder 20 , which has a food chamber 21 for this purpose. The slicer frame 10 has a feed plate 11 as well as a fixed plate 12 , between which a blade 13 , preferably V-shaped, is arranged. In this context, the feed plate 11 is arranged below the blade 13 in such a way that the food that is being moved on the feed plate 11 towards the blade 13 strikes the blade 13 , a process in which it is sliced by the latter. In order to allow a desired cutting thickness to be set, the feed plate 11 can be moved steplessly surface-parallel to the fixed plate 12 on which the piece of food from which a slice has been cut off continues to move beyond the blade 13 . The slice of the food that has been cut off falls below the fixed plate 12 into a bowl (not shown) situated, for example, underneath the kitchen slicer 1 . For this purpose, the bottom of the kitchen slicer 1 has a support shoulder 19 that can be removed if necessary but which, in the arrangement shown in FIG. 1 , serves to rest on the edge of a bowl (not shown).
FIG. 2 shows the kitchen slicer 1 in a side view. The kitchen slicer 1 with the food holder 20 can be seen here, although the kitchen slicer 1 can certainly also be used without the food holder 20 . In this case, the holder is removed from its guide in which it normally runs along the surface of the kitchen slicer 1 in the slicer frame 10 , and the food can be pushed as desired over the blade 13 , also by hand.
FIG. 3 shows the structure of the kitchen slicer 1 in the form of an exploded view. Here, it can be seen that the feed plate 11 is movably mounted in the slicer frame 10 by means of height-adjustment guides 16 . Matching height-adjustment tabs 16 a on the feed plate 11 engage into the height-adjustment guides 16 , so that the feed plate 11 is prevented from deflecting in any direction other than in the vertical direction. Once the feed plate 11 has been put in place, it is followed by a positioning slide 14 which, in turn, runs in a lateral guide 17 . The positioning slide 14 has a plurality of sliding surfaces 18 a that match corresponding runners 18 on the feed plate 11 . If the positioning slide 14 is then pressed against the feed plate 11 , which is done by inserting the guide tabs 17 a into the lateral guide 17 , then the runners 18 of the feed plate 11 rest firmly on the corresponding sliding surfaces 18 a of the positioning slide 14 . The latter is held in the lateral guide 17 , in other words, it, in turn, can only deflect in a lateral direction. If the positioning slide 14 is moved, for instance, towards the blade, the feed plate 11 cannot follow such a movement since it is laterally affixed. For this reason, the feed plate 11 will deflect upwards due to force exerted by the sliding surfaces 18 a onto the runners 18 . In the opposite direction, a folded-over edge of the sliding surface 18 a —which engages with matching grooves in the area of the runners 18 of the feed plate 11 —ensures that the feed plate 11 will be carried along when the positioning slide 14 is moved in the other direction.
The positioning slide can be affixed, for example, by means of an eccentric adjustment knob 15 that is connected via an eccentric suspension 15 a to the feed plate 11 and to the positioning slide 14 .
In this context, FIG. 4 shows a plan view from the bottom of the kitchen slicer 1 in which the eccentric adjustment knob 15 is set to a “lock” position. In this position, the feed plate 11 is set beyond the height of the blade 13 so that the blade 13 is concealed behind the feed plate 11 . This prevents injury to a user due to accidental contact with the blade 13 . If the eccentric adjustment knob 15 is then turned to the left, owing to the eccentric suspension 15 a , the feed plate 11 and the positioning slide 14 move with respect to each other in such a way that the feed plate 11 is lowered with respect to the blade 13 . A graduated scale has been applied around the eccentric adjustment knob 15 , and said scale provides information about the cutting thickness that is currently set.
FIG. 5 shows a food holder 20 that has a semispherical food chamber 21 . The food holder 20 has a projection 23 that forms a protective shield for the user's fingers. Thanks to such a projection, the fingers can be kept outside of the area of the blade 13 , that is to say, the fingers are covered by the projection 23 . When the slicer is being used properly, the user holds the food holder by a grip 25 that has several gripping surfaces 24 and moves it back and forth over the slicer frame. In this process, the user can check the current filling level in the food chamber 21 of the food holder 20 since the outer wall is made of transparent plastic. Moreover, the food holder 20 has a cutout 22 in the area of its bottom which is provided in order to accommodate elongated types of food that are to be sliced. In this manner, the device can also be used to slice foods that cannot be accommodated in the food chamber.
FIG. 6 shows an alternative food holder 20 that has a removable lid 28 . This lid 28 has a holding plate 26 that is provided with teeth. These teeth pierce the food being held in the food holder 20 , so that the food is secured with respect to the lower surface. This allows a clean cut of the food, which is also pushed over the blade 13 with a certain amount of force. The holding plate is supported by means of a pressure spring 27 so that the holding plate 26 can extend downwards as the food continues to be sliced. The lid 28 can be secured with a closure 29 so that here as well, a closed food chamber 21 is formed.
Above, a kitchen slicer is described that allows the feed plate to be raised and lowered uniformly, thus ensuring that the food can be sliced uniformly.
While preferred embodiments of the invention have been described and illustrated here, various changes, substitutions and modifications to the described embodiments will become apparent to those of ordinary skill in the art without thereby departing from the scope and spirit of the invention.
LIST OF REFERENCE NUMERALS
1 kitchen slicer
10 slicer frame
11 feed plate
12 fixed plate
13 blade
14 positioning slide
15 eccentric adjustment knob
15 a eccentric suspension
16 height-adjustment guide
16 a height-adjustment tab
17 lateral guide
17 a lateral guide tab
17 b insertion guide
18 runners
18 a sliding surfaces
19 support shoulder
20 food holder
21 food chamber
22 cutout
23 projection
24 gripping surfaces
25 grip
26 holding plate
27 pressure spring
28 lid
30 closure | In order to set the cutting thickness in kitchen slicers, it is a known procedure to arrange a feed plate at a slant relative to the blade. As an alternative, solutions are known according to which the feed plates are changed so that a suitable feed plate is provided for each cutting thickness that can be set. The objective of the invention is to provide a simple alternative. Towards this end, the invention proposes that the feed plate ( 11 ) can be moved surface-parallel to a fixed plate ( 12 ) that is connected to the blade ( 13 ). This movement can be effectuated by means of a combination of vertical and horizontal movements of the feed plate and of a positioning slide ( 14 ) associated with said feed plate. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a thin film semiconductor substrate for a display device and its method for manufacturing incorporated in an active matrix-type liquid crystal display device used mainly for a direct viewing type display apparatus or a projection-type display apparatus.
A conventional prior art method for manufacturing a thin film semiconductor substrate to be incorporated in the active matrix-type liquid crystal display device is composed of the following processes:
(A) A process of making a single crystal semiconductor layer formed on a single crystal semiconductor substrate containing an insulating oxide film between them into a thin film semiconductor circuit layer by means of high resolution semiconductor processing;
(B) A process of sticking together the thin film semiconductor circuit layer and a support substrate with an adhesive layer between them; and
(C) A process of removing the single crystal semiconductor substrate by means of grinding or etching while leaving the oxide film layer of the single crystal semiconductor substrate and the thin film semiconductor circuit layer.
However, the above-mentioned conventional manufacturing method has the following problems.
In the process of removing a single crystal semiconductor substrate by means of the former manufacturing method, first, a thickness of 625 μm is shaved off to about 125 μm by means of grinding and next, the rest of it is removed by means of anisotropic etching while using the oxide layer as a stopper layer. In this case there is a problem such that before the etching is finished a thin film semiconductor circuit layer is destroyed by stripping off the thin film semiconductor circuit layer from its circumference part, since the etching agent penetrates into the boundary face between the support substrate and the adhesive layer from the circumference and erodes the adhesive layer as the etching proceeds and the thickness of the single crystal semiconductor substrate becomes reduced. Furthermore, where the difference in levels of a pattern of a thin film semiconductor circuit layer is large, there is also a problem that according to the progress of the etching and as the thickness of the single crystal semiconductor substrate becomes reduced, the stress concentrated on the level difference part of the pattern, which has been suppressed by the thickness of the single crystal semiconductor substrate until that time, becomes released, and exfoliation of the thin film semiconductor circuit layer begins at this point.
An object of the present invention is to solve the above-mentioned prior art problems and to provide a new method for manufacturing a thin film semiconductor substrate by removing a single crystal semiconductor substrate while leaving an oxide film layer and a thin film semiconductor circuit layer after sticking together a support substrate and the thin film semiconductor circuit layer formed on the single crystal semiconductor substrate and containing the oxide layer therebetween.
SUMMARY OF THE INVENTION
In a first embodiment, the present invention is characterized in that, after sticking together the thin film semiconductor circuit layer and the support substrate which are formed so as to contain therebetween the insulating oxide film layer, in a manufacturing method of a thin film semiconductor substrate by removing the single crystal semiconductor substrate while leaving the oxide film layer and the thin film semiconductor circuit layer, said thin film semiconductor circuit layer is stuck with said support substrate by means of a fluorine containing epoxy family resin adhesive. In another emobodiment, the invention is characterized in that, a thin film semiconductor circuit layer and a support substrate are stuck together by means of a fluorine containing epoxy family adhesive after forming a smoothing layer having silicon dioxide as the main ingredient on the thin film semiconductor circuit layer in a method for manufacturing a thin film semiconductor device by removing a single crystal semiconductor substrate while leaving an oxide film layer and a thin film semiconductor circuit layer after sticking together a support substrate and the thin film semiconductor layer formed on the single crystal semiconductor circuit substrate in a way to contain the oxide film layer therebetween.
In the thin film semiconductor device according to the present invention as described above, since a thin film semiconductor circuit layer and a support substrate formed on a single crystal semiconductor substrate containing an insulating oxide film layer therebetween are stuck together by means of a fluorine containing epoxy family adhesive of high chemical resistivity, subsequent etching off of the single crystal semiconductor substrate by using the oxide film layer as a stopper layer does not erode the adhesive layer. As a result, the etching process can be finished without exfoliation or destruction of the thin film semiconductor circuit layer from its circumference. Further, after the formation of a smoothing layer, having silicon dioxide as the main ingredient, on the thin film semiconductor circuit layer, formed on a single crystal semiconductor substrate with an oxide film layer between the circuit layer and the substrate, a support substrate is stuck on the smoothing layer by means of a fluorine containing epoxy family adhesive, thereafter, when etching off the single crystal semiconductor substrate by using the oxide film layer as a stopper, a level difference part on the thin film semiconductor circuit layer is smoothed by the smoothing layer and the stress concentrated on the level difference part is dispersed. As a result, even when the etching proceeds and the thickness of the single crystal semiconductor substrate becomes reduced, the thin film semiconductor circuit layer can be protected from exfoliation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(A) to 1(E) show cross-sectional views of a first embodiment of a method for manufacturing a thin film semiconductor device according to the present invention;
FIGS. 2(A) to 2(F) show a cross-sectional view of a second embodiment of a method for manufacturing a thin film semiconductor device according to the present invention;
FIG. 3 is an enlargement of a cross-sectional view of the fluorine containing epoxy adhesive of the invention;
FIG. 4 is an explanatory figure showing one method for making a support substrate and a thin film semiconductor circuit layer adhere to each other;
FIG. 5 is an explanatory figure showing a method for applying an adhesive to a support substrate or a thin film semiconductor circuit layer;
FIG. 6 is an explanatory figure showing another method for applying an adhesive to a support substrate or a thin film semiconductor circuit layer;
FIG. 7 is an explanatory figure showing one method for making a support substrate and a thin film semiconductor circuit layer adhere to each other;
FIG. 8 is an explanatory figure showing an outline of an apparatus for injecting an adhesive into a slit;
FIG. 9 is an explanatory figure showing one method for sticking together a support substrate and a thin film semiconductor circuit layer; and
FIG. 10 is an explanatory figure showing an outline of a vacuum sticking apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention are described below, referring to the drawings.
FIG. 1(A) to (E) show cross-sectional views of a first embodiment of a thin film semiconductor device manufacturing method of the present invention.
First, as shown in FIG. 1(A), for example, an insulating oxide film layer 2 made of silicon oxide (an inorganic substance), is formed on a single crystal semiconductor substrate 3 made of silicon. A thin film semiconductor circuit layer 1 is then formed with an integrated circuit on the silicon oxide layer by means of high resolution semiconductor processing.
Next, as shown in FIG. 1 (B), an adhesive layer is formed with a fluorine containing epoxy family adhesive 4. As shown in FIG. 1 (C), the thin film semiconductor circuit layer 1 and a support substrate 5 are then stuck together with the fluorine containing epoxy family adhesive 4, and then the adhesive is set. The support substrate 5 is made of a hardened insulating material such as glass, quartz or the like. In this case, either of an ultraviolet rays setting type, thermosetting type and 2-liquid setting type may be used as a setting mechanism for the fluorine containing epoxy family adhesive 4 to stick together the thin film semiconductor circuit layer 1 and the support substrate 5.
FIG. 1 (D) shows a state in the course of removing the single crystal semiconductor substrate 3 while leaving the oxide layer 2 and the thin film semiconductor circuit layer 1. As a method for removing the single crystal semiconductor substrate 3, methods such as grinding, etching or the like are suitable. In the embodiment, about 80% of the original thickness of the single crystal semiconductor substrate 3 was removed by grinding.
FIG. 1(E) shows a state in which the rest of the single crystal semiconductor substrate 3 in FIG. 1 (D) has been removed. Etching is used as a removing method and the oxide film layer 2 can be used as a stopper layer for the etching.
In the thin film semiconductor substrate manufactured as described above, the etching could be finished without exfoliation of the single crystal semiconductor substrate 3 from its circumference, since the fluorine containing epoxy family adhesive 4 is not eroded by the etching agent even when the etching proceeds to reduce the thickness of the single crystal semiconductor substrate.
FIGS. 2 (A) to (F) show cross-sectional views of a second embodiment of a thin film semiconductor device manufacturing method of the invention.
First, as shown in FIG. 2 (A), for example, an oxide film layer 2 made of a silicon oxide film is formed on a single crystal semiconductor substrate 3 made of silicon, on which is formed a thin film semiconductor circuit layer 1 being formed with an integrated circuit on a silicon layer by means of high resolution semiconductor processing.
Next, as shown in FIG. 2 (B), the rough surface of the thin film semiconductor circuit layer 1 is smoothed by forming a smoothing layer 6 having silicon dioxide as the main ingredient on the thin film semiconductor circuit layer 1 by means of a spin-coating method or the like. Next, as shown in FIG. 2 (C), an adhesive layer is formed by means of a fluorine containing epoxy family adhesive 4.
As shown in FIG. 2 (D), the thin film semiconductor circuit layer 1 and a support layer 5 are stuck together through the smoothing layer 6 by means of the fluorine containing epoxy family adhesive 4, and thereafter the adhesive is set. The support substrate 5 is made of a hardened insulating material such as glass, quartz or the like. In this case, either of an ultraviolet rays setting type, thermosetting type and 2-liquid setting type may be used as a setting mechanism for the fluorine containing epoxy family adhesive 4 to stick together the thin film semiconductor circuit layer 1 and the support substrate 5.
FIG. 2 (E) shows a state in the course of removing the single crystal semiconductor substrate 3 while leaving the oxide layer 2 and the thin film semiconductor circuit layer 1. Grinding, etching or the like are suitable as methods for removing the single crystal semiconductor substrate 3. In the present embodiment, about 80% of the original thickness of the single crystal semiconductor substrate 3 was removed by grinding.
FIG. 2 (F) shows a state in which the rest of the single crystal semiconductor substrate 3 in FIG. 2 (E) has been removed. Etching is used as a removing method, and at this time the oxide film layer 2 can be used as a stopper layer for the etching.
In the thin film semiconductor substrate manufactured as described above, the etching could be finished without exfoliation of the single crystal semiconductor substrate 3, since the stress concentrated on the level difference part of the surface of the thin film semiconductor circuit layer 1 is dispersed by smoothing the rough surface by means of a smoothing layer 6 even when the etching proceeds to reduce the thickness of the single crystal semiconductor substrate.
FIG. 3 is a cross-sectional view of a thin film semiconductor substrate in which the thickness of the fluorine containing epoxy family adhesive has been controlled in the first or second embodiment of the invention. Thickness of the adhesive can be controlled in a uniform manner either by applying the fluorine containing epoxy family adhesive 4, after mixing transparent plastic particles 7 to it, to the thin film semiconductor circuit layer 1 or by applying the fluorine containing epoxy family adhesive 4 to the thin film semiconductor circuit layer 1 after spreading the transparent plastic particles 7 in specified density on the circuit layer 1 and then sticking the support substrate 5 on it. The transparent particles 7 have a specified size which is effective to establish a uniform thickness of the adhesive layer 4. For example, the diameter of the plastic particle may be generally equal to the thickness of the adhesive layer 4 as shown in FIG. 3. Since the single crystal semiconductor substrate 3 can be uniformly removed by grinding or etching by controlling in constant thickness the adhesive in this manner, the thin film semiconductor circuit layer 1 can be more reliably protected from exfoliation.
FIG. 4 is an explanatory figure showing one of the methods for sticking together a support substrate 5 and a thin film semiconductor circuit layer 1 in the first or second embodiment of the invention. The adhering process is completed by applying a fluorine containing epoxy family adhesive 4 to at least one of the support substrate 5 and a thin film semiconductor circuit layer 1, sticking them together face to face, and then hardening the adhesive.
FIG. 5 is an explanatory figure showing one method for applying an adhesive 4 to a support substrate 5 or a thin film semiconductor circuit layer 1 in FIG. 4. A relief 9 formed in a specified shape (shape desired to apply) is stuck on a roll 8, and a fluorine containing epoxy family adhesive 4 is transferred onto the relief 9 from the roll 8. The adhesive 4 is transferred onto the thin film semiconductor circuit layer 1 in the specified pattern from the relief 9 on the roll 8 by moving the roll 8 or the thin film semiconductor circuit layer 1 relatively to each other after transferring the adhesive 4.
FIG. 6 is an explanatory figure showing another method for applying the adhesive 4 to the support substrate 5 or the thin film semiconductor circuit layer 1 in FIG. 4. The fluorine containing epoxy family adhesive 4 diluted with a solution is deposited on the support substrate 5 or the thin film semiconductor circuit layer 1 as an adhesive in a state of mist 11 by being sprayed from a nozzle 10. At this time, the support substrate 5 or the thin film semiconductor circuit layer 1 is conveyed by a conveyer belt 12 to move from left to right in the figure. In the course of conveying the support substrate 5 or the thin film semiconductor circuit layer 1 having the adhesive deposited on it from a state of mist by means of the conveyer belt 12, the solution is volatilized and only the adhesive is uniformly applied.
FIG. 7 and 8 are figures explaining one method for sticking together the support substrate 5 and the thin film semiconductor circuit layer 1 in the first or second embodiment of the invention. The support substrate 5 and the thin film semiconductor circuit layer 1 are stuck together face to face after forming a sealing agent 13 in a shape of frame on the circumference of the wafer. At this time, an inlet 14 is formed in a part of the frame-shaped sealing agent. A thermosetting resin, ultraviolet rays setting resin or the like is used as the frame-shaped sealing agent 3. A slit is formed between the support substrate 5 and the thin film semiconductor circuit layer 1 by sticking them together after spreading transparent plastic particles (not shown in the figure) on one of their faces facing each other before sticking together the support substrate 5 and the thin film semiconductor circuit layer 1.
FIG. 8 is an explanatory figure showing an outline of an apparatus for injecting the adhesive into the slit. The thin film semiconductor circuit layer 1 and the support substrate 5, which have a slit formed between them by the frame-shaped sealing agent 13, are hung inside a pressure container 16 so that the inlet 14 may come downward. This container 16 is connected with an exhaust system through an exhaust valve 17 and can intake air through an exhaust valve 18. An adhesive storing container 15 containing the fluorine containing epoxy family adhesive 4 is placed at the bottom of the pressure container 16.
In the above-mentioned system, the pressure container 16, the thin film semiconductor circuit layer 1 and the support substrate 5 are, first, exhausted by opening the exhausting valve 17 and making the exhausting system operate. As a result, gas inside the slit between the thin film semiconductor circuit layer 1 and the support substrate 5 is quickly exhausted to a vacuum state. At this time, the air which has dissolved in the fluorine containing epoxy family adhesive 4 in the adhesive storing container 15 can be also exhausted. After the exhaustion has been fully made, the exhausting valve 17 is closed and the inlet 14 of the thin film semiconductor circuit layer 1 and support substrate 5 hung down is immersed in the fluorine containing epoxy family adhesive 4.
Next, when the inhaling valve 18 is opened and air or nitrogen gas flows into the pressure container, the surface of the fluorine containing epoxy family adhesive 4 is pressurized. As a result, the fluorine containing epoxy family adhesive 4 is injected into the slit between the thin film semiconductor circuit layer 1 and the support substrate 5. After the slit has been filled with the fluorine containing epoxy family adhesive 4, the thin film semiconductor circuit layer 1 and the support substrate 5 are taken out from the pressure container 15, and then the fluorine containing epoxy family adhesive 4 is cured to complete the adhering process. According to such a method, since an adhesive layer of uniform thickness having no air bubbles can be formed, a thin film semiconductor circuit layer and a support layer can be firmly stuck together.
FIG. 9 is an explanatory figure showing one of methods for sticking together the thin film semiconductor circuit layer and the support substrate in the first or second embodiment of the invention. First, a frame-shaped sealing material 13 is formed on the support substrate 5 or the thin film semiconductor circuit layer 1. A thermosetting resin, ultraviolet rays setting resin or the like is used as the frame-shaped sealing material. Next, the fluorine containing epoxy family adhesive 4 is dropped in one time or several times near the middle of the area surrounded by the sealing material 13 on the support substrate 5 or the thin film semiconductor circuit layer 1. At this time, in order to keep the space uniform between the support substrate 5 and the thin film semiconductor circuit layer 1, the fluorine containing epoxy family adhesive 4 mixed with transparent plastic particles (not shown in the figure) is dropped, or the fluorine containing epoxy family adhesive 4 is dropped after spreading the transparent plastic particles on the support layer 5 or the thin film semiconductor circuit layer 1.
FIG. 10 is a figure showing an outline of a vacuum sticking apparatus. One layer of the support substrate 5 and the thin film semiconductor circuit layer 1 which has the frame-shaped sealing material 13 formed on it and has the fluorine containing epoxy family adhesive 4 dropped on it and the other layer having no sealing material on it are disposed with their faces to be stuck together facing each other so that the former layer may be under the latter layer. In order to stick both layers together, the pressure container 16 is first exhausted by opening the exhausting valve 17 and making the exhausting system operate. At this time the air which has dissolved in the fluorine containing epoxy family adhesive 4 dropped on the thin film semiconductor circuit layer 1 or the support substrate 5 can be also exhausted. After the exhaustion is fully made, the thin film semiconductor circuit layer 1 and the support substrate 5 are stuck together. Next, after restoring the pressure inside the pressure container to the atmospheric pressure by opening the inhaling valve 18 and letting air or nitrogen gas flow in, the thin film semiconductor circuit layer 1 and the support substrate 5 are taken out, and then the adhering process is completed by curing the fluorine containing epoxy family adhesive 4 and the sealing material 13. According to a method such as this, since an adhesive layer of uniform thickness having no air bubbles can be formed, not only a thin film semiconductor circuit layer and a carrier layer can be firmly stuck together, but also the expensive fluorine containing epoxy family adhesive can be saved.
As described above, the invention has an excellent effect in that thin film semiconductor substrates can be manufactured with a high yield rate by sticking together a thin film semiconductor circuit layer and a carrier layer by means of a fluorine containing epoxy family adhesive of high chemical resistivity. | A thin film semiconductor substrate for a display device includes a thin film semiconductor circuit layer formed on a single crystal semiconductor substrate and a support substrate formed over the thin film semiconductor circuit layer. An adhesive layer made of a fluorine-containing epoxy family adhesive is provided between the insulating layer and the support substrate. When the single crystal semiconductor substrate is removed, the yield rate in production of the thin film semiconductor substrate is greatly improved. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
The application is a non-provisional application of U.S. Provisional Patent Application No. 62/066,889, filed Oct. 21, 2014 and incorporated herein by reference.
FIELD
A vortex-induced vibration (VIV) suppression device having an anti-fouling member, more specifically a VIV suppression device having an anti-fouling layer. Other embodiments are also described herein.
BACKGROUND
A difficult obstacle associated with the exploration and production of oil and gas is management of significant ocean currents. These currents can produce vortex-induced vibration (VIV) and/or large deflections of tubulars associated with drilling and production. VIV can cause substantial fatigue damage to the tubular or cause suspension of drilling due to increased deflections. Both helical strakes and fairings can provide sufficient VIV suppression.
Helical strakes and fairings are both popular VIV suppression devices. However, the effectiveness of helical strakes and fairings can be substantially degraded due to the presence of marine growth or other rough elements on its external surface. Presently, the technologies that are applied to prevent marine growth fouling (also known as “anti-fouling” methods) consist of paints or coatings that are applied by spraying the material onto the (helical strake or fairing) surface.
Present anti-fouling methods are expensive and often have lifetimes that are insufficient for oil and gas platform tubulars that must resist fouling for periods of 30-50 years or more. In addition, these paints and coatings require multiple applications so that the manufacturing can be increased substantially. Finally, some present methods impose substantial surface roughness onto the strake from particles in the coating, which partially defeats the purpose of using an anti-fouling coating.
SUMMARY
The present invention consists of anti-fouling methods that incorporate an anti-fouling sheet, such as a copper sheet or film, that is bonded or attached to the surface of the VIV suppression device. The method disclosed herein provides an anti-fouling sheet that is relatively inexpensive to apply and can be effective for a number of years (e.g. 50 years or more). In addition, the anti-fouling sheet may be quick to apply and suitable for keeping the surface of the VIV suppression device relatively smooth.
In one embodiment, a vortex-induced vibration (VIV) suppression device is provided. The device may include a body dimensioned to at least partly envelope a tubular member in an interior area of the body. The device may further include at least one extension member extending from the body and an anti-fouling member mechanically coupled to at least one of the body or the extension member. The extension member may be, for example, a fin in the case of a helical strake VIV suppression device or a fin in the case of a fairing. The anti-fouling member may be positioned over an outer surface of a wall of the body and/or the extension member. The anti-fouling member may include a sheet of anti-fouling material. For example, the anti-fouling material may be copper, a copper-nickel alloy, a copper-zinc alloy or a copper-tin alloy. In some embodiments, the sheet of anti-fouling material is mechanically attached to the at least one of the body or the extension member by a fastener. Still further, the sheet of anti-fouling material may be attached to the body by inserting the sheet within a channel along an edge of the body. The body may include at least two sections that fit together to form the body. The extension member may be a fin that includes a slot dimensioned to receive a band for securing the body to a tubular member.
In another embodiment, the invention relates to a helical strake assembly including a helical strake having a body section and a fin helically arranged around the body and an anti-fouling sheet coupled to the helical strake. The anti-fouling sheet may be positioned along an exterior surface of the helical strake. The anti-fouling sheet may be coupled directly to the body section and the fin. In some cases, the anti-fouling sheet may be dimensioned to conform to an exterior surface of the helical strake. In one embodiment, the anti-fouling sheet may be coupled to the helical strake by a “C” shaped clamp positioned along an edge of the body section.
In another embodiment, the invention relates to a fairing assembly for suppressing a vortex-induced vibration (VIV) of a tubular, the fairing assembly comprising a fairing having a wall forming a body portion, a tail portion and an end portion, and an anti-fouling sheet coupled to an interior surface and an exterior surface of the wall of the fairing.
A process of manufacturing a vortex-induced vibration (VIV) suppression device is further provided. The process may include providing a VIV suppression device having a body dimensioned to at least partly envelope a tubular member in an interior area of the body and at least one extension member extending from the body. The process may further include attaching an anti-fouling member to the VIV suppression device. The anti-fouling member may be attached to the device by, for example, fastening the anti-fouling member to the exterior surface of the wall of the body and/or positioning a band around the anti-fouling member and the body of the VIV suppression device. In other embodiments, the anti-fouling member may be positioned within a channel formed along an edge of the wall of the body. In still further embodiments, a thermal or chemical process may be used to attach the anti-fouling member to the exterior surface of the wall of the body. In some embodiments, the anti-fouling sheet is preformed to have a shape of the VIV suppression device prior to attaching the anti-fouling sheet to the VIV suppression device.
The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all apparatuses that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments disclosed herein are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and they mean at least one.
FIG. 1A illustrates a perspective view of one embodiment of a helical strake, consisting of two halves, that is banded to the surface of a cylinder.
FIG. 1B illustrates a perspective view of one embodiment of a helical strake half with an anti-fouling member over the external surface.
FIG. 1C illustrates a side view of the edge of the helical strake half of FIG. 1B with one embodiment of a clamp along the edge to secure an anti-fouling member to the helical strake.
FIG. 1D illustrates a side view of the edge of the helical strake half of FIG. 1B with another embodiment of a clamp along the edge to secure an anti-fouling member to the helical strake.
FIG. 2A illustrates a perspective view of another embodiment of a VIV suppression device having an anti-fouling member attached thereto.
FIG. 2B illustrates a perspective view of another embodiment of the VIV suppression device of FIG. 2A having an anti-fouling member attached thereto.
FIG. 3 illustrates one embodiment of a process for manufacturing a VIV suppression device having an anti-fouling member.
DETAILED DESCRIPTION
In this section we shall explain several preferred embodiments with reference to the appended drawings. Whenever the shapes, relative positions and other aspects of the parts described in the embodiments are not clearly defined, the scope of the embodiments is not limited only to the parts shown, which are meant merely for the purpose of illustration. Also, while numerous details are set forth, it is understood that some embodiments may be practiced without these details. In other instances, well-known structures and techniques have not been shown in detail so as not to obscure the understanding of this description.
Referring now to the invention in more detail, FIG. 1A illustrates a perspective view of one embodiment of a VIV suppression device. In particular, FIG. 1A illustrates a helical strake design consisting of helical strake 101 having a body 105 formed by wall 108 . Wall 108 is dimensioned to at least partially, or fully, encircle or envelope an underlying tubular 100 . As can be seen in more detail in FIG. 1B , wall 108 includes an outer surface 106 and an inner surface 107 . The inner surface 107 faces, and in some cases contacts, the exterior surface of tubular 100 when helical strake 101 is positioned around tubular 100 such that tubular 100 is enveloped by an interior area 110 of helical strake 101 . Wall 108 is separated into two separate sections by gap 111 such that helical strake 101 includes helical strake half 101 A and helical strake half 101 B. Helical strake half 101 A and helical strake half 101 B are banded to tubular 100 using bands 103 which reside in channels 104 . Each of helical strake half 101 A and helical strake half 101 B cover less than an entire circumference of tubular 100 , however, in combination almost entirely encircle tubular 100 . Fins 102 are shown attached to, or part of, helical strake 101 . Fins 102 extend from an outer surface 106 of wall 108 and may therefore also be referred to herein as extension members. In particular, fins 102 may include a base portion 113 which contacts, or otherwise attaches to, wall 108 of helical strake 101 and a protruding portion 116 , which extends from base portion 113 and wall 108 . Fins 102 may be positioned along a length dimension of wall 108 such that they are helically arranged around helical strake 101 .
Again referring to FIG. 1A , while this figure shows helical strake 101 consisting of two halves, the helical strake is not restricted to consisting of two halves and can be of a single piece or of more than two pieces. In FIG. 1A , bands 103 travel through channels 104 and are put in tension which, in turn, presses helical strake half 101 A and helical strake half 101 B against tubular 100 . This allows helical strake 101 to be constrained from axial motion relative to tubular 100 .
Still referring to FIG. 1A , any number of bands may be used in the helical strake and the fins 102 may be of any size or shape. While FIG. 1A shows channels 104 between adjacent fins 102 , fins 102 may be continuous and not have channels 104 present. Fins 102 may also utilize slots that allow bands 103 to travel through fins 102 and thereby, when bands 103 are put into tension, press helical strake 101 against tubular 100 . Fins 102 may be formed separately from helical strake half 101 A and helical strake half 101 B and then attached by any suitable mechanism (this also applies to the copper aspects disclosed herein).
Still referring to FIG. 1A , all parts shown may be made of any suitable material including, but not limited to, plastic, metal, rubber or elastomer, ceramic, wood, composite, and synthetics.
Referring now to FIG. 1B , helical strake half 101 A, which also has channels 104 present, is shown covered with anti-fouling member or sheet 151 . In one embodiment, anti-fouling sheet 151 is attached to helical strake half 101 A using fasteners 121 . Anti-fouling sheet 151 may be mechanically attached to an outer surface 106 of helical strake half 101 A. The outer surface 106 may be a surface which faces away from tubular 100 , when helical strake half 101 A is positioned around the tubular 100 as shown in FIG. 1A . Fasteners 121 may be any type of fastener suitable for attaching two structures together, for example, fasteners 121 may be screws or pins which are inserted through openings in anti-fouling sheet 151 and corresponding openings within helical strake half 101 A.
Again referring to FIG. 1B , anti-fouling sheet 151 is shown as a single sheet but can consist of multiple pieces to cover helical strake half 101 A (anti-fouling sheet may be used to cover helical strake half 101 B shown in FIG. 1A , and can be used to cover any or all of helical strake 101 shown in FIG. 1A - FIG. 1B . FIG. 1B simply illustrates one embodiment of how anti-fouling sheet 151 may cover a portion of a helical strake. Anti-fouling sheet 151 may cover all or part of a helical strake half or section (for example, different sections of anti-fouling sheet 151 may be used to cover each of the fins and other sections may be used to cover the base portion of the strake). Different pieces of anti-fouling sheet 151 may overlap (or underlap) and may, or may not, cover the ends or underside of helical strake half 101 A. Representatively, in one embodiment, anti-fouling sheet 151 may be a short piece of copper that covers ⅓ of the circumference of helical strake 101 and several of these pieces are assembled axially along helical strake 101 to cover helical strake 101 . In addition, anti-fouling sheet 151 may, in some embodiments, be preformed to the strake shape prior to installing on the helical strake 101 .
While FIG. 1B shows anti-fouling sheet 151 attached to helical strake half 101 A using fasteners 121 , other attachment means may be used in addition to, or in place of the use of fasteners 121 . Any suitable attachment means may be used, including bands (such as bands 103 in FIG. 1A ), adhesives, any fastening methods such as screws, bolts, nuts, rivets, or clamps, or other structural members (which may also be used to assist with adhesive attachment means). Any combination of methods may also be utilized. The anti-fouling material (e.g. copper) may also be plated to helical strake half 101 A or attached by other thermal means to form a anti-fouling sheet. It should be understood, however, that the anti-fouling sheet 151 as disclosed herein is different from other anti-fouling methods in which a liquid including an anti-fouling material (e.g. copper particles) is applied to a VIV device, such as by painting, to form a coating over the VIV device surface. In other words, the anti-fouling sheet 151 is different form a coating in that it is a solid sheet of material that is mechanically attached to the helical strake and can maintain the desired shape without the presence of the helical strake it is attached to. Other existing methods of applying anti-fouling particles such as painting or coating, however, may be used in conjunction with the subject invention. Anti-fouling sheet 151 may be fairly soft and manually formed to the shape of the helical strake or may be relatively hard and formed to the helical strake by a heating method such as vacuum forming or drape molding. Parts of anti-fouling sheet 151 may be relatively soft and manually formed to the helical strake and other parts of anti-fouling sheet 151 may be hard and heated to the desired shape. For example, anti-fouling for the fins may be formed separately.
Still referring to FIG. 1B , anti-fouling sheet 151 may be of any suitable thickness and does not have to be of constant thickness and various sections or pieces of anti-fouling sheet 151 may be of different sizes or thicknesses. Anti-fouling sheet 151 will typically be of a thickness ranging from 3 mils to 125 mils. Fasteners 121 may be of any size, shape, type or quantity, and any of the various attachment methods may be used to permanently attach anti-fouling sheet 151 to helical strake half 101 A or may be used temporarily, for example to hold anti-fouling sheet 151 in place until bands may be attached. Anti-fouling sheet 151 may have holes or openings. For example, if the fins are continuous then slots may be cut in both the fins and in anti-fouling sheet 151 so that bands may travel through the slots for installation. Multiple holes or openings may also be present in anti-fouling sheet 151 so that it resembles netting or meshing (with no limit on the porosity of anti-fouling sheet 151 ).
Still referring to FIG. 1B , while anti-fouling sheet 151 is presumably made of anti-fouling, the anti-fouling does not need to be pure copper and can consist of various copper alloys such as copper-nickel alloys, copper-zinc alloys (brass), and copper-tin alloys (bronze). Fasteners 121 may be made of any suitable material including, but not limited to, metal, plastic, composite, and synthetics.
Referring now to FIG. 1C , this figure illustrates a possible modification to one or more edges of a VIV suppression device to facilitate attachment of an anti-fouling sheet to the VIV suppression device. Representatively, in this embodiment, anti-fouling sheet 151 may be held in place along an edge of a helical strake half 101 A, such as that previously described, by a receiving member 170 formed along the edge of the helical strake half 101 A. The receiving member 170 may be, for example, a “C” shaped clamp, which forms a channel 171 along the edge 115 of helical strake half 101 A. In particular, receiving member 170 may include an end portion 172 from which two side arms 173 A, 173 B extend. The channel 171 may be formed by the inner (interfacing) surfaces of end portion 172 and two side arms 173 A, 173 B. Side arms 173 A, 173 B may be spaced a sufficient distance from one another such that channel 171 is wide enough to receive both the end of strake half 101 A and sheet 151 and hold the two pieces together. Representatively, in one embodiment, end portion 172 is positioned along the edge 115 of strake half 101 A such that side arm 173 A is positioned along the outer surface 106 of the wall 108 of strake half 101 A and side arm 173 B is positioned along the inner surface 107 of the wall 108 of strake half 101 A. In other words, side arm 173 B is between strake half 101 A and tubular 100 , for example, adjacent to tubular 100 . To accommodate the positioning of side arm 173 B between strake half 101 A and tubular 100 , a recessed region 180 for receiving side arm 173 B may be formed along the inner surface 107 of the wall 108 of strake half 101 A.
Again referring to FIG. 1C , any number or length of edges of helical strake half 101 A may have receiving member 170 in place. Receiving member 170 may be attached to helical strake half 101 A, to anti-fouling sheet 151 , or to tubular 100 . Receiving member 170 may also be held in place by pressure on helical strake half 101 A and anti-fouling sheet 151 against tubular 100 . This pressure may come from an adjacent location such as from an adjacent band. The pressure may also simply come from an interference fit of the channel 171 of receiving member 170 onto helical strake half 101 A and anti-fouling sheet 151 .
Still referring to FIG. 1C , receiving member 170 may be of any suitable size or shape and may be attached to helical strake half 101 A, to anti-fouling sheet 151 , or to tubular 100 by any suitable means including, but not limited to, banding, clamping, fastening, and chemical bonding.
Still referring to FIG. 1C , receiving member 170 may be made of any suitable material including, but not limited to plastic, metal, elastomer, or composite.
Referring now to FIG. 1D , this figure illustrates another possible modification to one or more edges of the subject invention. Helical strake half 101 A and anti-fouling sheet 151 are held in place at the edge by receiving member 175 , which includes channel 185 and is adjacent to tubular 100 . Receiving member 175 is shown optionally attached to helical strake half 101 A and anti-fouling sheet 151 by screw 181 and nut 182 .
Again referring to FIG. 1D , helical strake half 101 A and anti-fouling sheet 151 have an adjusted shape to accommodate receiving member 175 , screw 181 , and nut 182 . While screw 181 and nut 182 are optional, any suitable means may be used for attaching or connecting receiving member 175 to helical strake half 101 A or anti-fouling sheet 151 . Receiving member 175 may, or may not, contact tubular 100 .
Still referring to FIG. 1D , Receiving member 175 may be made of any suitable size, shape, or quantity. While a C-shape cross section is shown for channel 185 , any suitable shape may be used for channel 185 which may be replaced by other structural shapes and merely illustrates that a structural member may be used to assist with connecting anti-fouling sheet 151 and helical strake half 101 A (this also applies to receiving member 170 in FIG. 1C ).
Still referring to FIG. 1D , receiving member 170 may be made of any suitable material including, but not limited to plastic, metal, elastomer, or composite.
FIG. 2A illustrates a perspective view of another embodiment of a VIV suppression device having an anti-fouling member attached thereto. In this embodiment, the VIV suppression device is a fairing 201 , which is dimensioned to suppress VIV of an underlying structure or tubular 210 . Fairing 201 may include a wall 202 that forms a body portion 220 which encircles an underlying structure or tubular 210 and a tail portion 222 that extends from body portion 220 and tapers to form an end portion 224 . The tail portion 222 may also be referred to herein as an extension member. Fairing 201 may be include first section 201 A and second section 201 B that can be separated along opening 204 so that fairing 201 can be positioned around underlying structure or tubular 210 . Once fairing 201 is positioned around tubular 210 , it is free to weathervane with changes of angle of the incoming current. In some embodiments, fairing 201 , including first section 201 A and second section 201 B are integrally formed pieces that are formed together as a single unit. In other embodiments, first section 201 A and second section 201 B of fairing 201 are separate modules, that are formed independently of one another. Fairing 201 can be made of plastic, rubber, wood, fiberglass or other composite materials, metals, or any suitable material that allows it to maintain its approximate shape.
Fairing 201 may further include an anti-fouling member 206 attached to the wall 202 . The anti-fouling member 206 may be similar to the anti-fouling member previously discussed in reference to FIG. 1A - FIG. 1D , except in this case it is dimensioned to cover a fairing 201 . Representatively, anti-fouling member 206 may be a sheet of anti-fouling material that is wrapped around an outer surface 208 of wall 202 of fairing 201 . Anti-fouling member 206 may be attached to wall 202 mechanically using fasteners 205 . Fasteners 205 may be similar to the fasteners 121 previously discussed in reference to FIG. 1A - FIG. 1D .
FIG. 2B illustrates a perspective view of another embodiment of the VIV suppression device of FIG. 2A having an anti-fouling member attached thereto. In this embodiment, however, the anti-fouling member 206 is shown also positioned over the inner surface 207 of wall 202 of fairing 201 . Representatively, anti-fouling member 206 may be wrapped around the outer surface 208 of wall as previously discussed, and then over the end portion 224 such that it extends over the inner surface 207 of fairing wall 202 . Positioning of the anti-fouling member 206 between the fairing wall 202 and tubular 210 helps to impede marine growth between fairing 201 and tubular 210 . In addition, in some embodiments, anti-fouling member 206 may be optionally held in place along fairing wall 202 by an interior support block 212 (shown in dashed lines) positioned within fairing 201 . A tape, or other similar material, may further be positioned around the edges of fairing 201 and anti-fouling member 206 to reduce the sharpness of the edges.
FIG. 3 illustrates one embodiment of a process for manufacturing a VIV suppression device having an anti-fouling member. In one embodiment, process 300 includes providing a VIV suppression device (block 302 ). The VIV suppression device may, for example, be helical strake 101 , and include a body having a wall dimensioned to at least partly envelope a tubular member in an interior area of the body and at least one fin protruding outward from an exterior surface of the wall. Process 300 may further include attaching an anti-fouling member to the VIV suppression device (block 304 ). For example, the anti-fouling member may be attached to the VIV suppression device by, for example, fastening the anti-fouling member to the exterior surface of the wall of the body. In other embodiments, the anti-fouling member may be attached to the VIV suppression device by positioning a band around the anti-fouling member and the body of the VIV suppression device. Still further, the anti-fouling member may be positioned within a channel formed along an edge of the wall of the body, such as by receiving member 170 or receiving member 175 previously discussed in reference to FIG. 1C and FIG. 1D . Alternatively, a thermal or chemical bonding process may be used to attach the anti-fouling member to the exterior surface of the wall of the body. In some embodiments, the anti-fouling sheet is preformed to have a shape of the VIV suppression device prior to attaching the anti-fouling sheet to the VIV suppression device.
The above aspects of this invention may be mixed and matched in any manner suitable to achieve the purposes of this invention. It is recognized that, while a helical strake has been used to illustrate the invention herein, the concepts presented may be applied to any VIV suppression device such as for a fairing.
In broad embodiment, the present invention consists of methods for attaching pieces of anti-fouling sheet to a VIV suppression device.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. For several of the ideas presented herein, one or more of the parts may be optional. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. | A vortex-induced vibration (VIV) suppression apparatus including a body having a wall dimensioned to at least partly envelope a tubular member in an interior area of the body; at least one extension member extending from the body; and an anti-fouling member mechanically coupled to at least one of the body or the extension member. A method of manufacturing a vortex-induced vibration (VIV) suppression device including providing a VIV suppression device having a body dimensioned to at least partly envelope a tubular member in an interior area of the body and at least one extension member extending from the body. The method further including attaching an anti-fouling sheet to the VIV suppression device. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application with Ser. No. 62/350,629 filed on Jun. 15, 2016, the contents of which are incorporated herein by its entirety.
TECHNICAL FIELD
[0002] The disclosed technology relates generally to depositing a hard mask coating onto a surface of a graphene sheet. More specifically, the present invention relates to depositing a hard mask coating onto a surface of a graphene sheet to provide a protective layer.
BACKGROUND
[0003] Graphene is composed of a single thin layer of carbon atoms that are bonded together in a repeating pattern of hexagons. Graphene has many extraordinary properties, which includes high mechanical strength, high electron mobility, and superior thermal conductivity. Because graphene is a great thermal and electrical conductor, graphene material is often used to construct graphene based biosensors, transistors, integrated circuited, and other electronic applications.
[0004] While there has been much academic interest in the application and utilization of graphene, attempts to commercialize graphene based electronic devices and sensors have largely failed. As such, much of the currently known techniques for handling and preparing graphene are limited to techniques that are only suitable for research and academic purposes, and thus fail to take into consideration manufacturing costs, product assembly requirements, and the need for long-term durability.
[0005] More specifically, current methods for preparing and handling graphene often leave the graphene sheet exposed to the environment conditions when constructing the graphene based devices. Because the graphene sheets are left exposed without a protective layer, the graphene is often contaminated and even damaged, especially when exposed to the air for periods of time. Additionally, the exposed graphene surface may further be susceptible to damage during the processing, constructing, and packaging of the graphene based electronic devices and sensors.
[0006] While some limited methods for providing a protective layer on the surface of graphene sheets are currently available, such methods may still damage the graphene. For example, one method may include depositing the surface of the graphene sheet directly with a photoresist or polymethylmethacrylate (hereinafter “PMMC”) layer. However, such direct contact with the graphene sheet often leaves a residue on the graphene that cannot be completely removed, even with the application of acetone or other solvents. As such, any remaining photoresist or PMMC residue on the surface of the graphene significantly lowers the quality of the graphene and is further likely to degrade the overall performance of the graphene based electronic devices and sensors.
[0007] Other methods may also include providing a protective copper layer on the surface of the graphene sheet. However, copper is also known to leave a contaminating residue on the graphene sheet that is difficult to completely remove, which also lowers the quality of the graphene and further likely to degrade the performance of the graphene based electronic devices and sensors. As such, there currently is a need to provide a way for providing a temporary protective layer on a graphene sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The technology disclosed herein, in accordance with one or more various embodiments, is described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or example embodiments of the disclosed technology. These drawings are provided to facilitate the reader's understanding of the disclosed technology and shall not be considered limiting of the breadth, scope, or applicability thereof. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.
[0009] FIG. 1 illustrates the different progressions of depositing a temporary protective layer onto a surface of a graphene sheet according to one embodiment.
[0010] FIG. 1A illustrates a graphene sheet transferred onto a substrate according to one embodiment.
[0011] FIG. 1B illustrates a graphene sheet with a temporary metal layer according to one embodiment.
[0012] FIG. 1C illustrates a graphene sheet with a temporary metal layer removed from a surface of the graphene sheet according to one embodiment.
[0013] FIG. 2 illustrates the different progressions of patterning a graphene sheet with a hard mask layer according to one embodiment.
[0014] FIG. 2A illustrates a graphene sheet transferred onto a substrate according to one embodiment.
[0015] FIG. 2B illustrates a graphene sheet with a metal layer according to one embodiment.
[0016] FIG. 2C illustrates a graphene sheet with a metal layer and a photoresist layer for lithographic patterning according to one embodiment.
[0017] FIG. 2D illustrates a graphene sheet with a metal layer and a photoresist layer exposed to a radiation source to create a pattern template according to one embodiment.
[0018] FIG. 2E illustrates a graphene sheet with a metal layer and a photoresist layer exposed to a metal etchant solution to pattern the metal layer according to one embodiment.
[0019] FIG. 2F illustrates a graphene sheet with a metal layer and a photoresist layer exposed to a plasma etchant solution to pattern the graphene sheet according to one embodiment.
[0020] FIG. 2G illustrates a patterned graphene sheet with a metal layer according to one embodiment.
[0021] FIG. 2H illustrates a patterned graphene sheet according to one embodiment
[0022] The figures are not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be understood that the invention can be practiced with modification and alteration, and that the disclosed technology be limited only by the claims and the equivalents thereof.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the disclosed embodiments. The present embodiments address the problems described in the background while also addressing other additional problems as will be seen from the following detailed description. Numerous specific details are set forth to provide a full understanding of various aspects of the subject disclosure. It will be apparent, however, to one ordinarily skilled in the art that various aspects of the subject disclosure may be practiced without some of these specific details. In other instances, well-known structures and techniques have not been shown in detail to avoid unnecessarily obscuring the subject disclosure.
[0024] Some embodiments disclosed herein include depositing a temporary protective layer onto a surface of a graphene sheet. It should be noted that depositing layers onto the graphene sheet may include a wide range of techniques as appreciated by one of ordinary skill in the art, such as coating techniques, focused ion beam, filament evaporation, sputter deposition, and electrolysis by way of example only.
[0025] This temporary protective layer may protect the graphene from the environment and prevent the contamination of the graphene sheet. By way of example only, the temporary protective layer may include a thin metal layer to protect the graphene from contamination or harm during the packaging and assembly of the graphene based device. The thin metal used to coat the graphene sheet may include gold, by way of example only. Because gold is an inert metal that has the characteristic property of being resistant to corrosion and oxidation, depositing the graphene sheet with a gold layer may protect the graphene. Additionally, due to gold's characteristically inert qualities, the temporary gold layer on the surface of the graphene sheet may further provide thermal protection and prevent oxidation, especially when the graphene is exposed to high temperature treatments during epoxy curing, oven baking, and burn testing. Furthermore, the temporary gold coating may also protect the graphene from potentially being contaminated during wire bonding, encapsulation, wafer dicing, and cleaning. Thus, this allows the graphene to be handled in a factory setting for large manufacturing production.
[0026] However, other inert metals may also be used to temporarily coat the graphene sheet, which may include, but are not limited to, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, and the like.
[0027] FIG. 1A illustrates a graphene sheet 115 transferred onto a substrate, such as a wafer 105 , according to one embodiment. The graphene sheet 115 may be grown using chemical vapor deposition, especially when producing large sheets of graphene. However, other methods of growing the graphene layer may also include, but are not limited to, reducing oxidized graphite on a selected substrate or via mechanical exfoliation techniques.
[0028] The graphene sheet 115 may then be transferred onto another surface, such as the surface of an electronic chip or sensor. More specifically, the surface of the electronic chip or sensor may include the surface of a thin semi-conductor material, such as a wafer 105 . The wafer 105 may serve as a foundation upon which the proper electronic integrated circuits can be applied. By way of example, the wafer 105 may be a silicon substrate or a silicon dioxide substrate. Additionally, the wafer 105 may be coated with platinum 110 , whereby the platinum 110 acts as the bottom electrode to create the proper electrical connections.
[0029] Next, the graphene sheet 115 may be treated with a temporary thin metal layer, such as a metal layer 120 , as illustrated in FIG. 1B . The metal layer 120 may act as a mask or protective barrier configured to protect the graphene from being contaminated or degraded during the preparation of the graphene. To properly coat the graphene sheet 115 with the metal layer 120 , the wafer 105 with the graphene sheet 115 may be placed in an electron beam evaporation chamber. Electron beam evaporation is a physical vapor disposition technique whereby an intense electron beam is generated from a filament and steered via electric and magnetic fields to strike source material, such as gold pellets, and to vaporize it within a vacuum environment. As such, by using the electron beam evaporation technique, a thin metal layer 120 may be slowly deposited onto the graphene sheet 115 .
[0030] By way of example only, the metal layer 120 may include a gold metal layer. However, it should be noted that the metal layer 120 may include any inert metal that does not negatively react with graphene. Additionally, the metal layer 120 may be any inert metal that has the characteristic property of being resistant to corrosion and oxidation. By way of example only, such inert metals may include, but are not limited to ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, and the like.
[0031] The temporary gold metal layer 120 may range in a thickness from 10 nanometers to 1 micrometer. By way of another example, the gold metal layer 120 may be applied onto the graphene sheet 115 by dipping the graphene sheet 115 into a gold plating solution. Additionally, other methods of depositing a temporary metal layer may be provided. For example, other methods may also include utilizing a focused ion beam, filament evaporation, sputter deposition, electrolysis, and the like to provide a temporary gold metal layer 120 on the surface of a graphene sheet 115 .
[0032] Once the metal layer 120 is deposited on top of the graphene sheet 115 , metal leads or connections may be established. Furthermore, additional processes or constructions may be made on top of the gold metal layer 120 that are now layered on the surface of the graphene sheet 115 . Again, due to inert nature of the metal layer 120 , the metal layer 120 may help protect the graphene from being contaminated or degraded, even as the graphene is being prepped and assembled for use within select graphene based devices.
[0033] Once the preparation of the graphene completed, the metal layer 120 may now be removed, as illustrated in FIG. 1C . For example, the metal layer 120 may be washed with potassium iodide solution for a duration ranging from 30 seconds to 5 minutes, or for a time period where all trace of the metal layer 120 is removed from the surface of the graphene sheet 115 . The now fully exposed graphene sheet 115 may then be washed with deionized water to remove any remaining metal layer particles or other materials left on the surface of the graphene sheet 115 . The now exposed graphene sheet 115 may further be available for any additional processes required to further manufacture and assemble a proper and functional graphene based device.
[0034] In other embodiments, a metal layer placed on top of a graphene sheet may include additional coatings or layers that are deposited on top of the metal layer, as illustrated in FIG. 2 . More specifically, FIG. 2A illustrates a graphene sheet 215 transferred onto a substrate according to one embodiment. Next, the graphene sheet 215 may be treated with a thin metal layer, such as a gold metal layer 220 , as illustrated in FIG. 2B . The gold metal layer 220 may act as a mask or barrier configured to protect the graphene from being contaminated or degraded. As discussed above, the thin metal layer may be any inert metal inert metal that has the characteristic property of being resistant to corrosion and oxidation, such that depositing the graphene sheet with a gold layer protects the graphene from being contaminated or degraded. As such, the thin metal layer may include any of the following inert metals or combination thereof: ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, and the like.
[0035] The graphene sheet 215 with the gold metal layer 220 may additionally be coated with a photoresist layer 225 , as further illustrated in FIG. 2C . The photoresist layer 225 may include photosensitive material that experiences a change in its physical properties when exposed to a radiation source. By selectively exposing the photoresist layer 225 with radiation, such exposed areas of the photoresist layer 225 may be etched away, thus exposing portions of the metal gold layer 220 directly underneath the photoresist layer 225 . In other words, the photoresist layer 225 may act as a template for accurately patterning the graphene sheet 215 underneath the photoresist layer 225 . Thus the pattern etched onto the photoresist layer 225 via the radiation source may be used as a template to etch the same pattern onto the graphene sheet 215 directly below the photoresist layer 225 .
[0036] As further illustrated in FIG. 2D , once the photoresist layer 225 is exposed with a radiation source with a particular pattern etched onto the photoresist layer 225 , the etched away portions of the photoresist layer 225 expose portions of gold metal layer 220 directly below.
[0037] To pattern the graphene sheet 215 underneath the gold metal layer 220 , the gold metal layer 220 must also be etched away in accordance to the pattern etched onto the photoresist layer 225 , as further illustrated in FIG. 2E . To do so, for example, the wafer 205 may be submerged in an etchant solution that etches away only the exposed gold metal layer 220 not covered with the photoresist layer 225 . For example, the etchant solution may be a potassium iodide solution. However, it should be noted that the etchant solution need not be limited to a potassium iodide solution, but instead, may also include a cyanide based chemical or an aqua regia with a mixture of nitric and hydrochloric acids. Because the etchant solution only reacts with the gold and not the photoresist layer 225 , only the exposed gold metal layer 220 is removed and thus forms a negative space pattern in accordance to the pattern etched onto the photoresist layer 225 .
[0038] With the photoresist layer 225 and the gold metal layer 220 now etched away in accordance to the etched template from the photoresist layer 225 , the graphene sheet 215 is now exposed, as further illustrated in FIG. 2E . As such, the graphene sheet 215 may now be patterned accordingly to the specific pattern that etched away specific portions of the photoresist layer 225 . For example, the wafer 205 with the graphene sheet 215 may undergo plasma etching, which only removes the exposed graphene sheet 215 in areas where the gold metal layer 125 was removed from the etchant solution, as illustrated in FIG. 2F . As such, the graphene sheet 215 is now patterned accordingly.
[0039] Upon proper patterning of the graphene sheet 215 via plasma etching, the photoresist layer 225 may now be removed, as further illustrated in FIG. 2G . For example, the wafer 205 with the photoresist layer 225 may be rinsed with acetone for 2 to 10 minutes followed by isopropanol alcohol for another 1 to 5 minutes, which will effectively and have completely dissolved the photoresist layer 225 . This now completely exposes the remaining gold metal layer 220 on the wafer 205 . However, it should be noted that other solvents may also be used, such as acetone, methyl isopropyl ketone and the like.
[0040] Next, the gold metal layer may now be removed, as illustrated in FIG. 2H . For example, the gold metal layer 220 may be washed with potassium iodide solution for 30 seconds to 5 minutes such that the thin metal gold layer 220 is no longer coated on the surface of the graphene sheet 215 . The exposed graphene sheet 215 may then be washed with deionized water to remove any remaining gold particles or other materials on the surface of the graphene sheet 215 . The now exposed patterned graphene sheet 215 is available for any further additional processing or preparation.
[0041] While various embodiments of the disclosed technology have been described above, it should be understood that they have been presented by way of example only, and not of limitation. Likewise, the various diagrams may depict an example architectural or other configuration for the disclosed technology, which is done to aid in understanding the features and functionality that can be included in the disclosed technology. The disclosed technology is not restricted to the illustrated example architectures or configurations, but the desired features can be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations can be implemented to implement the desired features of the technology disclosed herein. Also, a multitude of different constituent module names other than those depicted herein can be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.
[0042] Although the disclosed technology is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the disclosed technology, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the technology disclosed herein should not be limited by any of the above-described exemplary embodiments.
[0043] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.
[0044] The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, can be combined in a single package or separately maintained and can further be distributed in multiple groupings or packages or across multiple locations.
[0045] Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration. | Embodiments of the disclosed technology include patterning a graphene sheet for biosensor and electronic applications using lithographic patterning techniques. More specifically, the present disclosure is directed towards the method of patterning a graphene sheet with a hard mask metal layer. The hard mask metal layer may include an inert metal, which may protect the graphene sheet from being contaminated or damaged during the patterning process. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to new 1-oxa-2-oxo-3-R-3-aza-5-Z-cyclopentane derivatives (I). Similar compounds are described in U.S. Pat. No. 3,120,510.
SUMMARY OF THE INVENTION
It is an object of this invention to provide such compounds.
Upon further study of the specification and appended claims, further objects and advantages of this invention will become apparent to those skilled in the art.
These objects have been achieved by providing new 1-oxa-2-oxo-3-R-3-aza-5-Z-cyclopentane derivatives (I) wherein:
R is alkyl or hydroxyalkyl having in each case 1-6 C atoms, cycloalkyl having 3-8 total C atoms (optionally substituted by alkyl), unsubstituted aryl or aralkyl each of 6-15 C atoms in total or aryl or aralkyl each of which has a total of 6-15 C atoms and, in the aryl radical, is monosubstituted to trisubstituted by alkyl (e.g., of 1-6 C atoms), alkoxy (e.g., of 1-6 C atoms), OH and/or Cl or monosubstituted by methylenedioxy,
Z is -(CHOH) n -H and
n is 2, 3, 4 or 5.
DETAILED DESCRIPTION
The compounds I can be prepared by reacting a compound of the formula R--NH--CH 2 --CHOH--Z (II) with a reactive derivative of carbonic acid.
Compounds of the formula II are in part known and all can be conventionally obtained, for example, by reacting amines of the formula R--NH 2 with aldehydes of the formula Z--CHOH--CHO and by subsequently or simultaneously reducing the resulting Schiff's bases or half-aminals of the formlae ##STR1## Suitable examples of amines of the formula R--NH 2 are methylamine, ethylamine, propylamine, isopropylamine, butylamine, isobutylamine, sec.-butylamine, tert.-butylamine, pentylamine, 1-ethylpropylamine, 1-methylbutylamine, isopentylamine, neopentylamine, tert.-pentylamine, hexylamine, isohexylamine, 1,1-dimethylbutylamine, 1-methylpentylamine, 2-hydroxyethylamine, 2-hydroxypropylamine, 3-hydroxypropylamine, 2-hydroxy-1-methylethylamine, 2-, 3- or 4-hydroxybutylamine, 5-hydroxypentylamine, 6-hydroxyhexylamine, cyclopropylamine, cyclobutylamine, cyclopentylamine, cyclohexylamine, 1-, 2- or 3-methylcyclopentylamine, 1-, 2-, 3- or 4-methylcyclohexylamine, cycloheptylamine, cyclooctylamine, 2-phenylethylamine, 1-methyl-2-phenylethylamine, 1,1-dimethyl-2-phenylethylamine, 2phenylpropylamine, 3-phenylpropylamine, 1-methyl-3-phenylpropylamine, 2-, 3- or 4-phenylbutylamine, 2-(1-naphthyl)ethylamine, 2-(2-naphthyl)-ethylamine, 2-, 3- or 1-p-methoxyphenylethylamine, 2-(3,4-dimethoxyphenyl)-ethylamine, 2-(3,4-methylenedioxyphenyl)-ethylamine, aniline, o-, m- or p-toluidine, o-, m- or p-anisidine, o-, m- or p-aminophenol, o-, m- or p-chloroaniline, 3,4-dimethoxyaniline or 3,4-methxlenedioxyaniline. All alkyl portions in the R groups can correspondingly be selected from those mentioned above.
Examples of suitable aldehydes of the formula Z--CHOH--CHO are 2,3,4-trihydroxybutanals, such as the DL-, D- or L-forms of erythrose or threose, 2,3,4,5-tetrahydroxypentanals, such as the DL-, D- or L-forms of ribose, arabinose, xylose or lyxose, or 2,3,4,5,6-pentahydroxyhexanals, such as the DL-, D- or L-forms of allose, altrose, glucose, mannose, gulose, idose, galactose or talose. Examples of typical compounds of the formula II are N-R-2,3,4-trihydroxybutylamines, such as N-methyl-2,3,4-trihydroxybutylamines, N-R-2,3,4,5-tetrahydroxypentylamines, such as N-phenyl-2,3,4,5-tetrahydroxypentylamines, 2N-R-2,3,4,5,6-pentahydroxyhexylamines, such as N-phenyl2,3,4,5,6-pentahydroxyhexylamines, N-m-tolyl-2,3,4,5,6-pentahydroxyhexylamines, or N-methyl-, N-ethyl-, N-isopropyl- or N-tert.-butyl-2,3,4,5,6-pentahydroxyhexylamines, for example the N-R-glucamines derived from D-glucose (N-R-2S,3R,4R,5R,6-pentahydroxyhexylamines).
Examples of suitable carbonic acid derivatives are phosgene, dialkyl carbonates, such as dimethyl or diethyl carbonate, urea or carbonyldiimidazole.
The reaction of II with the carbonic acid derivative can be carried out in the absence or presence of an inert solvent, such as dimethylformamide (DMF), methanol or ethanol, at temperatures between about 0 and about 200°. Thus the reaction is preferably carried out with carbonyldiimidazole at about 0°-30° in DMF, or, with the other carbonic acid derivatives mentioned, at about 80°-150° without a solvent, but the addition of a base, such as NaOH, KOH, triethylamine or pyridine can be advantageous.
In some cases it is also possible to react further OH groups in II with the carbonic acid derivative, particularly if the latter is employed in excess. The carbonates thus formed can, however, be saponified readily under alkaline conditions with the formation of the desired compounds I.
Oxidative cleavage of the compounds (I), for example using HIO 4 or salts thereof, KMnO 4 or lead tetraacetate, and subsequent reduction of the 1-oxa-2-oxo-3-R-3-aza-5-formylcyclopentanes formed as intermediates leads to the corresponding 1-oxa-2-oxo-3-R-3-aza-5-hydroxymethylcyclopentanes (III), for example to toloxatone (R=m-tolyl). If compounds (I) wherein the C(5) atom has the S-configuration are used, the corresponding 1-oxa-2-oxo-3-R-3-aza5S-hydroxymethylcyclopentanes are obtained. The conversion of the 3-isopropyl compound into S-propranolol is known. The corresponding 5-chloromethyl, 5-bromomethyl, 5-acyloxymethyl (for example also 5-methanesulphonyloxymethyl or 5-p-toluenesulphonyloxymethyl), 5-alkoxymethyl or 5-aryloxymethyl derivatives can be prepared from the compounds III by reaction with SOCl 2 or PBr 3 or by esterification or etherification.
The compounds I can be used as intermediate products for the preparation of active compounds for medicaments, such as toloxatone or certain beta receptor blockers.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
In the preceding text and the following examples, all temperatures are set forth uncorrected in degrees Celsius and all parts and percentages are by weight; unless otherwise indicated.
EXAMPLE 1
1.62 g of carbonyldiimidazole are added to a solution of 2.71 g of N-m-tolyl-2S,3R,4R,5R,6-pentahydroxyhexylamine [IIa; m.p. 111°-114°, obtainable from D-glucose and m-toluidine/H 2 /Pd-C in methanol/water] in 30 ml of DMF, and the mixture is stirred for 3 hours at 20°. After the mixture has been concentrated, imidazole is removed by distillation at 130°/0.2 bar. This gives 1-oxa-2-oxo-3-m-tolyl-3-aza-5S-(1R,2R,3R,4-tetrahydroxybutyl)-cyclopentane (Ia), which is purified by chromatography over silica gel. Rf 0.45 (90:10:5 methylene dichloride/methanol/acetic acid).
EXAMPLE 2
A mixture of 2.71 g of IIa, 10 ml of diethyl carbonate and 0.5 ml of triethylamine is stirred for 23 hours at 110°-120°. The mixture is evaporated and the residue is chromatographed over silica gel to give Ia.
EXAMPLE 3
A mixture of 2.71 g of IIa, 0.72 g of urea and 0.1 g of KOH is heated at 140°-150° for 2 hours. After cooling, the Ia obtained is chromatographed over silica gel.
EXAMPLE 4
A mixture of 2.71 g of IIa and 4 g of ethylene carbonate is heated at 100° for 3 hours. The mixture is evaporated and the residue is chromatographed over silica gel to give Ia.
EXAMPLES 5 to 20
The following 1-oxa-2-oxo-3-aza-5S-(1R,2R,3R,4-tetrahydroxybutyl)-cyclopentanes are obtained, analogously to Example 1, 2, 3 or 4, from N-methylglucamine, N-ethyl-glucamine, N-propylglucamine, N-isopropylglucamine, N-butylglucamine, N-isobutylglucamine, N-sec.-butylglucamine, N-tert.-butylglucamine, N-(2-hydroxyethyl)-glucamine, N-cyclohexylglucamine, N-phenylglucamine, N-p-methoxyphenylglucamine, N-(2-phenylethyl)-glucamine, N-(1,1-dimethyl-2-phenylethyl)-glucamine, N-[2-(3,4-dimethoxyphenyl)-ethyl]-glucamine and N-[2-(3,4-methylenedioxyphenyl)-ethyl]-glucamine respectively:
5. The 3-methyl derivative, m.p. 155°.
6. The 3-ethyl derivative.
7. The 3-propyl derivative.
8. The 3-isopropyl derivative, m.p. 163°.
9. The 3-butyl derivative.
10. The 3-isobutyl derivative.
11. The 3-sec.-butyl derivative.
12. The 3-tert.-butyl derivative, m.p. 158°.
13. The 3-(2-hydroxyethyl) derivative.
14. The 3-cyclohexyl derivative.
15. The 3-phenyl derivative.
16. The 3-p-methoxyphenyl derivative.
17. The 3-(2-phenylethyl) derivative.
18. The 3-(1,1-dimethyl-2-phenylethyl) derivative.
19. The 3-[2-(3,4-dimethoxyphenyl)-ethyl] derivative.
20. The 3-[2-(3,4-methylenedioxyphenyl)-ethyl] derivative.
EXAMPLE 21
1-oxa-2-oxo-3-isopropyl-3-aza-5R-(1R,2R,3R,4-tetrahydroxybutyl)-cyclopentane is obtained, analogously to Example 2, from N-isopropyl-2R,3R,4R,5R,6-pentahydroxyhexylamine (m.p. 122°; obtainable by treating a solution of D-mannose and isopropylamine in methanol/water with H 2 over 5% Pd-on-C for 3 hours at 50° and 3 bar).
EXAMPLE 22
100 mg of KOH powder are added to a solution of 2.37 g of N-tert.-butyl-2S,3R,4R,5R,6-pentahydroxyhexylamine (m.p. 112°; obtainable from D-glucose and tert.-butylamine/H 2 /Pd-C) in 10 ml of diethyl carbonate, and the mixture is heated at 120° for 4 hours. The mixture is concentrated, the residue is taken up in ethanol and the solution is filtered. After cooling, the crystals which have been precipitated are filtered off with suction; m.p. 212°. The carbonate-ester groups which have been formed are saponified by warming the intermediate product briefly with a mixture of 3 ml of methanol, 3 ml of water and 0.5 g of KOH. After neutralization with hydrochloric acid; the solution is concentrated, the residue is extracted with methylene dichloride, and the extract is evaporated to give 1-oxa-2-oxo-3-tert.-butyl-3-aza-5S-(1R,2R,3R,4-tetrahydroxybutyl)-cyclopentane, m.p. 158°.
USE EXAMPLE 1
7.2 g of NaIO 4 are added at 20° to a suspension of 2.97 g of Ia in 180 ml of water, and the mixture is stirred for 30 minutes. The pH is then adjusted to 8 and 0.2 g of NaBH 4 are added in portions at 20°. After being stirred for a further 1.5 hours, the mixture is extracted with methylene dichloride, the extract is dried with Na 2 SO 4 and evaporated and the residue is purified by chromatography. This gives 1-oxa-2-oxo-3-m-tolyl-3-aza-5S-hydroxymethylcyclopentane.
USE EXAMPLES 2 to 17
The following 1-oxa-2-oxo-3-aza-5S-hydroxymethylcyclopentanes are obtained, analogously to Use Example 1, by oxidative cleavage and subsequent reduction of the compounds mentioned in Examples 5 to 20:
2. The 3-methyl derivative.
3. The 3-ethyl derivative.
4. The 3-propyl derivative.
5. The 3-isopropyl derivative, m.p. 55°-58°.
6. The 3-butyl derivative.
7. The 3-isobutyl derivative.
8. The 3-sec.-butyl derivative.
9. The 3-tert.-butyl derivative.
10. The 3-(2-hydroxyethyl) derivative.
11. The 3-cyclohexyl derivative.
12. The 3-phenyl derivative.
13. The 3-p-methoxyphenyl derivative.
14. The 3-(2-phenylethyl) derivative.
15. The 3-(1,1-dimethyl-2-phenylethyl) derivative.
16. The 3-[2-(3,4-dimethoxyphenyl)-ethyl] derivative.
17. The 3-[2-(3,4-methylenedioxyphenyl)-ethyl]derivative.
The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. | New 1-oxa-2-oxo-3-R-3-aza- 5-Z-cyclopentane derivatives, wherein
R is alkyl or hydroxyalkyl having in each case 1-6 C atoms, cycloalkyl having 3-8 C atoms, unsubstituted aryl or aralkyl or aryl or aralkyl each of which has a total of 6-15 C atoms and, in the aryl radical, is monosubstituted to trisubstituted by alkyl, alkoxy, OH and/or Cl or monosubstituted by methylenedioxy,
Z is --(CHOH) n --H and
n is 2, 3, 4 or 5,
can be used as intermediate products for the preparation of active compounds for medicaments, such as toloxatone. | 2 |
RELATED APPLICATIONS
This application is related to the following applications, all of which are filed on the same day and assigned to the same assignee as the present application:
“Aggregation Design in Database Services”—Ser. No. 09/338,212, filed on Jun. 22, 1999 issued as U.S. Pat. No. 6,366,905 on Apr. 2, 2002,
“Aggregation Size Estimation in Relational and OLAP Databases”—Ser. No. 09/338,390 filed on Jun. 22, 1999,
“Aggregation Performance Estimation in Relational and OLAP Databases”—Ser. No. 09/337,751 filed on Jun. 22, 1999 issued as U.S. Pat. No. 6,374,234 on Apr. 16, 2002,
“Usage Based Aggregation Optimization”—Ser. No. 09/337,226 filed Jun. 22, 1999, and
“Record for Multidimensional Database With Flexible Pathing”—Ser. No. 09/338,207 filed on Jun. 22, 1999.
COPYRIGHT NOTICE AND PERMISSION
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice shall apply to this document: Copyright © 1999, Microsoft, Inc.
FIELD
The present invention pertains generally to computer-implemented databases, and more particularly to storing records in such databases.
BACKGROUND
Online analytical processing (OLAP) is a key part of most data warehouse and business analysis systems. OLAP services provide for fast analysis of multidimensional information. For this purpose, OLAP services provide for multidimensional access and navigation of data in an intuitive and natural way, providing a global view of data that can be drilled down into particular data of interest. Speed and response time are important attributes of OLAP services that allow users to browse and analyze data online in an efficient manner. Further, OLAP services typically provide analytical tools to rank, aggregate, and calculate lead and lag indicators for the data under analysis.
In this context, a dimension is a structural attribute of a cube that is a list of members of a similar type in the user's perception of the data. Typically, there is a hierarchy associated with the dimension. For example, a time dimension can consist of days, weeks, months, and years, while a geography dimension can consist of cities, states/provinces, and countries. Dimension members act as indices for identifying a particular cell or range of cells within a multidimensional array. Each cell contains a value, also referred to as a measurement.
One issue regarding the design of multidimensional databases is how to represent the cells in the multidimensional space. One potential design choice is to represent the multidimensional space as an array of cells, with the size of the array determined by the multiplication of the number of points in each dimension. A significant problem with this approach is that the size of the database grows exponentially as the number of dimensions and the size of each dimension increases. This leads to a rapid depletion of the physical resources such as persistent storage and RAM required to implement the database. This phenomenon is known as data explosion for multidimensional databases.
In addition, much of the space is wasted in the above-mentioned approach. Data in multidimensional databases tends to be sparse, that is, not every cell is expected to have a value associated with it. For example, consider a Store dimension having a hierarchy of Country, State, and City specifying the location of a store, and a Product dimension having a product identification and a product count measure. No store in the in the database will be expected to stock every possible product, and in fact any one store may only stock 20% of the available products. In this situation, most of the cells in the multidimensional space would contain no data, thus wasting much of the space allocated to the database.
A second issue relates to locating cells in the multidimensional space. It is desirable to be able to locate cells quickly in order to provide acceptable system throughput. Representing the cells as a multidimensional array provides for rapid access to the cells, but has the data explosion problem mentioned above.
A third issue relates to the capability to perform aggregations on the multidimensional data. Databases are commonly queried for aggregations (e.g. summaries, minimums, maximums, counts etc.) of detail data rather than individual data items. For example, a user might want to know sales data for a given period of time without regard to geographical distinctions. These types of queries are efficiently answered through aggregations. Aggregations are precomputed summaries of selected detail data that allow an OLAP system or a relational database to respond quickly to queries by avoiding collecting and aggregating detailed data during query execution. Without aggregations, the system would need to scan all of the rows containing the detailed data to answer these queries, resulting in potentially substantial processing delays. With aggregations, the system computes and materializes aggregations ahead of time so that when the query is submitted to the system, the appropriate summary already exists and can be sent to the user much more quickly. Calculating these aggregations, however, can be costly, both in terms of processing time and in terms of disk space consumed.
Thus there is a need for a system that stores cell data for a multidimensional database in an efficient manner. There is a need for such a system that provides the ability to locate cells rapidly and efficiently. Furthermore, there is a need for such a system that is able to perform aggregations in an efficient manner.
SUMMARY
The above-mentioned shortcomings, disadvantages and problems are addressed by the present invention, which will be understood by reading and studying the following specification.
The systems and methods described herein create and maintain cell data records in an OLAP database system. One aspect of the system is that cell data records are created that contain a system path. The system path is comprised of one or more dimension paths that define the location of a cell in a multidimensional database. The format used for the dimension paths provides an efficient mechanism for locating the cell, and in addition, can be indexed easily to allow rapid location of cell data.
A further aspect of the system is that the format of the system path provides an efficient mechanism for creating aggregations. Those dimension levels that are to be aggregated have their corresponding member index set to a null value in the dimension path of each record. The records are then scanned for a match to a system path representing the aggregation. Those that match have their measure data included in the aggregation.
The present invention describes systems, clients, servers, methods, and computer-readable media of varying scope. In addition to the aspects and advantages of the present invention described in this summary, further aspects and advantages of the invention will become apparent by reference to the drawings and by reading the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagram of the hardware and operating environment in conjunction with which embodiments of the invention may be practiced;
FIGS. 2A-2C are diagrams illustrating an exemplary dimension hierarchy within a multidimensional database;
FIG. 3 is a diagram illustrating a record structure for a cell data record according to an embodiment of the invention;
FIG. 4 is a system level overview of various embodiments of the invention;
FIG. 5 is a flowchart illustrating a process for creating a cell data record according to an embodiment of the invention; and
FIG. 6 is a flowchart illustrating a process for calculating an aggregation according to an embodiment of the invention.
DETAILED DESCRIPTION
In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
The detailed description is divided into five sections. In the first section, the hardware and the operating environment in conjunction with which embodiments of the invention may be practiced are described. In the second section, an exemplary cube for an OLAP system is described. In the third section, a system level overview of an exemplary embodiment of the invention is presented. In the fourth section, methods of an exemplary embodiment of the invention are provided. Finally, in the fifth section, a conclusion of the detailed description is provided.
Hardware and Operating Environment
FIG. 1 is a diagram of the hardware and operating environment in conjunction with which embodiments of the invention may be practiced. The description of FIG. 1 is intended to provide a brief, general description of suitable computer hardware and a suitable computing environment in conjunction with which the invention may be implemented. Although not required, the invention is described in the general context of computer-executable instructions, such as program modules, being executed by a computer, such as a personal computer. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types.
Moreover, those skilled in the art will appreciate that the invention may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCS, minicomputers, mainframe computers, and the like. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
The exemplary hardware and operating environment of FIG. 1 for implementing the invention includes a general purpose computing device in the form of a computer 20 , including a processing unit 21 , a system memory 22 , and a system bus 23 that operatively couples various system components including the system memory to the processing unit 21 . There may be only one or there may be more than one processing unit 21 , such that the processor of computer 20 comprises a single central-processing unit (CPU), or a plurality of processing units, commonly referred to as a parallel processing environment. The computer 20 may be a conventional computer, a distributed computer, or any other type of computer; the invention is not so limited.
The system bus 23 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The system memory may also be referred to as simply the memory, and includes read only memory (ROM) 24 and random access memory (RAM) 25 . A basic input/output system (BIOS) 26 , containing the basic routines that help to transfer information between elements within the computer 20 , such as during start-up, is stored in ROM 24 . The computer 20 further includes a hard disk drive 27 for reading from and writing to a hard disk, not shown, a magnetic disk drive 28 for reading from or writing to a removable magnetic disk 29 , and an optical disk drive 30 for reading from or writing to a removable optical disk 31 such as a CD ROM or other optical media.
The hard disk drive 27 , magnetic disk drive 28 , and optical disk drive 30 are connected to the system bus 23 by a hard disk drive interface 32 , a magnetic disk drive interface 33 , and an optical disk drive interface 34 , respectively. The drives and their associated computer-readable media provide nonvolatile storage of computer-readable instructions, data structures, program modules and other data for the computer 20 . It should be appreciated by those skilled in the art that any type of computer-readable media which can store data that is accessible by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, random access memories (RAMs), read only memories (ROMs), and the like, may be used in the exemplary operating environment.
A number of program modules may be stored on the hard disk, magnetic disk 29 , optical disk 31 , ROM 24 , or RAM 25 , including an operating system 35 , one or more application programs 36 , other program modules 37 , and program data 38 . A user may enter commands and information into the personal computer 20 through input devices such as a keyboard 40 and pointing device 42 . Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 21 through a serial port interface 46 that is coupled to the system bus, but may be connected by other interfaces, such as a parallel port, game port, or a universal serial bus (USB). A monitor 47 or other type of display device is also connected to the system bus 23 via an interface, such as a video adapter 48 . In addition to the monitor, computers typically include other peripheral output devices (not shown), such as speakers and printers.
The computer 20 may operate in a networked environment using logical connections to one or more remote computers, such as remote computer 49 . These logical connections are achieved by a communication device coupled to or a part of the computer 20 ; the invention is not limited to a particular type of communications device. The remote computer 49 may be another computer, a server, a router, a network PC, a client, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 20 , although only a memory storage device 50 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local-area network (LAN) 51 and a wide-area network (WAN) 52 . Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
When used in a LAN-networking environment, the computer 20 is connected to the local network 51 through a network interface or adapter 53 , which is one type of communications device. When used in a WAN-networking environment, the computer 20 typically includes a modem 54 , a type of communications device, or any other type of communications device for establishing communications over the wide area network 52 , such as the Internet. The modem 54 , which may be internal or external, is connected to the system bus 23 via the serial port interface 46 . In a networked environment, program modules depicted relative to the personal computer 20 , or portions thereof, may be stored in the remote memory storage device. It is appreciated that the network connections shown are exemplary and other means of and communications devices for establishing a communications link between the computers may be used.
The hardware and operating environment in conjunction with which embodiments of the invention may be practiced has been described. The computer in conjunction with which embodiments of the invention may be practiced may be a conventional computer, a distributed computer, or any other type of computer; the invention is not so limited. Such a computer typically includes one or more processing units as its processor, and a computer-readable medium such as a memory. The computer may also include a communications device such as a network adapter or a modem, so that it is able to communicatively couple other computers.
Exemplary Cube and Dimension
In the detailed description that follows, reference will be made to a small, three-dimensional OLAP cube. This cube has a Customers dimension with four levels: All, State, City and Customer. The second dimension, a Products dimension, has three levels: All, Category and Product. The final dimension is a time dimension with three hierarchy levels: year, quarter, and month. In addition, the cube has two measures, Purchases and Units. This cube is presented to provide a reference example of how the systems and methods of the invention operate. It will be appreciated that the OLAP cubes maintained by various embodiments of the invention can have more or fewer dimensions than in this example, and that the OLAP cube can have more or fewer hierarchy levels than in this example.
A graphical representation of the dimensions in the above-described cube is presented in FIGS. 2A-2C. A dimension is represented as a tree, referred to as a dimension tree. Leaf nodes in the tree correspond to the most detailed data in the dimension, while the inner branch nodes correspond to more aggregated data. The closer the node is to the root node, the more aggregated the data, with the root node representing the most aggregated, least detailed data in the dimension.
The Customer dimension is represented in FIG. 2 A. In this exemplary representation, the State level has three members: Maine, Oregon and Washington. The Cities level has four members: Portland (Me.), Portland (Oreg.), Redmond and Seattle. It should be noted although a member labeled Portland appears twice, each member is a distinct reference because it appears under a different State member in the hierarchy. The Customer level has four members: Alexander, Amir, Mosha and Sasha. The Products dimension is represented in FIG. 2 B. In the exemplary representation, the Category level has three members: Food, Drink, and Non-Consumable. The Product level has one member, Milk.
The Time dimension is represented in FIG. 2 C. In the exemplary representation, The Year level has three members: 1997, 1998, and 1999. The Quarter level has four members: Q 1 -Q 4 . The Month level has no members, indicating that no monthly data is available. In this case, the most detailed data available is at the Quarter level.
In order to uniquely identify a particular member, each of the members from the root node to the leaf node for the member must be specified. For example, in order to refer to the customer Amir in the Customers dimension shown in FIG. 2A the following sequence of members is specified: {All Customers}. {WA}. {Redmond}. {Amir}. Similarly, to refer to Quarter 2 in the Time dimension shown in FIG. 2C, the members specified are: {1998}.{Q 2 }.
Those of skill in the art will appreciate that the members shown in FIGS. 2A-2C represent an exemplary cube and that no embodiment of the invention is limited to a particular number or type of dimensions or dimension members.
In the above example, strings representing member names are used to designate a particular member of a dimension. In an embodiment of the invention, the strings above are replaced by numbers associated with each member in a dimension. It is desirable to represent the members using numbers as it is more efficient to represent objects using numbers rather than strings. In this embodiment, a path from the root node to a branch node is represented by the member number at each level of the dimension that is traversed to reach the leaf node. The number assigned to each member must be unique among the members having a common parent, in other words, a unique number must be assigned to each of the siblings of a parent. In one embodiment of the invention, the root node is assigned the number 1 while branch and leaf nodes are assigned a number representing their order among their siblings. However the invention is not limited to any particular numbering scheme for the node, all that is required is that the number be unique among the nodes having a common parent.
Thus, each member in a dimension can be represented by an array of numbers defining the path to the member. This array is the dimension path. The number of elements in the array is the number of levels in the dimension, and the position in the array reflects the hierarchy of levels. For example referring to FIG. 2A, the representation for member Amir in the Customers dimension is the dimension path {1-48-2-2}. This represents the path comprising the root node All Customers (1), the WA member at the state level (WA is the 48 th state alphabetically), the Redmond member at the city level (Redmond is the second city at that level under WA), and the member Amir at the customer level (Amir is the second customer under Redmond). Note that each level must be represented by a number in the array, if the member is not at a leaf node, the number 0 is used in one embodiment of the invention to represent the positions for the levels below the member. Thus the dimension path array for the member Portland, Oreg. in the Customer dimension is {1-38-1-0}.
Not all dimensions have a single root member. For example, consider the Time dimension of the exemplary cube. There is no single “all time” member at the top-most level in this dimension, rather the Time dimension contains three members, each specifying a particular year. In this case, one embodiment of the invention assigns an index number to each members in the top-most level based on a natural order of the members. This natural order can be based on a numeric order, an alphabetic order, or the temporal order in which the members were created. For instance, in FIG. 2C, the dimension path for Q 3 in the year 1998 is {2-3-0} (1998 is the second year at the top-most level, Q 3 is the third member under 1998, and there are no month members).
Each data cell in a multidimensional database is uniquely identified by specifying a coordinate on each dimension. In one embodiment of the invention, a cell is identified by specifying a dimension path for each dimension in a cube in the multidimensional database. The collection of dimension paths comprising the coordinates for the cell are concatenated and stored in an array referred to as the system path. In an embodiment of the invention, the order of dimension paths in the system path is dependent on the internal order of the dimensions in the cube, as determined by the metadata defining the cube. However, the invention is not limited to a particular ordering scheme and other ordering schemes are possible and within the scope of the invention. For example, the order of dimension paths could be determined alphabetically by the name of the dimension.
To illustrate the system path described above, consider the cell associated with the customer Amir for All Products in Quarter 4 of 1998. The string representation for the cell path is: ({Customers}. {All 13 Customers}. {WA}. {Redmond}. {Amir}, {Products}. {All Products}, {Time}.{1998}.{Q 4 }). The corresponding system path is: {1-48-2-2}-{1-0-0}- { 2-4-0 }.
Each cell in a multidimensional database has one or more measures associated with it. In the exemplary cube, two measures are defined, Purchases and Units, where Purchases is the dollar amount of a particular purchase, and Units is the number of units purchased. FIG. 3 illustrates a data structure for a cell record 300 according to one embodiment of the invention. Cell record 300 contains a system path 305 and one or more measures 310 . As described above, system path 305 comprises one or more dimension paths 315 . The order of measures 310 in record 300 can be determined by the order of the measures in the metadata defining the cube, the temporal order in which the measure were defined, or an alphabetic order. The invention is not limited to any particular ordering mechanism.
This section of the detailed description has described a representation of cells in a multidimensional database, and a data structure for storing a cell record. In the sections that follow, systems and methods for creating and manipulating the cell data will be described.
System Level Overview
A system level overview of the operation of an exemplary embodiment of the invention is described by reference to FIG. 4 . The concepts of the invention are described as operating in a multiprocessing, multithreaded virtual memory operating environment on a computer, such as computer 20 in FIG. 1 . The operating environment includes an OLAP client 402 , OLAP server 410 , local data store 414 , and fact data store 420 , all of which operate on the cell records for cubes, including the records and cube described in the previous section.
OLAP client 402 is an application program that requires the services of an OLAP system. OLAP client 402 can be any type of application that interacts with the OLAP system, for example, a data mining application, a data warehousing application, a reporting application etc. OLAP client 402 typically interacts with OLAP server 260 by issuing OLAP queries. These queries are parsed, as is known in the art, into a request for data from a cell or range of cells, and the request is passed to the OLAP server 410 .
OLAP server 410 receives queries and controls the processing of queries. In one embodiment of the invention, the server maintains a local store 414 that contains the cell data used to answer the queries. In one embodiment of the invention, the OLAP server 410 is a version of the SQL Server OLAP product from Microsoft Corporation.
The local store 414 contains records describing the cells that are present in a multidimensional database, with one record used for each cell that actually has measurement data present (i.e. no records exist for those cells having no measurement data). The general format of these records is described above with reference to FIG. 3 . In one embodiment of the invention, local store 414 is a relational database, such as SQL Server. In this embodiment, records are stored in a relational table. This table can be indexed based on the dimensional paths of the record to allow rapid access to cell measurement data contained in the record. The indexing can be performed using hash indexing or AVL tree indexing as is known in the art.
OLAP server 410 populates local store 414 by reading data from fact data store 420 . Fact data store 420 is also a relational database system. In one embodiment of the invention, the system used is the SQL Server Database from Microsoft Corporation. In alternative embodiments of the invention, database systems such as Oracle, Informix or Sybase can be used. The invention is not limited to any particular type of relational database system.
OLAP server 410 reads the fact data (also known as detail data) from fact data store 420 at predetermined times, and converts the fact data into cell data records for populating local data store 414 . In one embodiment of the invention, the fact data is read once during a 24 hour period, typically during a time when the fact data store is not busy responding to user queries. In an alternative embodiment of the invention, the fact data is read and converted when a system administrator issues a command to the OLAP server 410 to do so. Updates to the local data store 414 can be incremental, or they can result in a complete refresh of the data. Incremental updates are desirable, because only the data that has changed in fact data store 420 need be converted and added to local data store 414 . However, if the structure of the data in either fact data store 420 or local data store 414 changes, then a complete refresh is required. The frequency of updates to the local store 414 will generally be determined by user requirements as to how current (or accurate) the cell data must be, and the volume of data that must be updated.
In one embodiment of the invention, the OLAP server 410 maintains a cache 412 of cell records. In this embodiment, the cache maintains cell data records that have been recently requested, or those cell data records that are frequently requested. Maintaining cell record data in a cache is desirable, because it provides quicker responses to queries that can be satisfied by records appearing in the cache.
Methods of an Exemplary Embodiment of the Invention
In the previous section, a system level overview of the operation of an exemplary embodiment of the invention was described. In this section, the particular methods of the invention performed by an operating environment executing an exemplary embodiment are described by reference to a series of flowcharts shown in FIGS. 5 and 6. The methods to be performed by the operating environment constitute computer programs made up of computer-executable instructions. Describing the methods by reference to a flowchart enables one skilled in the art to develop such programs including such instructions to carry out the methods on suitable computers (the processor of the computer executing the instructions from computer-readable media). The methods illustrated in FIGS. 5 and 6 are inclusive of the acts required to be taken by an operating environment executing an exemplary embodiment of the invention.
A method for creating a cell data record is illustrated in FIG. 5 . The method begins when a program executing the method, such as OLAP server 420 , discovers that a new cell is required, and receives a value to be used for the measure of the new cell (block 502 ). Typically the new cell will be required because OLAP Server 410 has discovered that a new row has been added to a detail table in a fact data store 420 (FIG. 4) since the last update of the local data store 414 .
Next, the program determines the dimension path for each dimension in the cube to which the cell belongs (block 504 ). As discussed above, cells are located by specifying members in each dimension of the cube. The members will reside at a particular level of a dimension tree formed by the levels of the dimension and the members at each level. In one embodiment of the invention, the dimension path is an array of ordinal numbers, one for each level in the dimension. The position of each ordinal number in the array is determined by the position of the level in the dimension hierarchy. The ordinal number at a position is determined by an ordering of the members at the particular level represented by the position that have a common parent. If the new cell is not a leaf node, then a value of 0 is used in the dimension path to represent each of the levels below the new cell.
The program then proceeds to concatenate the dimension paths formed at block 504 into a system path (block 506 ) for the new cell record. In one embodiment of the invention, the ordering of the dimension paths in the system path is determined by order the dimensions are defined in the cube metadata. However, the invention is not so limited, and in alternative embodiments, the ordering can be determined by temporal order or alphabetic order.
Next, the measure data is copied into an appropriate field in the cell record (block 508 ). The cell record contains a field for each measure present in the cube. The ordering of measures within a record is also determined by the metadata defining the cube.
Finally, the cell record is stored in the local data store (block 510 ). In one embodiment of the invention, the cell record is stored as a row of a relational database. The row can be indexed by the system path, allowing subsequent queries requiring the cell's measures to find the cell quickly.
FIG. 6 shows a method for creating an aggregation of cell data records created using the method described above in reference to FIG. 5 . Table 1 below provides an exemplary set of data that will be used to demonstrate the results of executing the method. The system paths shown in Table 1are created using the dimensions of the multidimensional database illustrated in FIGS. 2A-2C. Table 1 contains four records created as described above in reference to FIG. 5 . The Member column shows the name of the member in the customer dimension, the System Path column shows the system path corresponding to the cells location in the customer, product and time dimensions (in that order). The third column shows the Product Sales measure for the cell referenced by the system path. The four records represent sales to four customers, Sasha, Alexander, Amir and Mosha for all products in the fourth quarter of 1998.
TABLE 1
Member
System Path
Product Sales
Alexander
{1-48-2-1}-{1-0-0}-{2-4-0}
$3,000.00
Amir
{1-48-2-2}-{1-0-0}-{2-4-0}
$2,500.00
Mosha
{1-48-2-3}-{1-0-0}-{2-4-0}
$5,000.00
Sasha
{1-20-1-1}-{1-0-0}-{2-4-0}
$8,000.00
A program executing the method, such as OLAP server 410 , begins by identifying a dimension and level to aggregate (block 602 ). Typically this will be in response to a request to create an aggregation. The request may come from a system administrator, or it can be a system generated request. As an example, consider a request to aggregate all of the customer sales in Redmond, Wash. in the fourth quarter of 1998.
In response to the request, the system then creates a system path for the aggregation record using the dimensions and levels specified in the request (block 604 ). For the example case, the aggregation system path is {1-48-2-0}-{1-0-0}-{2-4-0}.
Next, the system scans the local data store containing the cell data records, and “nullifies” (sets to null) the level numbers in the dimension paths for those levels at or below the levels are to be aggregated (block 606 ). Table 2 shows the results of nullifying the appropriate level numbers.
TABLE 2
Member
System Path
Product Sales
Alexander
{1-48-2-0}-{1-0-0}-{2-4-0}
$3,000.00
Amir
{1-48-2-0}-{1-0-0}-{2-4-0}
$2,500.00
Mosha
{1-48-2-0}-{1-0-0}-{2-4-0}
$5,000.00
Sasha
{1-20-1-0}-{1-0-0}-{2-4-0}
$8,000.00
Next, a program executing the method sums the desired measure for all cell records where the system path of the cell record matches the system path of the aggregation record (block 608 ). In the example shown above, the aggregation record is: {1-48-2-0}-{1-0-0}-{2-4-0}{$10500.00}
This aggregation reflects the fact that system paths for Customer members Alexander, Amir and Mosha matched the aggregation system path.
Finally, the system stores the aggregation record (block 610 ). In one embodiment of the invention, the aggregation record is stored in a cache maintained by the OLAP server. This is desirable, because it allows the aggregation record to be located quickly, thereby increasing system throughput.
In one embodiment of the invention, the nullification of dimension path elements is accomplished using temporary buffers. The source records are kept in their original, unconverted state and the nullification and summation operations described above are performed on copies of the source records maintained in the temporary buffers. This has the advantage that there is no need to restore values in the source records after the aggregation has been performed, the system need only delete the temporary buffers.
Conclusion
The creation and maintenance of a cell data record for a multidimensional database has been described. The systems and methods of the invention provide advantages not found in previous systems. For example, only those cells that actually contain measure data have records allocated to them. This provides for the efficient storage of cell data, even when the cell data is sparse. In addition, the format used to specify the dimensions and levels used to locate the cell can be easily indexed to allow the cell data to be located quickly. Furthermore, the format of the record allows cell data to be easily aggregated.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of the present invention. For example, those of ordinary skill within the art will appreciate that while the systems and methods have been described in the context of a multidimensional database system, the systems and method of the invention can be applied to other data that is hierarchical in nature. The terminology used in this application with respect creating and maintaining cell records is meant to include all of these environments. Therefore, it is manifestly intended that this invention be limited only by the following claims and equivalents thereof. | Creating and maintaining cell data records in a multidimensional database is disclosed. The systems and methods of the invention define an efficient mechanism to specify a cell's location within the multidimensional database where there are hierarchies of levels within a dimension. The format used lends itself well to indexing, and also to creating aggregations of the cell data. | 8 |
This application is a continuation-in-part of U.S. patent application Ser. No. 09/272,824, filed on Mar. 19, 1999, having the title “Support System for Vessels Such as Swimming Pools,” which was a continuation of U.S. patent application Ser. No. 08/858,637, now issued as U.S. Pat. No. 5,884,347, filed May 19, 1997, having the same title, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to vessels such as swimming pools and more particularly to strapless support systems for above-ground swimming pools and to buttresses for walls of the above-ground swimming pools.
BACKGROUND OF THE INVENTION
The popularity of swimming pools, particularly in residential areas, continues to increase. This increased popularity is based at least in part on the availability of aesthetically appealing above-ground pools, whose durability permits cost-effective purchasing by consumers. Above-ground pools additionally are particularly useful in areas where substantial excavation is either impermissible or undesirable. In densely-populated regions, for example, residential lawns may not be sufficiently large to accommodate the space required for in-ground pools. Moreover, in some cases they may be inadequate to accommodate the equipment necessary to excavate in-ground pools, even if space for such pools exists. Alternatively, above-ground pools may be preferable because of the decreased time typically needed for installation (and, if necessary, removal) or the lesser maintenance requirements and costs often associated with them.
Many substantially-permanent above-ground pools are generally either circular or oval in shape, with each type comprising multiple vertical walls and a frame. Because of their strength, galvanized steel or other compositions are usually chosen as materials from which the walls are made. Nonetheless, water pressure present at and near the bottoms of filled pools often requires the walls of above-ground pools to be braced for reliable performance. This bracing requirement is particularly pertinent in connection with oval pools, whose elongated side walls are especially vulnerable to collapse from the outward pressure exerted by the water contained therein.
As a consequence of this vulnerability, existing oval above-ground pools are constructed with braces supporting the lower sections of their side walls. Each brace includes three pieces, denominated an “upright” portion, an “angled” portion, and a “connecting” portion. FIG. 1 illustrates such braces 10 of above-ground pool 14 , whose generally oval shape requires use of multiple vertical side walls 18 . As shown in FIG. 1, upright portion 22 extends upward from bottom 26 of side wall 18 , with connecting portion 28 being either at ground level or buried underground. An end of each of upright portion 22 and angled portion 30 connects to a respective end of connecting portion 28 , while the other end 34 of angled portion 30 attaches to upright portion 22 . The resulting structure resembles the outline of a right triangle, with angled portion 30 constituting the hypotenuse.
FIG. 1 details the protruding nature of braces 10 . Such braces 10 frequently extend outward several feet from side walls 18 on both sides of pool 14 , increasing the surface area of the lawn required for installing the pool. This increased surface area can cause difficulties in installing pools in areas subject to covenants or zoning regulations, as insufficient land may remain post-installation to meet setback and other legal or contractual requirements. Braces 10 may also inhibit lawn maintenance adjacent pool 14 and, to some, may detract from the aesthetic appeal of the pool itself. The three-piece structure of each brace 10 additionally increases its associated manufacturing and installing cost, while supporting less than the entire vertical height of a side wall 18 .
Furthermore, the nature of above-ground pools requires support straps that extend a substantial horizontal distance beneath the pool. Such straps render it difficult to construct a pool having a “deep” end because the straps run the substantial horizontal length of the pool and prevent the liner forming the bottom of the pool from filling a hole that has a depth extending below the straps. Removing the straps changes pressure allocations. It is thus desirable to provide a pool that alleviates the need for straps extending a substantial distance below the pool and that alleviates the protruding braces shown in FIG. 1, while providing support for a deep pool or a pool having a deep end. It is also desirable to provide such a pool that keeps the pool removable, i.e., that does not require a concrete fill and that is easy to assemble.
SUMMARY OF THE INVENTION
The present invention, by contrast, provides a support system intended to resolve these issues. Particularly suited for vessels such as elongated above-ground pools, the support system includes a set of, typically, one-piece buttresses adapted to support the entire vertical height of one or each of a series of side walls. The flared design of the buttress, furthermore, matches the support it provides the side wall to the outward water pressure present along its height for enhanced reliability, permitting use of fewer buttresses than the number of existing braces that would otherwise be necessary. The one-piece design of the buttress further eliminates some of the manufacturing and installation costs associated with existing braces, while its sleek appearance is more likely to please discerning observers.
The diminished footprint of the innovative buttress additionally reduces the surface area required for its corresponding pool. Setback and similar requirements thus pose fewer problems than with existing pools, permitting pools incorporating the present invention to be located in smaller (especially narrower) lawns. Consequently, more residential customers in densely-populated areas are able to situate these pools in the lawn space available to them, increasing the market for the pools beyond that existing today. Abolishing the open areas between the angled portions of current braces and the ground additionally avoids many of the difficulties associated with providing lawn care in those areas. Additionally, residential and other customers are able to enjoy pools having deep ends because of a feature that makes it possible to provide an area of the pool that is deeper than a standard installation provides.
In some embodiments of the invention, each buttress is a unitary structure whose height approximates that of the side wall or walls of its associated pool. At least one surface of the buttress contacts the side wall along substantially its entire height, supporting the height of the wall continuously against the outward pressure exerted when the pool is filled with water. Because the buttress defined by these embodiments flares along its height it assumes, in side elevational view, the general form of a truncated, solid triangle. Embodiments of the buttress further comprise notched sections to retain the bottom rim of the pool—and therefore help retain the side walls—in place.
Additionally included in some support systems of the present invention may be elongated cross-members spanning the width of the pool. Often called “omegas” because of their cross-sectional appearance, the cross-members, when present, are buried so that only their upper surfaces are above the ground. Buttresses on each side of the pool may be bolted or otherwise attached to the upper surfaces to retain them in position relative to the ground. Protruding from the upper surface of a cross-member adjacent its ends are one or more tabs, which in use fit into slots in the bottom rim of the pool to maintain its position. The buttresses, side walls, bottom rim, and cross-members thus can interact to preserve the position and structure of the pool relative to the ground. Alternatively, the buttresses may extend below ground level and be bolted, interlocked, or otherwise connected or fitted to the cross-members.
A further option that may be included in some embodiments of the invention is a support system that alleviates the straps that extend below the pool. This feature may accompany the pool system or may be sold as a separate kit. It permits above-ground pool owners to have a deeper pool than is conventionally available.
It is therefore an object of the present invention to provide a system for supporting a vessel designed to be filled with water or similar fluid.
It is also an object of the present invention to provide a system including one or more buttresses for supporting the side wall or walls of an above-ground swimming pool.
It is a further object of the present invention to provide a system in which a buttress supports a wall of a pool substantially continuously along the height of the wall.
It is another object of the present invention to provide a system for supporting pool walls in which the supporting structures extend only minimally beyond the exteriors of the walls.
It is an additional object of the present invention to provide a system, including one or more buttresses, for supporting a vessel such as an above-ground pool, in which the buttresses comprise notched sections to retain the bottom rim of the pool in position.
It is yet another object of the present invention to provide a system for supporting an above-ground swimming pool in which buttresses, side walls, the bottom rim, and cross-members interact to maintain the position and structure of the pool relative to the ground.
It is also an object of this invention to provide a system for supporting an above-ground swimming pool that enables a deep pool or a pool having a deep end, while still maintaining the position and structure of the pool relative to the ground.
It is still a further object of this invention to provide a substantially strapless support system that uses plates and beams that support the pool relative to the ground, while incorporating buttresses that extend only minimally beyond the exterior of the walls.
Other objects, features, and advantages of the present invention will be apparent with reference to the drawings and remainder of the text of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an oval pool having an existing set of braces.
FIG. 2 is a perspective view of an oval pool utilizing a support system of the present invention.
FIG. 3 is a side elevational view of a portion of the pool and of a buttress of the support system of FIG. 2 .
FIG. 4 is a top plan view of the buttress of FIG. 3 .
FIG. 5 is a side elevational view of the buttress of FIG. 3 together with a surface of a cross-member of the support system of the present invention.
FIG. 6 is a perspective view of a portion of the cross-member of FIG. 5 .
FIG. 7 is a (nominally) front elevational view of the buttress of FIG. 3 together with portions of the cross-member of FIG. 5 and the bottom rim of the pool of FIG. 2 .
FIG. 8 is a perspective view of an alternative buttress of the present invention.
FIGS. 9A-C are (nominally) front elevational views of yet alternative buttresses and cross-members for use as support systems of the present invention.
FIG. 10 is a perspective view of a portion of a strapless support system of the present invention.
FIG. 11 is an exploded perspective view of the strapless support system of FIG. 10 .
FIGS. 12A-B are top plan views of oval pools having a strapless support system of FIG. 10 installed at or near opposing sides of the pools.
DETAILED DESCRIPTION
FIGS. 2-5 and 7 illustrate buttresses 38 of the present invention. As shown in FIG. 2, buttresses 38 may be used in connection with pool 14 ′ instead of braces 10 . Doing so can diminish significantly the surface area required for installation of pool 14 ′, permitting pool 14 ′ to be positioned in areas inadequate for placement of pool 14 . As noted earlier, setback and similar requirements additionally pose fewer problems for pool 14 ′ because of its smaller overall size.
FIGS. 2 and 3 detail typical locations of buttresses 38 in connection with pool 14 ′. Illustrated in FIG. 2 is a set of buttresses 38 spaced along side 42 of (generally) oval pool 14 ′. Although not shown in FIG. 2, a similar set of buttresses 38 may be spaced along opposite side 46 of pool 14 ′. Because pool 14 ′ is oval, sides 42 and 46 are elongated relative to ends 50 and 54 and subject to greater stresses caused by the pressure of water W within the pool 14 ′.
This pressure within pool 14 ′ additionally is greatest at bottom 26 of side wall 18 (adjacent ground G) and decreases toward the corresponding top 58 of the wall 18 . To support the entirety of height H of side wall 18 , the above-ground height of buttresses 38 may be substantially similar or identical to height H and, as shown in FIG. 3, most or all of their surfaces 62 A and 62 B (see FIGS. 4 and 7) may contact the side wall 18 . To match more closely the support provided side wall 18 to the pressure of water W as a function of height H, buttresses 38 additionally may be flared in depth as illustrated in FIGS. 2 and 3. Such flaring results in buttress 38 having its minimum depth D 1 at its top 66 and its maximum depth D 2 at its bottom 70 (also adjacent ground G), with the depth increasing substantially continuously between top 66 and bottom 70 . Buttress 38 thus resembles, in the side elevational view shown in FIG. 3, a right triangle.
Unlike brace 10 , however, buttress 38 of FIG. 3 has solid sides 74 A and 74 B, a solid face 78 , and is truncated at top 66 . Surfaces 62 A and 62 B, moreover, function as flanges of buttress 38 . The result is a unitary structure for buttress 38 that both provides greater and more uniform and continuous support for side wall 18 and has a sleeker profile than braces 10 . Furthermore, for some embodiments of buttress 38 , maximum depth D 2 does not exceed ten inches, an amount significantly less than the distance (typically thirty-six inches) from pool 14 that braces 10 protrude. Other dimensions of an exemplary buttress 38 include height between approximately forty-two and sixty inches, width of approximately four inches, and a minimum depth D 1 of approximately two to four inches. Buttress 38 is usually made of metal such as galvanized steel but may be manufactured of other materials when necessary or appropriate. The face 78 , sides 74 A and 74 B, and surfaces 62 A and 62 B of buttress 38 additionally need not be integrally formed, although so forming them may avoid reducing the strength of the overall structure. Surfaces 62 A and 62 B also need not necessarily be formed at substantially right angles to respective sides 74 A and 74 B as shown in FIG. 4 .
FIG. 5 illustrates notched section 82 of buttress 38 . In use, buttress 38 may be connected (by bolts or other suitable means) to a cross-member 86 spanning the width of pool 14 ′. Such a cross-member 86 is shown in FIG. 6 and is buried in ground G so that only upper surface 90 is visible, and it is to this surface 90 that buttress 38 connects. Attaching buttress 38 to cross-member 86 in this manner thus retains the buttress 38 in position relative to ground G. Once buttress 38 is positioned, rim 94 (see FIG. 7) may be fitted into section 82 to assist in fixing its placement relative to the ground G. Slots of rim 94 additionally may receive tabs 98 protruding from upper surface 90 of cross-member 86 to complete its positioning. Side wall 18 may then be fitted into rim 94 in conventional fashion to retain it in place. Those skilled in the art will thus recognize that buttresses 38 , side wall 18 , rim 94 , and cross-members 86 of the present invention may be designed if desired to interact appropriately to preserve the position and structure of pool 14 ′ relative to the ground G.
Shown in FIG. 8 is an alternative buttress 38 ′. Unlike corresponding components of buttress 38 , face 78 ′ of buttress 38 ′ is curved, and surfaces 62 A′ and 62 B′ are formed at acute angles to respective sides 74 A′ and 74 B′. Buttress 38 ′ additionally extends beyond notched section 82 ′ to terminate at lower edge 102 , which in use is buried underground.
FIGS. 9A-C detail alternate cross-members 106 A-C. Like upper surface 90 of cross-member 86 , upper surfaces 110 of cross-members 106 A-C are at or near the level of ground G. Similar to buttress 38 ′, furthermore, buttresses 114 A-C extend so that lower edges 118 A-C are buried underground. In the buttress 114 A of FIG. 9A, lower edges 118 A are bent to form flanges 122 , which include apertures in which bolts 126 or other fasteners may be placed. Horizontal sections 130 additionally include apertures for receiving bolts 126 , thereby permitting buttress 114 A to be fastened to cross-member 106 A. By connecting buttress 114 A to horizontal sections 130 rather than vertical sections 134 of cross-member 106 A, bolts 126 are subjected to reduced shear stresses. Optionally excavating ground G to pour a concrete or other base C beneath horizontal section 130 may enhance the ability of buttress 114 A to support a pool.
Cross-members 106 B and 106 C instead may include slots 138 or recessed segments 142 for receiving pins or tabs 146 of buttresses 114 B or 114 C. Such slots 138 or recesses formed by segments 142 effectively retain buttresses 114 B or 114 C in position relative to respective cross-members 106 B or 106 C by engaging, or interlocking with, tabs 146 below ground G. Although lower edge 118 B is flanged and lower edge 118 C is not, such edges 118 B-C may be interchanged as necessary or desired. In any case, the result is a relatively secure positioning of a buttress 38 ′, 114 A, 114 B, or 114 C vis{grave over (-a)}-vis a cross-member 106 A, 106 B, or 106 C by connecting them underground.
FIGS. 10-12 illustrate strapless support system 210 of the present invention. This system alleviates the use of at least one pair of straps that extend a substantial length underneath the water-containing portion of traditional above-ground pools. The system allows a deeper excavation area, but still provides support for the walls using a system of buttresses, cross-members, vertical beams, and a plates that support the walls against the pressure of the water in the pool.
If the system is sold as an expandable kit, intended to expand the size of an already-installed pool, it is possible to provide different sized kits for different sized pools. Such kits permit the pool to be deeper on just one side, i.e., a “deep end,” or they may provide for a deeper pool in general.
As shown in FIG. 10, buttress 38 may be used in connection with alternate cross-members 212 , plates 220 , 224 , and 226 , and vertical beam 222 . Similar to cross-member 86 , alternate cross-member 212 is adapted to cooperate with buttress 38 and pool rim 94 . More particularly, it may cooperate in any of the ways previously described. For example, alternate cross-member may cooperate with buttress 38 as illustrated and described in reference to FIGS. 9A-C or it may have a tab protruding from its horizontal upper surface 218 that may be received by slots of rim 94 in order to serve as a guide for the placement of rim 94 , as discussed above.
Alternate cross-member 212 , however, is also adapted to cooperate with vertical beam 222 and with plates 220 , 224 , and 226 . In a preferred embodiment, each of two alternate cross-members 212 , two associated vertical beams 222 , and two buttresses 38 , are supported by three plates 220 , 224 , and 226 . However, it may be possible to achieve similar support effects using only two of the plates, i.e., using plate 220 and only one of plates 224 and 226 located anywhere along cross-member 212 . The assembly is supported in the ground G by block 240 , which is typically a concrete block, but may be made from any suitable material. Block 240 acts as a support to keep system 210 level in the ground G and to provide a means for suitable weight distribution. Any suitable support means may serve this purpose.
FIG. 11 details the location of alternate cross-member 212 in connection with the additional support system elements including buttress 38 , vertical beam 222 and plates 220 , 224 , and 226 . Cross member 212 may be any length that provides appropriate support for the system. A particularly suitable length for an alternate cross-member is about four feet. Buttress 38 (or 38 ′ as shown in FIG. 8) is connected at or near the first end 214 of alternate cross-member 212 by means similar to those described above and has the features described above.
Vertical beam 222 has a channel 246 , resembling a U-shaped channel, which in use cooperates with channel 244 of alternate cross-member 212 . Vertical beam 222 is of a length and depth appropriate to provide support for the system, and preferably has a length of about twelve inches so that it appropriately stabilizes the system in the ground. Vertical beam 222 is usually made of metal such as galvanized steel but may be manufactured of other materials when necessary or appropriate. It is connected at or near the second end 216 of alternate cross-member 212 (by bolts, screws, or nuts, or other suitable means, non-limiting examples including truss head machine screws and hex nuts) and is substantially perpendicular to the longitudinal axis of alternate cross-member 212 .
Plates 220 , 224 , and 226 function to support and secure system 210 in place. They provide correct structural support for the system, i.e., ensure that the buttresses 38 are placed at correct distances from one another. Plates 220 , 224 , and 226 also provide lateral support. They are usually made of metal such as galvanized steel, but may be manufactured from any suitable material. Plates 220 , 224 , and 226 may have various dimensions, exemplary dimensions including a range from about forty three inches to about forty seven inches. Plates 220 , 224 , and 226 may each have a flange 252 to facilitate connecting the plate to the system. Flange 252 may also act as a further support by “grabbing” ground G and alleviating any slippage that may occur when system 210 is in place. Plates 220 , 224 , and 226 may also have grooves 254 which prevent buckling that may occur if a flat plate is used, providing further structural support.
Front plate 220 also secures system 210 in ground G, as shown in FIG. 10 . It also acts to “grab” into ground G, which is one of the aspects of system 210 that allows the removal of the traditional straps. Front plate 220 is connected to vertical beam 222 using suitable connecting means, such as those described above. Front plate 220 will be at an angle that is substantially perpendicular to cross-member 212 . Plates 224 and 226 are connected to the horizontal upper surface 218 of alternate cross-member 212 at or near first and second ends 214 and 216 , respectively, using suitable connecting means. As noted, although the three plates 220 , 224 , and 226 provide the preferred support, the invention may be practiced using less than the three plates 220 , 224 , and 226 . For example it may be possible to retain only front plate 220 for support. The system 210 is shown as additionally supported by block 240 and angle brace 242 .
FIG. 11 also illustrates optional inserts 250 and 248 , which may be made of Styrofoam or other relatively pliable or pressure absorbing material, which may optionally be inserted into channel 244 of alternate cross-member 212 and channel 246 of vertical beam 222 . Inserts 250 and 248 help prevent system 210 from sinking into ground G by providing a surface for ground G to abut. They essentially act as space-fillers to keep the dirt from entering channels 244 and 246 . An optional angle brace 242 may be attached to alternate cross-member 212 to stabilize alternate cross-member on block 240 . Angle brace 242 holds alternate cross-member 212 (and thus strapless support system 210 ) in place. Although angle brace 242 is particularly useful, any type of support or stabilization technique may be used to secure cross-member 212 on block 240 .
FIGS. 12A-B illustrate top plan views of the strapless support system 210 of this invention assembled and in place in the bottom of two types of pools. FIG. 12A shows the invention in connection with a relatively small pool, for example a fifteen by twenty-four foot pool. In this embodiment, system 210 completely replaces the conventional straps 402 (that are shown in FIG. 12 B), with plates 220 (not shown), 224 , and 226 and alternate cross-members 212 . An expandable liner (not shown) is used with system 210 to line the pool and to provide a deep or deeper pool than would conventionally be available. FIG. 12B shows the system 210 located at or near opposing sides of the pool, replacing one set of straps in order to create a deep pool or a pool having a deep end. It may also be possible to completely replace straps 402 using one or more system 210 on a larger sized pool.
In order to deepen a pool or to provide a deep end, a preferred embodiment of the strapless support system 210 is assembled according to FIG. 10 . Block 240 is placed in a trench in the ground G. The trench should correspond to the appropriate dimensions of the system components.
As detailed in FIG. 11, vertical beam 222 is attached to the second end 216 of alternate cross-member 212 and the buttress 38 is attached to the first end 214 of cross member 212 . Front plate 220 is attached to vertical beam 222 . Second and third plates 224 and 226 are attached to the top surface 218 of the alternate cross-member 212 at or near the first and second ends 214 and 216 , respectively. Inserts 250 and 248 are then inserted into the channels 244 and 246 of the alternate cross-member 212 and vertical beam 222 . An angle brace 242 or other form of support is installed on either the alternate cross member 212 at or near the first end 214 or on the block 240 to provide stability. The completed assembly may then be placed in the trench on block 240 and at least partially buried underground. The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. | Support systems for vessels such as above-ground swimming pools are disclosed. Each system may include one or more buttresses adapted to support substantially the entire vertical height of the side wall or each of a series of side walls of the pool. A strapless support system to provide a pool having a deep end is also disclosed. The buttresses, which flare along their lengths, closely match the support they provide each side wall to the outward water pressure present along its height for enhanced reliability. The diminished space required for installation of the disclosed buttresses reduces the surface area required for their associated pool. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of French Application No. 1101126, filed Apr. 13, 2011, the contents of which are expressly incorporated herein by reference.
FIELD OF ART
[0002] The present disclosure relates to the rotary wing rotors, more specifically for helicopters, as well as the blades for such rotors.
BACKGROUND
[0003] It is known that the blades of a rotary wing rotor are controlled in a collective pitch and in a cyclic pitch.
[0004] The collective pitch allows for the stationary flight of the helicopter through a positioning being identical in incidence to all the blades with respect to the rotation axis of said rotor, then confused with the driving axis for the pylon thereof, said collective pitch generating a general lift being aligned with the vertical and balancing the bulk of the helicopter.
[0005] As far as it is concerned, the cyclic pitch allows, through a positioning in incidence for each blade as a function of the azimuth, to tilt the general lift with respect to the vertical and thus to move said helicopter.
[0006] For the collective pitch and the cyclic pitch control, rotors generally comprise a mechanism, referred to as cyclic plate, mounted on the pylon of the rotor and comprising a rotary plate connected to each blade by a pitch control rod and driven in rotation by rotating scissors, a stationary plate sliding along the pylon of the rotor and able to be tilted with respect to the latter and a bearing link between said stationary and rotary plates.
[0007] Such a cyclic plate is disadvantageous in that it comprises a large number of mechanical parts requiring to be regularly maintained and checked.
[0008] It has therefore already been contemplated to remove said cyclic plate while mounting mobile flaps on said blades, the cyclic pitch thereof being controlled by the twist of said blades generated by the torsion moment induced by the extension of said flaps and the collective pitch of the blades being obtained either similarly to that of the propellers, or by an actuator arranged at the blade shank.
[0009] However, such mobile flaps also require using sophisticated and friction sensitive mechanical assemblies.
SUMMARY
[0010] The present method, system and device comprise a rotary wing blade, a rotor, more specifically for a helicopter, that does not comprise any cyclic plate and an implementing method for overcoming the drawbacks of the prior art, as set forth hereinabove.
[0011] The blade, according to the present method, system and device, of a wing rotating around the hub of a rotation frequency rotor, said blade, the rotation azimuth of which is known, of span (E), comprising a fastening part for said hub and an aerodynamic part, and having different distortion modes and, more specifically, a torsion mode around its span (E) with its own frequency, being a function of its torsion stiffness around said span (E), characterized in that:
[0012] it comprises dynamic twist means, approximately around its span, being able to be actuated in real time, that is during its rotation around said hub, at least at the rotation frequency of said rotor and in synchronism with the rotation azimuth of said blade, so that these dynamic twist means are able to generate a cyclic pitch even in the absence of a cyclic plate;
[0013] its torsion stiffness, apparent under a centrifugal force, approximately around its span, is sufficiently low for allowing for said dynamic twist means to obtain, in the right section plane of the free end of said blade, a resilient dynamic twist angle (v) for the chord of at least 14° as diving or stalling, while remaining sufficiently high so that the own torsion frequency of the blade around its span is equal to the rotation frequency of said rotor, in order to allow for a dynamic twist of the blade through torsion resonance and thus to minimize the energy required for generating the cyclic pitch;
[0014] its damping factor, under a centrifugal force, is strictly positive, so as to avoid the resonance divergence of the different modes.
[0015] It is to be reminded that it is well known to those skilled in the art that, for obtaining a twist angle with a given amplitude for a mechanical part, they have available a method consisting in adjusting the power of the torsion actuators and a second method consisting in adjusting the stiffness of said mechanical part. The solution implemented in the present method, system and device consists in combining these two methods using a blade being less stiff in torsion than in the state of the art so as to limit the weight of the actuators while having available a twist amplitude of at least 14° as stalling or diving, so as to achieve a cyclic pitch. In the state of the art, different means are known for decreasing the torsion stiffness of a mechanical part such as a blade: it is possible either to longitudinally split the shell of the blade (such as in the patent application of the same Applicant, published under no. FR 2,924,681) or to use structural, filling or coating materials, with a lesser torsion stiffness.
[0016] It is also to be reminded that those skilled in the art know, as any mechanic, different means for obtaining a strictly positive blade damping factor. They know, for example, the passive method consisting in adding to the structure of the blade a material with a damping factor higher than 10%, such as for instance rubber abutments at blade shank; or even the active method for an active control of vibrations.
[0017] It is further to be noticed that the materials and the structure of the blade are selected so as to be able to withstand twist with an amplitude of at least 14° as diving or stalling and repeated at frequencies able to be as high as several times the maximum rotation frequency of the rotor (case of the multi-cyclic control of the twist for achieving an active control of vibrations) while remaining in the resilient distortion field thereof.
[0018] Thus, thanks to the present method, system and device, a rotary wing rotor is obtained, more specifically for a helicopter, easy to be controlled in a cyclic pitch and with a low energy, allowing the cyclic plate to be omitted, while avoiding any coupling between the beat and torsion modes.
[0019] It is to be noticed that the flexibility of the blade could result either from that of the fastener, or from that of the aerodynamic part, or from both of them. For instance, when, as known, each one of said blades consists mostly in an aerodynamic part (that having the pitch variation aerodynamically active) connected to the hub of the rotor via a shorter fastening part, the own torsion frequency (as a whole) could be achieved through combining the coefficients of stiffness of said aerodynamic part or said fastening part. Such a combination advantageously allows the corresponding actuator to have available a sufficient torsion angular range for being used in a multicyclic mode.
[0020] Advantageously, according to a second embodiment, the present method, system and device comprise a blade according to the previous embodiment, characterized in that said fastening part has an apparent torsion stiffness of 10 to 100 lower than that of the aerodynamic part.
[0021] Advantageously, according to a third embodiment, the present method, system and device comprise a blade according to one of the two previous embodiments, characterized in that:
[0022] its structure is made in a composite material;
[0023] its coating is unidirectional and the direction of such a coating forms an angle substantially equal to 0° with the span of said blade, so as to obtain a minimum torsion stiffness of the blade around the span.
[0024] Advantageously, according to a fourth embodiment, the present method, system and device comprise a blade according to one of the three previous embodiments, characterized in that the aerodynamic part is provided with a longitudinal slit in one of its wing bottom or top surfaces and comprises:
a first spar forming the leading edge and the adjacent bottom and top parts thereof and having a longitudinal transversal side foaming the front edge of said slit; a second spar being separated from said first spar by said slit and having a longitudinal transversal side forming the rear edge of said slit; a shell forming the bottom and top surfaces of said blade, longitudinally slit by said slit and enclosing said first and second spars while being integral therewith: a filling material for said shell; the dynamic twist means comprise a dynamic twist actuator able to cause a relative slide, between the edges of said slit; and said shell is made in a fiber-resin composite material, with at least most part of the fibers being arranged so as to form an angle being substantially equal to 0° with the span of said blade.
[0031] Advantageously, according to a fifth embodiment, the present method, system and device comprise a blade according to the previous embodiment, characterized in that on both sides of said slit, in the vicinity of the latter, said shell is rigidly integral with said first and second spars, and in that outside of the vicinity of said slit, said shell is connected to the remainder of said blade via a link made in a resilient material with a damping factor higher than 10 %, able to filter the vibrations of the blade. such as an elastomer. and distributed, either continuously or discontinuously, between said shell and said remainder of the blade.
[0032] Thus, outside the vicinity of the slit, a (continuous or discrete) link is achieved, with a low resiliency modulus and an adapted damping allowing:
to significantly decrease the torsion stiffness while keeping the beat and drag stiffnesses.
to minimize the frequency of the first own torsion mode of the blade relatively close to the rotation frequency, and to obtain a damping of such a torsion mode, so that the optional coupling with the first beat and drag modes is not an unstable aeroelastic coupling.
[0036] On the other hand, in the vicinity of said slit, the stiff link, for example through gluing, ensures a good transmission of the movement of the actuator allowing for an easy twist of the blade.
[0037] Advantageously, according to a sixth embodiment, the present method, system and device comprise a blade according to the fourth or the fifth previous embodiment, characterized in that said filling material is a stiff to semi-stiff foam.
[0038] This stiff to semi-stiff material enables, on the other hand, to increase vibration filtering (said distortion modes) of the blade.
[0039] Advantageously, according to a seventh embodiment, the present method, system and device comprise a blade according to one of the previous fourth to sixth embodiments, characterized in that it comprises a resilient material strip with a damping factor higher than 10%, able to filter the own torsion frequency of the blade, such as. for instance, an elastomer, said strip covering the slit.
[0040] Advantageously, according to a eighth embodiment, the present method, system and device comprise a blade according to one of the previous fourth to seventh embodiments, characterized in that the dynamic twist actuator is arranged on the free end thereof, so as to facilitate its installation and its maintenance.
[0041] In each blade, the associated actuator could be electric, mechanical or hydraulic. However, preferably, it is of the piezoelectric type, similar to the actuator disclosed in WO 2009/103865.
[0042] Whatever its nature, the actuator could be arranged along the aerodynamic part of the blade or on the fastening part thereof.
[0043] However, preferably, in each blade, the actuator is arranged on the free end thereof, so as to facilitate its installation and its maintenance.
[0044] In addition, it could be advantageous that the profile of each blade is adapted (or even controlled), more specifically as a function of the incidence and of the apparent stiffness of the blade.
[0045] Advantageously, according to a ninth embodiment, the present method, system and device comprise a blade according to one of the first to eighth embodiments, characterized in that the dynamic twist means are dimensioned so as to be able to obtain, at the multiple frequencies of the rotation frequency of such rotor and in synchronism with the rotation azimuth of said blade, an amplitude of said resilient dynamic twist angle at least equal, in absolute value, to the maximum amplitude of the different distortion modes at these same multiple frequencies of the rotation frequency, so as to be able to carry out a multicyclic active control of vibrations.
[0046] Advantageously, according to a tenth embodiment, the present method, system and device comprise a blade according to one of the first to ninth embodiments, characterized in that its fastening part to the hub comprises means for progressively controlling its own torsion frequency, under a centrifugal force, around its span, able to slave, during its rotation around said hub, said own torsion frequency substantially on the rotation frequency of the rotor.
[0047] Advantageously, according to an eleventh embodiment, the present method, system and device comprise a blade according to the tenth embodiment, characterized in that said means for progressively controlling its own frequency, adjust said own frequency while adjusting the torsion stiffness, apparent under a centrifugal force, approximately around its span, of its fastening part.
[0048] Advantageously, according to a twelfth embodiment, the present method, system and device comprise a rotor wherein the rotary wing in rotation around its hub at the rotation frequency, included between a lower rotation frequency and an upper rotation frequency, comprises at least two blades, according to one of the previous embodiments, the rotation azimuths of which are known, said rotor being characterized in that it comprises:
means for controlling dynamic twist means of each one of said blades, able, even in the absence of a cyclic plate, to control in real time, that is at a frequency at least equal to the rotation frequency, during the rotation of said blades and in synchronism with their rotation azimuth, a cyclic pitch for each one of said blades: means for progressively controlling the own torsion frequency, under the centrifugal force, of each one of said blades around their span, able to slave, during this rotation, each own torsion frequency substantially on the rotation frequency of the rotor, so as to take advantage of the torsion resonance around their span so as to minimize the power required for generating a cyclic pitch through a dynamic twist.
[0051] Advantageously, according to a thirteenth embodiment, the present method, system and device comprise a rotor according to the twelfth previous embodiment, characterized in that said means for controlling the dynamic twist means are also able, in the absence of a cyclic plate, to control the collective pitch of said blades during the rotation of said rotor.
[0052] Advantageously, according to a fourteenth embodiment, the present method, system and device comprise a rotor according to one of the previous twelfth to thirteenth embodiments, characterized in that said means for progressively controlling the own torsion frequency are able to adjust, in both directions, the own torsion frequency, under a centrifugal force, around its span, of each one of said blades, between a minimum value corresponding to the lower rotation frequency of the rotor and a maximum value corresponding to the upper rotation frequency of said rotor, said means being, for instance, means for stiffening the fastening part of each said blade according to any of claims 2 to 10 allowing for the adjustment of the torsion stiffness, apparent under the centrifugal force, of each said blade around its span, between a minimum value corresponding to said stiffness of each blade, not stiffened by said means, and a maximum value corresponding to said stiffness of the aerodynamic part of each said blade.
[0053] Advantageously, according to a fifteenth embodiment, the present method, system and device comprise a rotor according to one of the twelfth to fourteenth previous embodiments, characterized in that it comprises spontaneous action means able to impose to each one of said blades, in the case of a failure of said controlling means, that said own frequency under a torsion centrifugal force of each one of said blades is equal to the own torsion frequency under centrifugal force of their aerodynamic part, so as to avoid any torsion resonance divergence for said blades.
[0054] Advantageously, according to a sixteenth embodiment, the present disclosure is directed to a dynamic twist method for at least one blade of a wing rotating around the hub of a rotor with a rotation frequency, ranging from a lower rotation frequency and an upper rotation frequency, said blade, having its rotation azimuth known, having a span, comprising a fastening part for said hub and an aerodynamic part, and having different distortion modes, in particular, a mode of torsion around its span with a own frequency, as a function of its torsion stiffness around said span, characterized in that it comprises the following tasks:
[0055] controlling in real time by dynamic twist means, that is at a frequency at least equal to the rotation frequency of said rotor, during the rotation of each said blade and in synchronism with the rotation azimuth of each said blade, the resilient dynamic twist angle (v) of the chord in the right section plane of the free end of each said blade, of at least 14° as diving or stalling, so that the dynamic twist means are able to generate a cyclic pitch even in the absence of a cyclic plate;
[0056] controlling, using the means, the own torsion frequency, being apparent under a centrifugal force, approximately around the span of each said blade, so that it is substantially equal to the rotation frequency around said rotor and that, consequently, said resilient dynamic twist is achieved with a minimum of power through a torsion resonance; and
[0057] filtering the own frequencies of the different distortion modes of each said blade, so as to avoid any resonance divergence.
[0058] Advantageously, according to a seventeenth embodiment, the present disclosure is directed to a method according to the sixteenth previous embodiment, characterized in that the control of the dynamic twist means is multicyclic, that is at a frequency multiple of the rotation frequency of said rotor, so as to actively control the different distortion modes of said blades in addition to controlling their cyclic pitch.
[0059] Advantageously, according to an eighteenth embodiment, the present disclosure is directed to a method according to one of the previous sixteenth to the seventeenth previous embodiments, characterized in that the control of the dynamic twist means controls the collective pitch of said blades in addition to controlling their cyclic pitch.
[0060] Advantageously, according to a nineteenth embodiment, the present disclosure is directed to a method according to one of the sixteenth to eighteenth previous embodiments, characterized in that the control of the own torsion frequency, apparent under a centrifugal force, approximately around its span, of each said blade, is obtained through progressively controlling the torsion stiffness, apparent under a centrifugal force, approximately around its span, of the fastening part of each said blade, said fastening part, being more flexible than the corresponding aerodynamic part, being able to be stiffened up to a maximum value equal to the apparent torsion stiffness, around its span, of said aerodynamic part.
[0061] Advantageously, according to a twentieth embodiment, the present disclosure is directed to a method according to one of sixteenth to seventeenth previous embodiments, characterized in that it comprises a task, imposin, in the case of a failure of said controlling means, that the own frequency under a centrifugal torsion force of each said blade around its span, is equal to the own torsion frequency, under centrifugal force, of their aerodynamic part around their span, so as to avoid any torsion resonance divergence of said blades.
BRIEF DESCRIPTION OF THE FIGURES
[0062] The FIGS. of the appended drawing will better explain how the present method, system and device can be implemented. In these FIGS. like reference numerals relate to like components.
[0063] FIG. 1 is a schematic perspective view of a rotary wing rotor of a helicopter.
[0064] FIG. 2 is a perspective view, from the bottom surface side, of a blade of a rotary wing rotor of a helicopter according to the present method, system and device.
[0065] FIG. 3 is a schematic sectional view of the blade along line III-III of FIG. 2 .
[0066] FIG. 4 is an exploded enlarged perspective view of the end of the blade of FIG. 2 , seen from the top surface side.
[0067] FIG. 5 illustrates, on a schematic perspective view, the twisting of the blade of FIG. 2 generated by the blade end actuator shown on FIG. 4 .
[0068] FIG. 6 schematically illustrates controlling means able to progressively adjust the own torsion frequency of each blade of the rotor according to the present method, system and device.
[0069] FIGS. 7A and 7B illustrate, in schematic sections, the operation of the controlling means of FIG. 6 , the latter being respectively in a position corresponding to locking in a maximum own torsion frequency ( FIG. 7A ) and to unlocking in a minimum own torsion frequency ( FIG. 7B ).
DETAILED DESCRIPTION
[0070] The rotary wing rotor RO for a helicopter, schematically shown on FIG. 1 , comprises a hub M driven in rotation around its axis Z-Z by a main gearbox (not shown) and blades P transversally connected to said hub M via fastening devices L. Thus, the blades P could rotate around the axis Z-Z, at the rotation frequency Ω of said hub M.
[0071] As shown on FIG. 2 , a blade P according to the present method, system and device comprises an aerodynamic part A and a fastening part B, shorter than said part A.
[0072] The fastening part B, for example with a cross-shaped section, cooperates with the fastening device L for fastening the blade P to the hub M.
[0073] The aerodynamic part A comprises a top surface 2 and a bottom surface 3 forming, at the front, a leading edge 4 and, at the rear, a trailing edge 5 .
[0074] In the vicinity of the leading edge 4 (see also FIG. 3 ), the bottom surface 3 is cut by a longitudinal slit 6 longitudinally distributing said aerodynamic part A (according to the span E) into a front longitudinal part A 1 comprising said leading edge 4 and a rear longitudinal part A 2 comprising said trailing edge 5 . On the other hand, said front A 1 and rear A 2 longitudinal parts are integrally formed through the top surface 2 being continuous.
[0075] In the embodiment shown on FIG. 3 , said aerodynamic part A comprises:
[0076] a leading edge spar 7 , forming said leading edge 4 and the parts of the top surface 2 and the bottom surface 3 adjacent to the latter; such spar 7 can be made in a fiber-resin composite material (for instance glass-epoxy or carbon-epoxy) and possibly incorporate a ballast mass 8 extended according to the leading edge 4 ;
[0077] a bottom surface spar 9 , separated from the leading edge spar 7 by the bottom surface longitudinal slit 6 , the front edge 6 A of the latter being formed by a longitudinal transversal side of the leading edge spar 7 whereas the rear edge 6 R of said longitudinal slit 6 is formed by a longitudinal transversal side of the bottom surface spar 9 ; the latter can also be made in a fiber-resin composite material;
[0078] a ridge spar 10 forming the trailing end 5 and, for instance, made in a fiber-resin composite material;
[0079] a shell 11 forming the top surface 2 and the bottom surface 3 (interrupted by the slit 6 ) and enclosing the spars 7 , 9 and 10 being simultaneously integral therewith;
[0080] a filling material 12 , for example, a rigid foam with a low resiliency modulus (for instance, polyurethane) filling said shell 11 between said spars 7 , 9 and 10 ; and
[0081] a strip 13 of an elastomer material with a low resiliency modulus, obstructing the slit 6 and being integral (preferably with a glue) with the edges 6 A and 6 B of the latter.
[0082] The shell 11 is made in a fiber-resin material (for instance, carbon fibers) and such fibers f 1 are arranged longitudinally with respect to said aerodynamic part of the blade, i.e. according to said span E. Possibly, said shell can comprise fibers f 2 being orthogonal to said span, but it does not comprise any fiber being tilted on the latter (see the cutaway view of the shell 11 shown on FIG. 5 ).
[0083] Moreover, in an area 14 being adjacent to the slit 6 and extending on both parts of the latter, the shell 11 is rigidly integral, for instance by gluing) with the leading edge spar 7 and said bottom surface spar 9 . In contrast, outside the area 14 , the shell 11 is connected to the spars 7 , 9 , 10 and to the filling material 12 by a connecting layer of a damping material with a low resiliency modulus. Such a connecting layer (not shown for clarity reasons in the drawing) can be continuous or discontinuous and be formed with an elastomer material.
[0084] It should be easily understood that an aerodynamic part A being little rigid in torsion around the span E is consequently obtained, with however a rigid integrity, located around the slit 6 , between the leading edge spar 7 and the bottom surface spar 9 , on the one side, and the shell 11 , on the other side. By selecting a fastening part B being even less rigid in torsion around the spar than the aerodynamic part A (for instance, 10 to 100 times lower), the blade P is able to sustain a torsion generating on the blade shank, i.e. on the side 15 of the free end 16 of the latter, a resilient dynamic twist angle v of at least 14°.
[0085] Furthermore, on the free end 16 of the blade P, an actuator 17 is inserted in the extension of the aerodynamic part A (see FIG. 4 ). The actuator 17 is piezoelectric and similar to that described in the document EP-1,788,646, as to which it is expressly referred. When the piezoelectric actuator 17 is fastened on the tip of the aerodynamic part A, it is located at least partly in the plane of the chord PC thereof. A removable hood 18 encloses and protects the piezoelectric actuator 16 and the end side 15 of the blade.
[0086] The piezoelectric actuator 17 exert a shear action and comprises two surfaces 19 and 20 being adapted to slide one relative to the other when said actuator is electrically supplied. Through a coupling part 21 , the surface 19 is formed integrally with the leading edge spar 7 , while the surface 20 is integrally formed with the bottom surface spar 9 .
[0087] In such a way, as illustrated on FIG. 5 , when said actuator 17 is excited, it generates a slide between said surfaces 19 and 20 , such sliding being directed according to the span and being transmitted to the spars 7 and 9 moving with each other. Thus, it results in a relative movement between the front part A 1 and the rear part A 2 (schematically illustrated by the arrows 22 and 23 on FIG. 5 ) and a buckling of the shell 11 resulting in a torsion distortion of the blade P around the torsion axis T-T arranged in the plane of the chord PC and directed according to the span E. Obviously, the strip 13 also suffers a shear distortion (see FIG. 5 ).
[0088] On FIG. 6 , an exemplary embodiment is schematically represented for a fastening device L for a blade P so that the latter is able to turn around the axis Z-Z of the rotor RO. In this exemplary embodiment, the fastening device L comprises:
[0089] a blade hub 24 made integral of the hub M of the rotor RO by any known means, not shown;
[0090] a flange (or flange portion) 25 being integral in rotation, on the one side, with said blade hub 24 and, on the other side, with the internal end 26 of the fastening part B of the blade P;
[0091] a rigid sleeve (or sleeve portion) 27 enclosing, with a big play, said fastening part B, said sleeve 27 , on the one side, comprising a flange (or flange portion) 28 arranged opposite the flange 25 and, on the other side, being made integral, through fastening means 29 , with the blade portion 30 making the transition between the aerodynamic part A and the fastening part B; and
[0092] at least one device 31 being able to progressively vary the pressure between the flanges 25 and 28 .
[0093] As shown on FIGS. 7A and 7B , the peripheries 25 A and 25 B of the flanges 25 and 28 being able to suffer a slight resilient distortion, are arranged inside a mobile yoke 32 of the device 31 and being mutually in contact through resilient blocks 33 being interposed between them.
[0094] The peripheries 25 A and 25 B are submitted, on the one side, to the action of a spring 34 and, on the other side, to the action of controllable cam 35 , said spring 34 and said cam resting on the mobile yoke 32 so as to exert antagonistic actions on said peripheries 25 A and 25 B.
[0095] The cam 35 is rotationally mounted around an axis 36 mounted on the yoke 31 and can turn around said axis under the control of an actuator represented by arrows F.
[0096] A return spring 37 is able to bring the cam 35 into the position of FIG. 7A in the case of a failure of the cam actuator F.
[0097] In the situation represented on FIG. 7A , the cam pushes the peripheries 25 A and 28 A by pushing the spring 34 , so that the pressure exerted between the flanges 25 and 28 is big. In such a case, the sleeve 27 is made integral with the blade hub 24 and the twist actuator 17 cannot exert any action on the blade fastening part B, only the aerodynamic part A being able to be twisted. Naturally, it results that own torsion frequency of the blade P is then at a maximum and identical to that of said aerodynamic part A.
[0098] In contrast, in the situation represented on FIG. 7B , the spring 34 is expanded and pushes the peripheries 25 A and 28 A against the cam 35 , so that the pressure between the flanges 25 and 28 is weak, even nil. The sleeve 27 is thus disengaged from the blade hub 24 and the twist actuator 17 can exert its action on the whole parts A and B of the blade. The own torsion frequency of the blade P is then at a minimum.
[0099] Obviously, through a rotation control of the cam 35 around its axis 36 between the positions illustrated by FIGS. 7A and 7B , it is possible to progressively vary, in both directions, the own torsion frequency on the whole blade comprising the parts A and B thereof and the maximum value corresponding to the own torsion frequency of the sole aerodynamic part A.
[0100] Furthermore, it will be noticed that in the case of a failure of the actuator F or the actuator 17 , for instance, due to an electrical supplying problem, or even in the case of a divergence in the blade twisting appearing, the return spring 37 brings back to the situation of FIG. 7A , corresponding to the maximum own torsion frequency. | The present disclosure is directed to a rotary wing rotor comprising one or more blades. Each blade has a torsion frequency around its span being substantially equal to a rotation frequency (Ω) of the rotor; torsion means twist to the rotation frequency of the rotor, in synchronization with said rotation; and comprising a material configured to dampen the torsion resonance, so as to avoid the resonance divergence. | 8 |
FIELD
[0001] Illustrative embodiments of the disclosure generally relate to electrical bus bars for electric vehicles (EVs). More particularly, illustrative embodiments of the disclosure relate to a deformable bus bar assembly and a bus bar installation method which compensate for differences in height between adjacent terminals on an HV battery.
BACKGROUND
[0002] Bus bars for HV (hybrid vehicle) battery arrays may be attached via studs on the battery cells. Nuts may be threaded and tightened on the studs to form a strong, electrically-conductive joint. The studs may be used to locate the bus bars in the correct location for contact of the bus bars with the cell terminal on the battery cell.
[0003] In some applications, it may be desirable to attach the bus bars to the cell terminals on the battery cell via welding. However, there may be differences in height between the positive and negative terminals on the battery cell. This may leave gaps between the bus bars and the terminals, compromising the integrity of the welds which secure the bus bars to the cell terminals.
[0004] Accordingly, a deformable bus bar assembly and a bus bar installation method which compensate for differences in height between adjacent terminals on an HV battery may be desirable.
SUMMARY
[0005] Illustrative embodiments of the disclosure are generally directed to a deformable bus bar assembly which compensates for differences in height between adjacent terminals on an HV battery. An illustrative embodiment of the bus bar assembly includes a deformable bus bar having a bus bar positive terminal flange, a bus bar negative terminal flange spaced-apart from the bus bar positive terminal flange and a flange connecting portion connecting the bus bar positive terminal flange and the bus bar negative terminal flange. A bus bar frame includes a bus bar frame positive terminal flange carried by the bus bar positive terminal flange of the deformable bus bar and a bus bar frame negative terminal flange carried by the bus bar negative terminal flange of the deformable bus bar.
[0006] Illustrative embodiments of the disclosure are further generally directed to a method of installing a deformable bus bar on positive and negative terminals of a battery cell. An illustrative embodiment of the method includes placing spaced-apart bus bar positive and negative terminal flanges of a deformable bus bar on the positive and negative terminals, respectively, of the battery cell; and applying pressure against one of the bus bar positive and negative terminal flanges of the deformable bus bar to deform the deformable bus bar until the one of the bus bar positive and negative terminal flanges contacts a corresponding one of the positive and negative terminals, respectively, of the battery cell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Illustrative embodiments of the disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:
[0008] FIG. 1 is a perspective view of an exemplary deformable bus bar;
[0009] FIG. 2 is a front view of an illustrative embodiment of a deformable bus bar assembly having the exemplary deformable bus bar illustrated in FIG. 1 ;
[0010] FIG. 3 is a front view of the illustrative deformable bus bar assembly clamped onto a positive terminal and a negative terminal of a battery cell, with an electrode gap initially existing between the negative terminal and the deformable bus bar due to a difference in height between the positive terminal and the negative terminal in installation of the deformable bus bar;
[0011] FIG. 4 is a front view of an illustrative deformable bus bar assembly with the deformable bus bar deformed to accommodate the difference in height between the positive terminal and the negative terminal; and
[0012] FIG. 5 is a flow diagram of an illustrative embodiment of a deformable bus bar installation method.
DETAILED DESCRIPTION
[0013] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable users skilled in the art to practice the disclosure and are not intended to limit the scope of the claims. Moreover, the illustrative embodiments described herein are not exhaustive and embodiments or implementations other than those which are described herein and which fall within the scope of the appended claims are possible. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
[0014] Referring initially to FIGS. 1 and 2 , an exemplary deformable bus bar 1 ( FIG. 1 ) which is suitable for an illustrative embodiment of a deformable bus bar assembly 10 ( FIG. 2 ) is shown. The deformable bus bar 1 may include any suitable flexible or deformable and electrically conductive material. The deformable bus bar 1 may include a bus bar body 2 . In some embodiments, the bus bar body 2 may be generally elongated and rectangular with a pair of parallel longitudinal body edges 2 a , 2 b , respectively, and transverse body edges 2 c extending between the longitudinal body edges 2 a , 2 b . A bus bar positive terminal flange 3 and a bus bar negative terminal flange 4 extend from the bus bar body 2 in spaced-apart relationship to each other along the longitudinal body edge 2 b . A bus bar slot 5 may extend between the bus bar positive terminal flange 3 and the bus bar negative terminal flange 4 . A flange connecting portion 6 may connect the bus bar positive terminal flange 3 and the bus bar negative terminal flange 4 between the bus bar slot 5 and the bus bar body 2 .
[0015] As shown in FIG. 2 , in exemplary application, which will be hereinafter described, the deformable bus bar 1 may be included as part of the deformable bus bar assembly 10 . The deformable bus bar assembly 10 may include a deformable bus bar frame 11 which may be plastic or other deformable material. The bus bar frame 11 may include a bus bar frame positive terminal flange 12 and a bus bar frame negative terminal flange 13 . A bus bar frame flange connector 14 may connect the bus bar frame positive terminal flange 12 and the bus bar frame negative terminal flange 13 . A bus bar flange slot 15 may separate the bus bar frame positive terminal flange 12 and the bus bar frame negative terminal flange 13 at the bus bar frame flange connector 14 . Accordingly, the bus bar frame positive terminal flange 12 and the bus bar frame negative terminal flange 13 of the bus bar frame 11 may rest on the bus bar positive terminal flange 3 and the bus bar negative terminal flange 4 , respectively, of the deformable bus bar 1 , with the bus bar slot 5 of the deformable bus bar 1 registering with the bus bar frame flange slot 15 of the bus bar frame 11 .
[0016] Referring next to FIGS. 3 and 4 , in exemplary application of the deformable bus bar 1 , the deformable bus bar assembly 10 is placed on a battery cell 18 of an HV vehicle. The battery cell 18 may be a conventional battery cell which is used to provide a source of electrical power to an EV (Electric Vehicle). The battery cell 18 may have a positive terminal 20 and a negative terminal 22 which are offset from each other, or different in height. The bus bar positive terminal flange 3 of the deformable bus bar 1 engages the positive terminal 20 of the battery cell 18 . However, due to the difference in height between the positive terminal 20 and the negative terminal 22 of the battery cell 18 , a contact gap 32 exists between the bus bar negative terminal flange 4 of the deformable bus bar 1 and the negative terminal 22 of the battery cell 18 . A positive terminal clamp finger 26 and a negative terminal clamp finger 28 may secure the deformable bus bar assembly 10 on the positive terminal 20 and the negative terminal 22 of the battery cell 18 as is known by those skilled in the art.
[0017] As illustrated in FIG. 4 , the negative terminal clamp finger 28 is tightened to progressively deform the bus bar frame negative terminal flange 13 at the bus bar frame flange connector 14 of the bus bar frame 11 and the underlying bus bar negative terminal flange 4 at the bus bar slot 5 and flange connecting portion 6 of the deformable bus bar 1 . Therefore, the bus bar negative terminal flange 4 and the bus bar frame negative terminal flange 13 traverse the contact gap 32 ( FIG. 3 ) until the bus bar negative terminal flange 4 makes solid contact or engagement with the negative terminal 22 of the battery cell 18 . The bus bar positive terminal flange 3 and the bus bar negative terminal flange 4 can then be welded to the positive terminal 20 and the negative terminal 22 , respectively.
[0018] It will be appreciated by those skilled in the art that the deformable bus bar 1 can be deformed to compensate for the difference in height between adjacent terminals on a battery cell responsive to application of pressure to the deformable bus bar. Compared to conventional bus bars, the deformable bus bar may result in significant reduction or elimination of a contact gap between the bus bar and the positive or negative terminal on a battery cell. Because the deformable bus bar requires substantially less clamp force which is necessary to be applied for deformation to reduce or eliminate the contact gap, the total pressure which is necessary to be applied on the battery array or pack during the welding operation is substantially reduced. This expedient may reduce the risk of damaging the battery array or pack due to overload forces. In addition, the flexibility of this busbar lowers any peel or sheer forces seen on the welds due to any movement of the cells after welding. These movements could be caused by handling of the battery cell array after welding assembly into the battery pack, and during life of the battery pack in the vehicle.
[0019] Referring next to FIG. 5 , a flow diagram 500 of an illustrative embodiment of a deformable bus bar installation method is shown. At block 102 , a bus bar positive terminal flange and a bus bar negative terminal flange of a deformable bus bar are placed on positive and negative terminals, respectively, of a battery cell. A bus bar slot extends between the bus bar positive terminal flange and the bus bar negative terminal flange. A contact gap exists between the bus bar positive terminal flange and the positive terminal and the bus bar negative terminal flange and the negative terminal.
[0020] At block 104 , pressure is applied against the bus bar positive terminal flange or the bus bar negative terminal flange of the deformable bus bar. In some embodiments, a bus bar frame may be placed on the deformable bus bar and the pressure may be applied to the bus bar frame. The deformable bus bar deforms at the bus bar slot until the bus bar positive terminal flange or the bus bar negative terminal flange traverses the contact gap and makes solid contact with the corresponding positive terminal or negative terminal, respectively. At block 106 , the bus bar positive terminal flange and the bus bar negative terminal flange of the deformable bus bar may be welded to the positive and negative terminals, respectively, of the battery cell.
[0021] Although the embodiments of this disclosure have been described with respect to certain exemplary embodiments, it is to be understood that the specific embodiments are for purposes of illustration and not limitation, as other variations will occur to those of skill in the art. | A bus bar assembly includes a deformable bus bar including a bus bar positive terminal flange, a bus bar negative terminal flange spaced-apart from the bus bar positive terminal flange and a flange connecting portion connecting the bus bar positive terminal flange and the bus bar negative terminal flange. A deformable bus bar frame includes a bus bar frame positive terminal flange carried by the bus bar positive terminal flange of the deformable bus bar and a bus bar frame negative terminal flange carried by the bus bar negative terminal flange of the deformable bus bar. A method of installing a deformable bus bar on positive and negative terminals of a battery cell is also disclosed. | 8 |
FIELD OF THE INVENTION
This invention relates to packing elements and more particularly relates to elements that are used to protect a product packed in a container such as a box. Specifically, the container and the product therein are each of a predetermined size and shape.
BACKGROUND OF THE INVENTION
Many products that are manufactured and ultimately sold for and used by an end user--whether it be a company or an individual--must be shipped at least once from where the product is produced to where the product is stored, consumed or used. In actuality, a product may be shipped several times, such as from the manufacturer to the distributor, to the warehouse, then to a retail store and ultimately to an end user. It is of course necessary that the product be protected during this time of shipping and storage so that it ultimately reaches the end user in an unharmed condition.
A very widely used--and indeed almost universally used--packaging system for protecting products that could be easily damaged during shipping and storage--typically items such as electrical or electronic appliances--consists of a cardboard box with packing material interposed between the product and the inner walls of the cardboard box. The packing material displaces the product from the cardboard box around all sides of the product so that almost any impact on the cardboard box will not directly reach the product. Further, the packing material preferably keeps the product in a fixed relation with respect to the cardboard box so that the product does not move around within the cardboard box. In order to keep the product in fixed relation within the cardboard box, it is necessary that the product fit snugly within the packing material and also that the packing material fit snugly within the cardboard box.
Two types of forces may be encountered by a packed product during shipping and storage. Firstly, there is movement of the cardboard box, which may be quite sudden or severe. This sudden or severe movement would cause the cardboard box to experience related accelerative and decelerative forces. Correspondingly, the product inside must move along with the cardboard box, and if there is no cushioning between the product and the cardboard box, the product would experience roughly the same accelerative and decelerative forces experienced by the cardboard box. Secondly, there are impact forces that can occur as a result of a sudden impact with the cardboard box by another object. Again, the accelerative forces are transmitted through the box to the product and must be cushioned in order to protect the product from potential damage.
In order that forces experienced under various shipping and storage conditions are not transmitted to the product, it is necessary to have some sort of packing material that will deform to some degree in order to absorb the impact forces slowly and evenly over a period of time. This will spread out the absorption of the energy of the impact forces such that the full impact forces will not be transmitted to the product. Resultingly, a smaller force will be transmitted over a longer period of time. The product will not experience as great a force, and therefore will be less likely to be damaged.
PRIOR ART
U.S. Pat. No. 4,905,835, issued to PIVERT et al discloses an Inflatable Cushion Packaging that comprises a flexible inflatable structure having three separate inflatable cushions that are in fluid communication with one another. Two of these structures are used to protect the product in a box. One structure forms the bottom and two opposed sides and the other structure forms the top and the other two opposed sides. This packaging product is inflated to whatever size is necessary, within limits, to snugly pack the product within the box. It is not of a fixed size and therefore is not product specific.
U.S. Pat. No. 3,889,743, issued to PRESNICK discloses Inflatable Insulation for packaging comprising a flexible, collapsible bag structure. The bag structure comprises a pair of flexible thermoplastic bags one inside the other. The bags are inflated, at least partially, to create a "dead air space" that provides physical and thermal insulation for packing. In use, the Inflatable Insulation is placed in a box and the product is then placed within the packaging and the packaging is then inflated. This insulation can accommodate various sizes of products and therefore is not product specific.
U.S. Pat. No. 4,551,379, issued to KERR discloses an Inflatable Packaging Material that is formed from a pair of juxtaposed sheets as a plurality of continuous passages between the two sheets with each of the passages being in limited fluid communication with adjacent passages. The passages are inflatable to provide a shock absorbing facility. The inflatable packaging material disclosed in this patent can be used for packing various sizes of products into various sizes of containers and therefore is not product specific.
U.S. Pat. No. 5,030,501, issued to COLVIN et al discloses a Cushioning Structure to be used as a packing material to protect packaged goods. The cushioning structure comprises a sheet of material having a plurality of cell structures bonded and sealed thereto. The cell structures are in fluid communication with one another but overall are sealed from the ambient surroundings. Restricted air flow between the cells provides the structure with its cushioning properties.
SUMMARY OF THE INVENTION
The present invention provides a modular supporting structure for positioning and supporting a product within an outer packing container such as a cardboard box. The modular supporting structure of the present invention is made up of a plurality of modules. These modules are separately inflatable one from the other. The modules may be formed as one continuous piece of material, in which case inflation of the module occurs during the blow molding manufacturing process. Alternatively, the module may include a removable cap that is used to provide access to the interior of the module for purposes of inflation and deflation. For purposes of packing, shipping and storing the modules per se, the modules are often deflated to a relatively uninflated reduced size--as compared to their full blow molded size. The modules are then kept relatively uninflated until they are ready to be used. Inflation of the modules is typically done shortly before the modules are in place within the packing container.
The modules are preferably made of polyethylene plastic and are blow moulded to a finished shape. The modules can also be made of other plastic resins such as polypropylene and rubber. The material is flexible, however, and the module can be collapsed to a fairly flat configuration. When the module is inflated, it takes on its full size and shape. The shape and thickness of the module are predetermined by the size and shape of the product that is being packed and the size and shape of the outer packing container. The overall size of each module can vary for any given product and outer packing container, depending on how much of the product is to be in direct contact with the modules.
The modules must of course interconnect one with another in order to form a modular supporting structure. This interconnection is accomplished by means of a connecting portion that is typically in the form of a flange. Preferably, the flange contains a pair of protruding locking members and at least a pair of co-operating openings therein. The locking members of one flange are received and retained by the cooperating openings of a flange of an adjacent module, thus forming a snap-type interconnecting means.
It is also possible to have an interconnecting member that spans between the modules of the modular supporting structure, thereby interconnecting the modules one to another without the modules actually contacting one another.
The modules of the present invention are composed of a plurality of compartments that are interconnected by a restrictive air passage that limits the passage of air between the compartments, thus providing for a cushioning effect through the damping of air flow between the compartments. The inclusion of a restrictive air passage is not necessary; however, it does improve the effectiveness of the cushioning of the modular supporting structure.
A modular supporting structure for positioning and supporting a product within an outer packing container, wherein the product to be supported has predetermined external dimensions and the outer packing container forms a chamber of predetermined internal dimensions, is disclosed. The supporting structure is such that, at least when in use in combination with the product and the outer packing container, the supporting structure comprises a plurality of modules, each module in turn comprising an at least partially inflated air bladder, and a connecting portion that is attached to the air bladder. The air bladder has a first compartment for receiving and retaining the air, an exterior surface that is generally shaped to fit within a portion of the outer packing container and to make contact therewith, and an inwardly directed receiving surface that is generally adapted to receive a portion of the product. When the modules are connected one to another, a product receiving socket is formed by the combination of the inwardly directed surfaces of the plurality of modules. The product receiving socket is shaped to fit the predetermined external dimensions of the product, and the exterior surface of the air bladder are generally shaped to fit the predetermined internal dimensions of the packing container.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of this invention will now be described by way of example in association with the accompanying drawings in which:
FIG. 1 is an isometric view of the modular supporting structure of the present invention comprising four individual modules;
FIG. 2 is an isometric view similar to FIG. 1 but of a single individual module;
FIG. 3 is a top view of the module of FIG. 2;
FIG. 4 is a sectional side view on line 4--4 of the module of FIG. 3;
FIG. 5 is an end view of the module of FIG. 2;
FIG. 6 is an enlarged scale view on line 6--6 of FIG. 3;
FIG. 7 is a top view of an alternative embodiment of the modular supporting structure of the present invention and shows an individual module;
FIG. 8 is an isometric view of an alternative embodiment of the modular supporting structure of the present invention and shows a single individual module;
FIG. 9 is a side view of a further alternative of the present invention and shows a single module;
FIG. 10 is a top view of an alternative embodiment of the modular supporting structure of the present invention; and
FIG. 11 is a top view of a further alternative embodiment of the modular supporting structure of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to FIG. 1, which shows the modular supporting structure 20 of the present invention in a constructed form, and comprised of four modules 22. In this preferred embodiment, each of the modules 22 is identical one to another. The resulting modular supporting structure is essentially a cruciform formation with a square product receiving socket 24--shown in dashed outline--formed by the relative positions of the four modules. Interconnection of the modules into a modular supporting structure and subsequent functioning of the modular supporting structure will be discussed in greater detail subsequently.
Reference will now be made to FIGS. 2, 3, and 4, which show a single module 22. The module 22 comprises a first compartment 30, a second compartment 32, and a flange 34. The first and second compartments together form an air bladder that is inflated. The preferred and most often used inflation medium is air. Other inflation media such as sulphur hexafluoride may also be used, if desired.
The first compartment 30 has a first exterior surface 40 that includes three separate outer faces. These three separate outer faces contact the packing container in one corner thereof with each of the three separate outer faces contacting a separate inner face--either the top, bottom or one of the sides--of the packing container. The second compartment 32 also has an exterior surface 42 at the bottom thereof for contacting a portion of one inner face of the packing container.
The first and second compartments 30, 32 together also have an inwardly directed surface 44, which is comprised of three separate portions. In the preferred embodiment, these three separate portions are at right angles to one another and form a corner shape that is adapted to receive a similarly shaped corner of a product. There is also an concavely shaped elongated recess 46 in the first compartment 30. This recess 46 receives a portion of one of the three corners--and the vertex of these three corners of the product being supported by the modular supporting structure 20. The corner and vertex are thereby precluded from cutting into the first compartment 30.
As can best be seen in FIG. 4, the first compartment 30 and the second compartment 32 are connected so as to be in fluid communication with one another by a virtue of restrictive air passage 48. The restrictive air passage 48 allows the first and second compartments 30, 32 to be in limited fluid communication with one another by restricting the amount of air that can pass from one compartment to another over a given period of time. The purpose for the two compartments being in fluid communication with one another in this restricted manner is to permit either compartment to deflate slightly if it experiences a sudden heavier load on it or sudden impact force on it, thus providing a damping effect. The diameter of the passage 48 is chosen so as to allow air to pass between the compartments 30, 32 quickly enough to allow either compartment to deform somewhat in the event of a sudden impact or increase in weight on it, but not so quickly as to allow either compartment to virtually collapse, thereby providing insufficient cushioning.
Alternatively, a two-way valve or two counterfacing one-way valves could conceivably be used to control the airflow between the first and second compartments 30, 32.
The first and second compartments 30, 32 are inflated through an inflation tube 50 which is in fluid communication with the second compartment 32 and is also selectably in fluid communication with the exterior of the module 22 at its end 52. A cap 54 is placed over the end 52 of the inflation tube 50 to preclude air within the first and second compartments 30, 32 from escaping through inflation tube 50. The cap 54 is also used to allow the air bladder to be deflated after the module 22 has been manufactured or after it has been used, and also to allow the air bladder to be refilled and resealed. Indeed, the module 22 may be reused several times and may be deflated and re-inflated each time. The module would of course be ultimately recyclable. Alternatively, a valve may be used to control air flow through the end 52 of the inflation tube 50.
It is further contemplated that the inflation tube 50 could have a permanently closed end in the form of a snip-off nipple. A module of this configuration would therefore be formed as one continuous piece of material, in which case inflation of the module occurs during the blow molding process. The module would remain in this fully inflated condition until the snip-off nipple is removed.
The flange 34 extends outwardly from the second compartment 32 and is generally--at least to some degree--in the same plane as the portion of the inwardly directed surface 44 on the second compartment 32. The flange 34 includes a first portion 56 and a second portion 58. The first portion 56 is located slightly above the second portion 58. As can be best seen in FIG. 5, the top surface 60 of the second portion 58 is approximately at the same level as the bottom surface 62 of the first portion 58. There is a pair of protruding locking members 64 that protrude downwardly from the bottom surface 62 of the first portion 56. These locking members 64 are adapted for insertion into cooperating openings 66 in the second portion 58. This combination of locking members 64 and co-operating openings 66 basically constitute a snap type fastener. As can best be seen in FIG. 6, which shows a cutaway view of a single locking member that has been received and retained by a cooperating opening 66, the diameter of the locking member 64 is slightly greater than the diameter of the cooperating opening 66, which causes the locking member 64 to be retained within the cooperating opening 66. When the modules 22 are interconnected one with another, the first portion 56 of one module overlaps the second portion 58 of the adjacent module.
The downwardly protruding locking members 64 on the first portion 56 of flange 34 are inserted into the co-operating openings 66 of the flange 34 of an adjacent module 22, and are retained therein. In this manner, individual modules 22 can be joined one to another in order to form the modular supporting structure as shown in FIG. 1.
Reference is again made to FIG. 1, which shows four modules 22 interconnected with one another. It can be seen that the module marked A has its first portion 56A of the flange 34A overlapped overtop of the second portion 58B of the adjacent module marked B and its second portion 58A overlapped underneath the first portion 56D of the module marked D. Similarly, the module marked B has its first portion 56B of the flange 34B overlapped overtop the second portion 58C of the flange 34C of the module marked C and its second portion 58B overlapped underneath the first portion 56C of the module marked C. Similarly, the flange 34C of the module marked C overlaps with the flanges of the adjacent modules marked B and D and the flange 34D of the module marked D overlaps with the flanges of the adjacent modules marked B and D. In this manner, the four modules are interconnected one with the other in an interleaved manner thus forming the modular supporting structure of the present invention. It can be seen that a square product receiving socket 24 is formed by such interconnection of these four identical modules.
The modular supporting structure of the present invention is commonly used in the following manner. A packing container, typically a cardboard box, is placed ready to receive packing materials and a product therein, with the top of the box being open. A modular supporting structure--typically made up of four modules 22--is placed at the bottom of the box with the product receiving socket 24 facing upwardly. The product to be packed is then placed in to the box and seated in the product receiving socket 24. The modules 22 are of a size such that the product receiving socket is essentially the same size as the particular product being retained therein. Thus, the product is held reasonably snugly. Another modular supporting structure is then placed on top of the product. This second modular supporting structure must of course be oriented with the product receiving socket 24 facing downwardly. The cardboard box can then be closed.
Reference will now be made to FIG. 7 which shows an alternative embodiment, wherein the module 70 has an extended flange 72. The extended flange 72 has two pairs of protruding locking members 74 and also two pairs of cooperating openings 76. Each pair of protruding locking members 74 can be received and retained by either pair of cooperating openings 76. In this manner, the size of the modular supporting structure that is formed from interconnecting four such modules is not limited to just one size.
Reference will now be made to FIG. 8 which shows an alternative embodiment of the present invention, wherein a module 80 has two locking members 82 and three co-operating openings 84. The two locking members 82 can be placed either in the two co-operating openings marked A and B or the two co-operating openings 84 marked B and C. By having this configuration of co-operating openings 84, it is possible to form more than one size of modular supporting structure. Further, it is possible to form a modular supporting structure that has a rectangularly shaped product receiving structure. It is of course also possible to include more than three co-operating openings 84, if desired.
Reference will now be made to FIG. 9, which shows a further alternative embodiment of the invention. In this alternative embodiment there is a module 90 having a first compartment 91 and a second compartment 92 as does the module in the preferred embodiment. Extending outwardly from the first compartment 91 in a first direction is a flange 93 and extending outwardly from the first compartment 91 in a second direction is second flange 94. The first flange 93 has a series of colinearly aligned protruding locking members 95 and the second flange 94 has a plurality of colinearly aligned co-operating openings 96 that are adapted to receive and retain the locking members 95. This embodiment of module can be used to form either square or rectangular modular supporting structures with the number of co-operating openings 96 determining how many sizes of modular supporting structure can be formed. Either square or rectangular modular supporting structures can be formed. It is also possible to have the first and second flanges 93, 94 extending outwardly from the second compartment 92 in a similar manner to that described above.
Reference will now be made to FIG. 10, which shows a still alternative embodiment of the present invention. In this alternative embodiment a modular supporting structure 100 has been formed from four modules 102, which are interconnected by an interconnecting member 104. The interconnecting member 104 is preferably a piece of plastic, either solid or with openings cut in it for weight reduction purposes, that spans between the four modules 102. The modules 102 connect to the interconnecting member 104 in a manner similar to that disclosed above. The module 102 has protruding locking members 106 that protrude upwardly from the module 102. The interconnecting member 104 has a pair of cooperating openings 108 that receive and retain the protruding locking members 106 of the module 102. In this manner, each module is fastened in fixed relation to the interconnecting member 104 which thereby keeps all four of the modules 102 in a fixed relation to one another. Further, the modules 102 form a product receiving socket 109 that is of a particular size and shape as determined by the size and shape of the interconnecting member 104. Advantageous features of this particular alternative embodiment are that virtually any size and shape of product can be accommodated by using the appropriate size and shape of interconnecting member 104. Further, only one size and shape of module 102 is specifically required to form any size of square or rectangular product receiving sockets 109.
Reference will now be made to FIG. 11, which shows yet another alternative embodiment of the present invention. In this alternative embodiment, the module 110 has a slot 111 horizontally disposed in the second compartment 112. An interconnecting member 113 is slid into the slot 111. A protrusion 114 on the bottom surface 115 of the slot 111 enters an aperture 116 in the interconnecting member 113. The interconnecting member 113 is retained in the slot 111 by the protrusion 114 in the aperture 116.
In another alternative embodiment, it is contemplated that the inwardly directed surface of a module could be curved in order to accommodate a round product, and the interconnecting member could be any shape as required.
In yet another alternative embodiment, it is contemplated that there could be more than two compartments, as necessary, with the various compartments being in restricted fluid communication with one another.
Other modifications and alterations may be used in the design and manufacture of the modular supporting structure of the present invention without departing from the spirit and scope of the accompanying claims. | A modular supporting structure for positioning and supporting a product within an outer packing container, is disclosed. The product to be supported has predetermined external dimensions, and the outer packing container forms a chamber of predetermined internal dimensions. The supporting structure is formed from a plurality of modules, each module in turn comprising an air bladder for receiving and retaining air. The air bladder has a first compartment and a second compartment that are in fluid communication one with the other via a restrictive air passage that limits the rate of flow of air therebetween, thus providing physical damping for the product being supported by the modules. There is a connecting portion in the form of a flange, which is attached to the air bladder, that allows the modules to be interconnected one with another. When the modules are connected one to another, a product-receiving socket is formed. The product-receiving socket is shaped to fit the predetermined external dimensions of the product. | 1 |
BACKGROUND OF THE INVENTION
This is a Continuation-In-Part application of application Ser. No. 09/886,924, filed Jun. 20, 2001, which is a Continuation-In-Part of application Ser. No. 09/665,992, filed Sep. 20, 2000, now U.S. Pat. No. 6,250,716.
FIELD OF THE INVENTION
The present invention relates generally to headrests for seats. More particularly, the invention concerns a fully adjustable headrest for use in connection with furniture and with passenger vehicles such as aircraft, trains and busses.
DISCUSSION OF THE PRIOR ART
Various types of headrests for use in passenger vehicles have been suggested in the past. As the general rule, these headrests are designed primarily to satisfy safety aspects rather than to provide a comfortable seating posture. Typically, the prior art vehicle headrests comprise only a vertically adjustable head support member designed to provide protection against injury in the event of an accident. However, some vehicle headrests have also been provided with lateral headrest elements. Exemplary of such a headrest is that described in U.S. Pat. No. 5,997,091 issued to Rech et al.
In addition to passenger vehicle headrests, a number of headrests have been designed for use in a emergency vehicles. These types of headrests are of a more complicated design and some include greater adjustability features. Exemplary of these types of headrests are those disclosed in U.S. Pat. No. 5,275,462 and in U.S. Pat. No. 5,934,749 both issued to Pond et al.
Even more complex headrests have been designed for use in military aircraft and, more particularly in military aircraft for use in conjunction with ejection seats. Typical of this class of headrest design are those disclosed in U.S. Pat. No. 4,883,243 and U.S. Pat. No. 4,899,961 both issued to Herndon. Another such headrest design is disclosed in U.S. Pat. No. 4,466,662 to issued to McDonald et al.
In addition to the development of headrests for use in military aircraft, significant advances have been made in recent years in the design of headrests for use in commercial aircraft. Many of these headrests are designed for personal comfort and include pivotally movable back and lateral supports. In these latter types of headrests, the head support members are typically slidably mounted on spaced apart rods that extend upwardly from the back of the seat and rely on friction to maintain the headrest in an elevated position.
As will become clear from the discussion that follows, the headrests of the present invention represents a substantial improvement over the prior art headrests and provide significantly greater adjustability and therefore greater support and comfort to the user.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an adjustable headrest that provides both support and comfort to the user and can be used in connection with furniture including household and office furniture and also in connection with various types of passenger vehicles.
Another object of the invention is to provide a headrest of the aforementioned character that includes slide means for permitting easy height adjustment of the headrest and also includes locking means for securely locking the headrest in a desired elevated position.
Another object of the invention is to provide easily adjustable, wing like, side support members that are pivotally connected to a centrally located, vertically adjustable head support member by means of constant torque hinges.
Another object of the invention to provide easily adjustable chin support members that are pivotally connected to the side support members by means of constant torque hinges.
Another object of the invention is to provide an adjustable headrest construction of the character described that includes strategically positioned comfort cushions for engagement by the user's neck, head and chin.
Another object of the invention is to provide an adjustable headrest construction of the type described in the preceding paragraphs in which the cushions are readily inflatable and deflatable.
Another object of the invention is to provide a headrest construction of the class described that is of a simple construction and one that can be inexpensively produced and easily installed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of one form of the seat headrest apparatus of the invention partly broken away to show internal construction.
FIG. 2 is a view taken along lines 2 — 2 of FIG. 1 .
FIG. 3 is an enlarged, cross-sectional view taken along lines 3 — 3 of FIG. 1 .
FIG. 4 is a view taken along lines 4 — 4 of FIG. 3 .
FIG. 5 is an enlarged, cross-sectional view taken along lines 5 — 5 of FIG. 1 .
FIG. 6 is a view taken along lines 6 — 6 of FIG. 5 .
FIG. 7 is an enlarged, cross-sectional view taken along lines 7 — 7 of FIG. 1 .
FIG. 8 is a view taken along lines 8 — 8 of FIG. 7 .
FIG. 8A is a view similar to FIG. 8, but showing the support assembly raised and the pawl type locking mechanism thereof in a locked position preventing downward movement of the support assembly.
FIG. 9 is a cross-sectional view taken along lines 9 — 9 of FIG. 8 .
FIG. 10 is a front view of one form of the slide mechanism of the invention.
FIG. 11 is a cross-sectional view similar to FIG. 7, but showing the head support assembly in an intermediate upraised position.
FIG. 11A is a generally perspective view of the apparatus of the invention shown affixed to the seat and illustration the articulation of the various support components of the headrest assembly of the apparatus.
FIG. 12 is a front view of an alternate form of the headrest apparatus of the invention having inflatable cushions or air bags affixed to the various support members of the apparatus.
FIG. 13 is an enlarged, cross-sectional view taken along lines 13 — 13 of FIG. 12 .
FIG. 14 is a front view of the apparatus shown in FIG. 12 as it appears when affixed to a seat.
FIG. 15 is a view similar to FIG. 14 but showing the support assembly in a raised position.
FIG. 16 is a generally schematic, block diagram view showing the various components that make up the control means of the apparatus for inflating and deflating the air bags.
FIG. 17 is a front view of an alternate form of seat headrest construction of the present invention.
FIG. 18 is a view taken along lines 18 — 18 of FIG. 17 .
FIG. 19 is a cross-sectional view taken along lines 19 — 19 of FIG. 17 .
FIG. 20 is a cross-sectional view taken along lines 20 — 20 of FIG. 17 .
FIG. 21 is a greatly enlarged, generally prospective view of one of the hinge assemblies that connects the front and back portions of the headrest.
FIG. 22 is a generally prospective view of one form of the carriage assembly of the invention that interconnects the front portion of the headrest with the rear portion thereof.
FIG. 23 is an enlarged, cross-sectional view taken along lines 23 — 23 of FIG. 17 .
FIG. 24 is a greatly enlarged, cross-sectional view taken along lines 24 — 24 of FIG. 23 .
FIG. 25 is a cross-sectional view taken along lines 25 — 25 of FIG. 23 .
FIG. 26 is a cross-sectional view taken along lines 26 — 26 of FIG. 23 .
FIG. 27 is front view of an alternate form of the headrest assembly of the present invention.
FIG. 28 is a rear view of the alternate form of the headrest assembly of the invention shown in FIG. 27 .
FIG. 29 is a plan view of the seat connector assembly of the apparatus that interconnects the headrest assembly with the aircraft seat.
FIG. 30 is a cross-sectional view taken along lines 30 — 30 of FIG. 27 .
FIG. 31 is a cross-sectional view taken along lines 31 — 31 of FIG. 27 .
FIG. 32 is a generally perspective view of the resistance imparting means of this latest form of the invention.
FIG. 33 is a cross-sectional view taken along lines 33 — 33 of FIG. 30 .
FIG. 34 is an enlarged, cross-sectional view taken along lines 34 — 34 of FIG. 33 .
FIG. 35 is a generally perspective, fragmentary view of the roller guide component of this latest form of the invention.
DESCRIPTION OF THE INVENTION
Referring to the drawings and particularly to FIGS. 1, 2 , and 11 A, one form of the seat headrest of the invention is there illustrated and generally designated by the numeral 14 . The seat headrest here comprises a seat connector assembly 16 that includes a connector member 18 that is connected to the seat “S” by any suitable means such as threaded connectors 20 (FIGS. 2 and 8 ). A support assembly 21 is slidably connected to connector member 18 for movement between a first position shown in FIG. 7 to an intermediate position shown in FIG. 11 and to an upraised position shown in FIG. 11 A.
Support assembly 21 here comprises a slide mechanism 22 , including a track 24 , that is connected to connector member 18 by a suitable connector such as connector 24 a (FIGS. 7 and 10 ). Slide mechanism 22 also includes a slide assembly 26 that slides within track 24 in a manner presently to be described. Connected to slide assembly 26 by a threaded connector 28 a is a mounting member 28 (FIG. 7 ). A first head support member 30 is pivotally connected to member 28 by means of a friction hinge pivot assembly 34 that includes a transversely extending pivot pin 36 and a connector bracket 37 (FIGS. 7 and 8 ). With this construction, first support member 30 can be pivoted about the axis of the shaft 36 a of a connector bolt 36 from a first position adjacent mounting member 28 to an angularly outwardly extending position as shown in FIGS. 7 and 11A. As best seen in FIG. 8, bracket 37 includes spaced apart apertured legs 37 a that receive the shaft of bolt 36 . Disposed between legs 37 a is a bearing 37 b having a transverse bore that receives shaft 36 a of bolt 36 . With this construction, when nut 36 b is snugged down against one of the legs, pivoting of support member 30 will be controllably frictionally resisted.
Pivotally connected to first head support member 30 by a constant torque hinge 38 is a first lateral, or side wing 40 that is pivotally movable from the position shown in FIGS. 1 and 2 wherein it is substantially coplanar with head support member 30 to a second angularly extending forward position shown by the phantom lines in FIG. 2 . In similar fashion, a second, or lateral side wing 42 is connected to the opposite side of support member 30 by a constant torque hinge 44 that is of identical construction to constant torque hinge 38 . Side wing 42 is also pivotally movable from the substantially coplanar position shown in FIG. 2 to the angularly outwardly extending position shown by the phantom lines in FIG. 2 . When side wings 40 and 42 are pivoted into the position shown by the phantom lines in FIG. 2, they can provide a comfortable lateral support to the passenger's head “H” in the manner shown in FIG. 2 .
Hingedly connected to side wing 40 , by means of a constant torque, friction imparting hinge 46 is a first chin support 48 . Similarly, a second chin support 50 is hingedly interconnected with side wing 42 by means of a constant torque hinge 52 that is of identical construction to hinge 46 (FIG. 1 ). Constant torque hinges 38 , 44 , 46 and 52 , which are readily commercially available from sources such as Reel Precision Manufacturing of St. Paul, Minn. function to maintain the side wings and chin supports in a selected position until a substantial force is exerted on the hingedly connected member to positively move it into a different position. More particularly, as best seen in FIG. 6, each of the constant torque hinges includes a torsion spring 53 that circumscribes pivot pin or rod 55 and engages the leaves of the hinge in a manner such that relative pivotal movement of the leaves of the hinges produce a constant torque tending to continuously resist the relative pivotal movement of the leaves. In this way, movement of one of the hingedly support members relative to the other is continuously, positively resisted. The use of the constant torque spring hinges in this manner uniquely overcomes a common drawback of prior art head rest construction in which the hingedly connected members tend to undesirably move as a result of vibration and other environmental forces. It is to be understood that a friction-imparting, constant-torque hinge could also be used to hingedly connect first head support member 30 to member 28 .
Referring particularly to FIGS. 7, 8 , 9 , 10 , and 11 , the novel slide means of the invention for slidably interconnecting the support assembly 21 with seat connector member 18 is there illustrated. In the present form of the invention, this slide means comprises the previously identified slide mechanism 22 which is of conventional construction and is readily commercially available from sources such as Dirak Gmbh & Co. of Ennepetal, Germany. As previously mentioned slide assembly 26 is controllably movable within track 24 from the position shown in FIG. 7 wherein slide member is substantially enclosed within the hollow housing portion of track 24 to a second extended position wherein the slide assembly extends outwardly from the track housing 24 a substantial distance.
As best seen by referring to FIGS. 9, 10 and 11 , the hollow housing of track 24 includes having an upper surface 24 a that is provided with a plurality of spaced-apart, angularly, downwardly extending notches 60 that are configured to receive the locking pin 62 a of a pawl 62 that is carried by track 24 for pivotal movement between a first retracted position shown in FIGS. 8 and 10 to a second position shown in FIG. 8A wherein pin 62 a is urged into a selected notch by means of a biasing spring 62 b . With this construction, as slide 26 moves upwardly within track 24 , locking pin 62 a will ride over the tooth-like portions 60 a located intermediate to notches 60 . However, due to the urging of spring 62 b , pin 62 a will drop into a selected notch when upward movement of the slide assembly ceases. When locking pin 62 a has thusly been urged into a selected notch, downward movement of slide assembly will be positively prevented. However, when the slide assembly reaches its uppermost position, pawl 62 will enter slot 60 b (FIG. 10) where it will once again move into a retracted position permitting the support assembly to move downwardly toward its starting position. As indicated in FIG. 9, mounting member 28 , which is interconnected with slide assembly 26 and moves therewith, is guided by guide means shown here as a pair of spaced-apart guide brackets 65 that are connected to connector member 18 by threaded connectors 67 . Each of the brackets 65 includes an angularly outwardly extending segment 65 a that guidingly engage the sloping side walls 28 a of mounting member 28 .
Turning next to FIGS. 12 through 16, an alternate form of the headrest apparatus of the present invention is there illustrated. This form of the invention is similar in many respects to that illustrated in FIGS. 1 through 11 and previously described herein. Because of the similarity of these embodiments, like numbers are used in FIGS. 12 through 16 to identify like components. The principal difference between this latest embodiment of the invention and that earlier described resides in the fact that inflatable cushions or air bags are attached to the various support components that make up the headrest assembly. More particularly, as shown in FIG. 12, three inflatable air bags or bladders 70 , 71 , and 72 are interconnected with the lower portion of support member 30 , while a single air bag 74 is affixed to each of the side panels 40 and 42 . In similar fashion, first and second air bags or bladders 76 and 78 are attached to each of the chin support members 48 and 50 . Air bags 70 , 71 , and 72 are disposed below a main cushion 80 that is affixed to the upper portion of support member 30 . Similarly, air bag 74 is positioned below a larger support cushion 82 that is affixed to side wing 40 while inflatable air bag 74 is disposed beneath a larger cushion 84 that is affixed to side wing 42 . Cushions 82 and 84 can be of a conventional padded cushion construction, or, if desirable, could also be inflatable bladder components. When installed to the support component in the manner illustrated in FIG. 12, the supporting cushions and inflatable air bags are covered by a conventional upholstery cover 87 so that the assembly takes on the finished configuration shown in FIG. 14 . Covering 87 can be of fabric or vinyl material and is suitably flexible to enable the inflation and deflation of the bladder component without unduly stressing the cover material. FIG. 15 illustrates the support assemblage shown in FIG. 14 in the upraised position wherein the support assembly has been moved to the uppermost position by sliding it along the sliding mechanism which is of the character previously described.
Referring to FIG. 16, one form of the control system, or control means of the invention for operating the air bags, or inflatable cushions, is there illustrated in schematic form. Shown in the left-hand portion of FIG. 16 are the inflatable bladders that have been previously identified and that are connected to the left, center and right support members. As indicated in FIG. 16, central bladder 70 is interconnected by means of a pneumatic hose 88 with an air pump 90 via a pneumatic junction 92 and a first solenoid valve 94 . Bladders 74 are, in turn, connected to bladder 70 by pneumatic hoses 88 a . Similarly, inflatable bladder 71 is interconnected by means of a pneumatic hose 96 with pump 90 via pneumatic junction 92 and a second solenoid valve 98 . Bladders 76 are, in turn, connected to bladder 71 by pneumatic hoses 96 a . In similar manner, inflatable bladder 72 is interconnected by means of a pneumatic hose 100 with air pump 70 via pneumatic junction 92 and a third solenoid valve 102 . Bladders 78 are, in turn, connected to bladder 72 by pneumatic hoses 100 a . First solenoid valve 94 is interconnected by means of an electric connnector 104 with the central processing unit 106 of the apparatus via a first relay 108 . Similarly, second solenoid 98 is interconnected by means of an electrical conduit 110 with central processing unit 106 via a second relay 112 . In similar manner third solenoid valve 102 is interconnected by means of an electrical conduit 114 with central processing unit 106 via a third relay 116 . Air pump 90 is interconnected with pneumatic junction 92 by means of an air hose 120 . Motor pump 90 is also operably interconnected with central processing unit 106 by an electrical connector 122 . Central processing unit 106 is of a conventional construction that is readily commercially available and is powered by a conventional external power source. Similarly pump 90 , pneumatic junction 92 , as well as the solenoids and relays that make up the control system are well understood by those skilled in the art and are also readily commercially available.
Central processing unit 106 is operably interconnected by an electrical connector 126 a with an occupant control means, shown here as a control panel 126 . In the form of the invention shown in FIG. 16, occupant control panel 126 includes an inflate switch 130 for use in inflating the bladders and a deflate switch 132 for use in deflating the bladders. Also provided on occupant panel 126 is an on/off massage switch 140 that can be manipulated to cause a massaging type action to be imparted to the passenger by the sequential inflation and deflation of the air bags or bladders that are affixed to the various support members. Switch 140 is operably coupled with switches 134 and 136 to enable faster and slower massage cycle rates. With the construction shown in FIG. 16, the inflatable air bags, or bladders, can be inflated or deflated independently either in series or in parallel for the purpose of controlling bladder firmness or for performing an upper back, neck, face and head message cycle for a preprogrammed time in accordance with a program contained within central processing unit 106 . Once again, switches 130 , 132 , 134 , and 136 are of a conventional design well understood by those skilled in the art.
Motor pump 90 can be powered by an existing seat power supply as, for example, a seat controller lumbar controller, seat motor controller or the like, or it may be powered by a power supply interconnected with and dedicated to motor pump 90 . It is to be understood that the electrical and pneumatic interconnection shown schematically in FIG. 16 is well understood by those skilled in the art as is the necessary programming of central processing unit 106 to accomplish the desired inflation and deflation sequencing of the various air bags or bladders.
For certain end use application, central support member 30 can be provided with a greater or lesser number of inflatable air bags. Similarly, side panels 40 and 42 may have more than one air bag and chin support member 48 can be provided with one, two or more inflatable bladders as may be desired by the system designer. Similarly the occupant control panel can be designed to accommodate more or less inflatable bladders and may also be designed to cooperate with the central processing unit to accomplish various other inflation/deflation and message type cycles as may be desired for the particular vehicle in which the apparatus is installed.
Referring next to FIGS. 17 through 26, an alternate form of seat headrest of the invention is there illustrated and generally designated by the numeral 114 . This latest embodiment of the invention comprises a seat connector assembly 116 that includes a generally planar first connector member 118 that is connected to the seat “S” by any suitable means. Slidably connected to first connector member 118 for movement between a first lowered position shown by the solid lines in FIG. 17 to an upraised position shown by the phantom lines in FIG. 17 is a head support assembly 220 (see also FIG. 26 ).
As best seen in FIG. 24, head support assembly 220 includes a carriage assembly 221 to which a generally planar central support member or panel 222 is pivotally connected by means of a constant torque hinge 224 (FIG. 19 ). Connected to central support panel 222 by a constant torque hinge 225 is a first lateral or side panel 226 , which is pivotally movable, a first position wherein it is substantially coplanar with central support panel 222 to a second angularly extending forward position. In similar fashion a second or lateral side panel 228 is connected to the opposite side of central support member 222 by a constant torque hinge 230 that is of identical construction to constant torque hinge 225 . Side panel 228 is also pivotally movable from a substantially coplanar position with central support panel 222 to an angularly outwardly extending position. When side panel's 226 and 228 are pivoted into the angularly outwardly extending position, they provide a comfortable lateral support to the passenger's head “H” in the manner shown in FIG. 2 . Constant torque hinges 225 and 230 are readily commercially available and function to maintain the side panels in a position desired by the user until a substantial force is exerted on the hingedly connected member to positively move it into a different position. As before, use of these constant torque hinges overcomes a common drawback of prior art headrest construction in which the hingedly connected members tend to undesirably move as a result of vibration or other environmental forces.
As indicated by the arrow 231 in FIG. 18, constant torque hinge 224 permits the headrest assembly 220 to be adjustably pivoted both forwardly and rearwardly relative to the seat connector assembly 116 . Constant torque hinge 224 , which is readily commercially available from several commercial sources, including Torqmaster, International of Stamford, Conn., functions to maintain the headrest assembly 220 in a position desired by the user until a substantial force is exerted on the headrest assembly to positively move it into a different position. As shown in FIGS. 20 and 23, hinge 224 is mounted on a plate 233 and includes a housing 224 a that carries a steel shaft 224 b that, in turn, carries a plurality of spring steel friction bands 224 c that function to controllably resist rotation of plate 223 and panel 222 that is attached thereto relative to connector assembly 116 . Connected to seat connector member 118 is an elongated guide 238 that includes oppositely disposed guide rails 238 a (FIG. 19) that are adapted to be rollably engaged by two pairs of spaced apart roller assemblies 244 that are mounted on carriage assembly 221 . The roller assemblies 244 , each of which are of identical construction, include a threaded connecting shaft 244 a that is threadably connected to carriage assembly 221 and a grooved roller 244 b that is rotatably mounted on shaft 244 a . With this construction, carriage assembly 221 along with headrest assembly 220 can be adjustably moved upwardly and downwardly relative to seat connector member 118 so as to enable the desired adjustment in the height of the headrest assembly relative to the seat connector member.
Forming and important aspect of the headrest assembly of this latest form of the invention is resistance imparting means for imparting resistance to the movement of head rest assembly 220 upwardly and downwardly relative to connector member 118 . In the present form of the invention, this novel resistance imparting means comprises a uniquely configured leaf spring designated in the drawings by the numeral 247 . As best seen in FIGS. 22 and 24, spring 247 includes a central portion 247 a that is affixed to carriage assembly 221 in the manner shown in the drawings. Spring member 247 also includes a pair of outwardly extending yieldably deformable side members 274 b that are connected to central portion 247 a . Each of the side members 247 b terminates in a surface engaging portion 247 c . As best seen in FIG. 24, when the resistance means is fully assembled portions 247 c are substantially parallel to central portion 247 a . With this construction, when carriage assembly 221 is interconnected with seat connector member 118 in the manner shown in FIG. 24, spring member 247 will be yieldably deformed in the manner shown in FIG. 24 so that surface engaging portions 247 are brought into pressural engagement with seat connector member 118 . As the headrest assembly is moved upwardly and downwardly in the manner indicated in FIG. 26, surface engaging portions 247 c will frictionally engage the outer surface of connector member 118 and will yieldably resist sliding movement of carriage assembly 221 relative to seat connector member 118 . In the preferred form of the invention a plastic film 249 is disposed between surface engaging portions 247 c and connector member 118 so as to insure smooth sliding of the headrest assembly relative to the connector member.
Turning now to FIGS. 27 through 35, still another form of seat headrest of the invention is there illustrated and generally designated by the numeral 254 . This latest embodiment of the invention is similar and several respects to the earlier described embodiments and like to numerals are used in FIGS. 27 through 36 to identify like components. This latest embodiment of the invention comprises a seat connector assembly 256 (FIG. 29) that includes a generally planar first connector member 258 that is connected to the seat “S” by any suitable means. Slidably connected to first connector member 258 for movement between a first lowered position shown by the phantom lines in FIGS. 27 and 28 and an upraised position shown by the solid lines in FIGS. 27 and 28 is a head support assembly 260 (see also FIG. 31 ).
As best seen in FIGS. 27, 28 and 30 , head support assembly 260 includes a generally planar central support member or panel 262 to which an elongated guide member 264 is connected by means of connectors 265 (FIG. 31 ). A first lateral or side panel 266 is pivotally connected to the central support member by means of a constant torque hinge 225 . Also connected to central support panel 262 by a constant torque hinge 230 is a second lateral or side panel 268 . As indicated in FIG. 30, side panels 266 and 268 are pivotally movable, a first position shown by solid lines in FIG. 30 wherein they are substantially coplanar with central support panel 262 to a second angularly extending forward position shown by phantom lines in FIG. 30 . When side panel's 266 and 268 are pivoted into the angularly outwardly extending position, they provide a comfortable lateral support to the passenger's head in the manner previously described and as shown in FIG. 2 .
The earlier identified elongated guide member 264 includes oppositely disposed guide rails 264 a (FIGS. 33, 34 and 35 ) that are adapted to be rollably engaged by two pairs of spaced apart roller assemblies 270 that are mounted on connector member 258 . The roller assemblies 270 , each of which are of identical construction, include a connecting shaft 272 that is connected to connector member 258 and a grooved roller 274 that is rotatably mounted on shaft 272 (FIG. 34 ). With this construction the headrest assembly 260 can be adjustably moved upwardly and downwardly relative to seat connector member 258 so as to enable the desired adjustment in the height of the headrest assembly relative to the seat connector member. As the headrest assembly is moved upwardly and downwardly, guide means, shown here as a pair of internal ears 275 formed on support member 258 (FIG. 30 ), slidably engage guide member 267 to guide the travel of the headrest assembly.
Forming and important aspect of the headrest assembly of this latest form of the invention is resistance imparting means for imparting resistance to the movement of head rest assembly 260 upwardly and downwardly relative to connector member 258 . In the present form of the invention, this novel resistance imparting means comprises a uniquely configured leaf spring designated in the drawings by the numeral 277 . As best seen in FIGS. 31 and 32, spring 277 includes a first end portion 277 a that is connected to support member 258 by a connector 280 (FIG. 31 ), a free end portion 277 b and a yieldably deformable, outwardly curved central portion 277 c . As indicated in FIG. 31, when the headrest assembly of the invention is fully assembled, central portion 277 c of the spring is in pressural engagement with the front surface, or face, 264 a of guide 264 . More particularly, when the headrest assembly 260 is interconnected with seat connector member 258 in the manner shown in FIG. 31, spring member 277 will be yieldably deformed in the manner shown in FIG. 31 so that central portion 277 c is brought into pressural engagement with face 264 a of the elongated guide 264 . With this construction, as the headrest assembly is moved upwardly and downwardly in the manner indicated in FIG. 28, spring 277 will yieldably resist sliding movement of headrest assembly 260 relative to elongated guide 264 and seat connector member 258 . In the preferred form of the invention a plastic film 279 is disposed between the central portion 277 c and the face 264 a of elongated guide 264 so as to insure smooth sliding of the headrest assembly relative to the connector member.
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims. | An adjustable headrest that provides both support and comfort to the user and one that can be used in connection with furniture including household and office furniture and also in connection with various types of passenger vehicles. The headrest includes slide means for permitting easy height adjustment of the headrest and also includes locking means for securely locking the headrest in a desired elevated position. Further, the headrest includes easily adjustable, wing-like, side-support members that are pivotally connected to a centrally located, vertically adjustable head support member by means of constant torque hinges and also includes easily adjustable chin support members that are pivotally connected to the side support members by means of constant torque hinges. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to the (L)-(+)-tartaric acid salt of 2-amino-N-{1-(R)-(2,4-difluoro-benzyloxymethyl)-2-oxo-2-[3-oxo-3a-(R)-pyridin-2-ylmethyl-2-(2,2,2-trifluoro-ethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridin-5-yl]-ethyl}-2-methyl-propionamide which is a growth hormone secretagogue.
[0002] Growth hormone (GH), which is secreted from the pituitary gland, stimulates growth of all tissues of the body that are capable of growing. In addition, growth hormone is known to have the following basic effects on the metabolic processes of the body:
[0003] 1. Increased rate of protein synthesis in substantially all cells of the body;
[0004] 2. Decreased rate of carbohydrate utilization in cells of the body; and
[0005] 3. Increased mobilization of free fatty acids and use of fatty acids for energy.
[0006] Deficiency in growth hormone results in a variety of medical disorders. In children, it causes dwarfism. In adults, the consequences of acquired GH deficiency include profound reduction in lean body mass and concomitant increase in total body fat, particularly in the truncal region. Decreased skeletal and cardiac muscle mass and muscle strength lead to a significant reduction in exercise capacity. Bone density is also reduced. Administration of exogenous growth hormone has been shown to reverse many of the metabolic changes. Additional benefits of therapy have included reduction in LDL cholesterol and improved psychological well-being.
[0007] In cases where increased levels of growth hormone were desired, the problem was generally solved by providing exogenous growth hormone or by administering an agent which stimulated growth hormone production and/or release. In either case the peptidyl nature of the compound necessitated that it be administered by injection. Initially the source of growth hormone was the extraction of the pituitary glands of cadavers. This resulted in an expensive product, and carried with it the risk that a disease associated with the source of the pituitary gland could be transmitted to the recipient of the growth hormone (e.g., Jacob-Creutzfeld disease). Recently, recombinant growth hormone has become available which, while no longer carrying any risk of disease transmission, is still a very expensive product which must be given by injection or by a nasal spray.
[0008] Most GH deficiencies are caused by defects in GH release, not primary defects in pituitary synthesis of GH. Therefore, an alternative strategy for normalizing serum GH levels is by stimulating its release from somatotrophs. Increasing GH secretion can be achieved by stimulating or inhibiting various neurotransmitter systems in the brain and hypothalamus. As a result, the development of synthetic growth hormone-releasing agents to stimulate pituitary GH secretion are being pursued, and may have several advantages over expensive and inconvenient GH replacement therapy. By acting along physiologic regulatory pathways, the most desirable agents would stimulate pulsatile GH secretion, and excessive levels of GH that have been associated with the undesirable side effects of exogenous GH administration would be avoided by virtue of intact negative feedback loops.
[0009] Physiologic and pharmacologic stimulators of GH secretion include arginine, L-3,4-dihydroxyphenylalanine (L-DOPA), glucagon, vasopressin, and insulin induced hypoglycemia, as well as activities such as sleep and exercise, indirectly cause growth hormone to be released from the pituitary by acting in some fashion on the hypothalamus perhaps either to decrease somatostatin secretion or to increase the secretion of the known secretagogue growth hormone releasing factor (GHRF) or an unknown endogenous growth hormone-releasing hormone or all of these.
[0010] This invention also relates to a method of treating insulin resistant conditions such as Non-Insulin Dependent Diabetes (NIDD) and reduced glycemic control associated with obesity and aging in a mammal in need thereof which comprises administering to said mammal an effective amount of the L-(+)-tartrate salt of the compound of Formula I, shown below.
[0011] Other compounds have been developed which stimulate the release of endogenous growth hormone such as analogous peptidyl compounds related to GRF or the peptides of U.S. Pat. No. 4,411,890. These peptides, while considerably smaller than growth hormones are still susceptible to various proteases. As with most peptides, their potential for oral bioavailability is low.
[0012] WO 94/13696 refers to certain spiropiperidines and homologues which promote release of growth hormone. Preferred compounds are of the general structure shown below.
[0013] WO 94/11012 refers to certain dipeptides that promote release of growth hormone. These dipeptides have the general structure
[0014] where L is
[0015] The compounds of WO 94/11012 and WO 94/13696 are reported to be useful in the treatment of osteoporosis in combination with parathyroid hormone or a bisphosphonate.
[0016] A generic disclosure of pharmaceutically-acceptable salts of the compound of Formula I of the instant application is disclosed, and the free base of the compound of Formula I of the instant invention is disclosed and claimed, in co-pending PCT application Ser. No. PCT/IB 96/01353 having an international filing date of Dec. 4, 1996, assigned to the assignee hereof.
[0017] It has been found that the L-(+)-tartaric acid salt of the compound of Formula I, shown below, can be isolated in crystalline form which has advantageous properties such as ease of making a formulation, high solubility, good stability and is more easily purified than a non-crystalline form.
SUMMARY OF THE INVENTION
[0018] This invention provides the L-(+)-tartaric acid salt of the compound of
[0019] are the stereochemical mixture or separated isomers having the configurations 3a-(S), 1-(R); 3a-(S), 1-(S); 3a-(R), 1-(S); and/or 3a-(R), 1-(R) isomers.
[0020] This invention also provides: a process for the preparation of the (D)-tararic acid or the (L)-tartaric acid salt of the compound of formula (E),
[0021] which comprises reacting the compound of formula (D),
[0022] with (D)-tartarc acid or (L)-tartaric acid in about 8:1 to about 9:1 mixture of acetone:water at a temperature between about 0° C. to room temperature. Preferred of the foregoing process is where (D)-tartaric acid is reacted with the compound of formula (D) and the compound of formula (E) has the R-configuration;
[0023] a process for the preparation of the compound of formula (J),
[0024] which comprises reacting the compound of formula (E),
[0025] with the compound of formula (X),
[0026] where Prt is an amine protecting group and X is OH, —O(C 1 -C 4 )alkyl or halo, in the presence of an organic base and a peptide coupling reagent at a temperature between about −78° C. to about −20° C. Preferred of the immediately foregoing process is where the peptide coupling reagent is 1-propane phosphonic acid cyclic anhydride and the compound of formula X has the R-configuration and the compound of formula E has the R-configuration. Even more preferred is a where Prt is tert-butyloxycarbonyl in the immediately foregoing process; and
[0027] a process for the preparation of the (L)-(+)-tartaric acid salt of the compound of formula I,
[0028] which comprises reacting the compound of formula (E),
[0029] with the compound of formula (X),
[0030] where Prt is an amine protecting group and X is OH, —O(C 1 -C 4 )alkyl or halo, in the presence of an organic base and a peptide coupling reagent at a temperature between about −78° C. to about −20° C., to yield the compound of formula (J),
[0031] deprotecting the compound of formula (J) under appropriate deprotecting conditions to yield the compound of formula (K),
[0032] reacting the compound of formula (K) with (L)-(+)-tartaric acid in a reaction inert solvent to yield the (L)-(+)-tartaric acid salt of the compound of formula I. Preferred of the immediately foregoing process is where Prt is tert-butoxycarbonyl, even more preferred of the immediately foregoing process is where the peptide coupling reagent is 1-propane phosphonic acid cyclic anhydride and the compound of formula I has the absolute and relative configuration 3a-(R), 1-(R).
[0033] In another aspect, this invention provides for:
[0034] the R,S-enantiomeric mixture, the R-enantiomner or the S-enantiomer of the compound of the formula
[0035] where the (D)-tartanic acid or the (L)-tartaric acid salt is preferred;
[0036] the 3a-(R,S), 1-(R) diastereomeric mixture, the 3a-(R), 1-(R) diastereomer or the 3a-(S), 1-(R) diastereomer of the compound of the formula
[0037] where Prt is an amine protecting group selected from the group consisting of t-BOC, FMOC and CBZ; and
[0038] the R,S-enantiomeric mixture, the R-enantiomer or the S-enantiomer of the compound of the formula
[0039] the R,S-enantiomeric mixture, the R-enantiomer or the S-enantiomer of the compound of the formula
[0040] where X is OH, —O(C 1 -C 4 )alkyl or halo and Prt is an amine protecting group; and where X is OH, Prt is BOC and the stereocenter is in the R-configuration is preferred.
[0041] In yet another aspect, this invention provides (where the compound of formula (I) is shown above):
[0042] methods for increasing levels of endogenous growth hormone in a human or other animal which comprise administering to such human or animal an effective amount of the (L)-(+)-tartaric acid salt of the compound of formula I;
[0043] pharmaceutical compositions which comprise a pharmaceutically-acceptable carrier and an amount of the (L)-(+)-tartaric acid salt of the compound of formula I;
[0044] pharmaceutical compositions useful for increasing the endogenous production or release of growth hormone in a human or other animal which comprise a pharmaceutically acceptable carrier, an effective amount of the (L)-(+)-tartaric acid salt of the compound of formula I according to claim 1 and a growth hormone secretagogue selected from the group consisting of GHRP-6, Hexarelin, GHRP-1, growth hormone releasing factor (GRF), IGF-1, IGF-2 and B-HT920 or an analog thereof;
[0045] methods for treating or preventing osteoporosis which comprise administering to a human or other animal in need of such treatment or prevention an amount of the (L)-(+)-tartaric acid salt of the compound of formula I which is effective in treating or preventing osteoporosis;
[0046] methods for treating or preventing diseases or conditions which may be treated or prevented by growth hormone which comprise administering to a human or other animal in need of such treatment or prevention an amount of the (L)-(+)-tartaric acid salt of the compound of formula I which is effective in promoting release of endogenous growth hormone; preferred is a method wherein the disease or condition is congestive heart failure, obesity or frailty associated with aging; also preferred is a method wherein the disease or condition is congestive heart failure; further preferred is a method wherein the disease or condition is frailty associated with aging;
[0047] methods for accelerating bone fracture repair, attenuating protein catabolic response after a major operation, reducing cachexia and protein loss due to chronic illness, accelerating wound healing, or accelerating the recovery of bum patients or patients having undergone major surgery, which methods comprise administering to a mammal in need of such treatment an amount of the (L)-(+)-tartaric acid salt of the compound of formula I which is effective in promoting release of endogenous growth hormone; preferred is a method wherein the method is for accelerating the recovery of patients having undergone major surgery; also preferred is a method wherein the method is for accelerating bone fracture repair;
[0048] methods for improving muscle strength, mobility, maintenance of skin thickness, metabolic homeostasis or renal homeostasis, which method comprise administering to a human or other animal in need of such treatment an amount of the (L)-(+)-tartaric acid salt of the compound of formula I which is effective in promoting release of endogenous growth hormone;
[0049] methods for the treatment or prevention of osteoporosis which comprise administering to a human or other animal with osteoporosis effective amounts of a bisphosphonate compound and the (L)-(+)-tartaric acid salt of the compound of formula I; preferred of a method for the treatment of osteoporosis is where the bisphosphonate compound is ibandronate; preferred of the method for the treatment of osteoporosis is where the bisphosphonate compound is alendronate;
[0050] methods for the treatment or prevention of osteoporosis which comprise administering to a human or other animal with osteoporosis effective amounts of estrogen or Premarin® and the (L)-(+)-tartaric acid salt of the compound of formula I and, optionally, progesterone.
[0051] methods for the treatment of osteoporosis which comprise administering to a human or other animal with osteoporosis effective amounts of calcitonin and the (L)-(+)-tartaric acid salt of the compound of formula I;
[0052] methods to increase IGF-1 levels in a human or other animal deficient in IGF-1 which comprise administering to a human or other animal with IGF-1 deficiency an effective amount of the (L)-(+)-tartaric acid salt of the compound of formula I;
[0053] methods for the treatment of osteoporosis which comprise administering to a human or other animal with osteoporosis effective amounts of an estrogen agonist or antagonist and the of the (L)-(+)-tartaric acid salt of the compound of formula I; preferred is a method wherein the estrogen agonist or antagonist is tamoxifen, droloxifene, raloxifene or idoxifene; also preferred is a method where the estrogen agonist or antagonist is cis-6(4-fluoro-phenyl)-5-[4-(2-piperidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol; (-)-cis-6-phenyl-5-[4-(2-pyrrolidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0054] cis-6-phenyl-5-[4-(2-pyrrolidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol; cis-1-[6′-pyrrolodinoethoxy-3′-pyridyl]-2-phenyl-6-hydroxy-1,2,3,4-tetrahydro-naphthalene; 1-(4′-pyrrolidinoethoxyphenyl)-2-(4″-fluorophenyl)-6-hydroxy-1,2,3,4-tetrahydroisoquinoline; cis-6-(4-hydroxyphenyl)-5-[4(2-piperidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol; or 1-(4′-pyrrolidinolethoxyphenyl)-2-phenyl-6-hydroxy-1,2,3,4-tetrahydro-isoquinoline;
[0055] methods for increasing muscle mass, which methods comprise administering to a human or other animal in need of such treatment an effective amount of the (L)-(+)-tartaric acid salt of the compound of formula I;
[0056] methods for promoting growth in growth hormone deficient children which comprise administering to a growth hormone deficient child an effective amount of the (L)-(+)-tartaric acid salt of the compound of formula I;
[0057] methods for treating insulin resistance in a mammal, which comprise administering to said mammal an effective amount of the (L)-(+)-tartaric acid salt of the compound of formula I; preferred is a method where the condition associated with insulin resistance is type I diabetes, type II diabetes, hyperglycemia, impaired glucose tolerance or an insulin resistant syndrome; also preferred is a method where the condition associated with insulin resistance is associated with obesity or old age;
[0058] methods for increasing levels of endogenous growth hormone, which comprise administering to a human or other animal in need thereof effective amounts of a functional somatostatin antagonist and the (L)-(+)-tartaric acid salt of the compound of formula I; preferred is a method where the functional somatostatin antagonist is an alpha-2 adrenergic agonist; and
[0059] methods of treating or preventing congestive heart failure, obesity or frailty associated with aging, which comprise administering to a human or other animal in need thereof effective amounts of a functional somatostatin antagonist and the of the (L)-(+)-tartaric acid salt of the compound of formula I.
[0060] The instant compound of formula I promotes the release of growth hormone, is stable under various physiological conditions and may be administered parenterally, nasally or by the oral route.
DETAILED DESCRIPTION OF THE INVENTION
[0061] The (L)-(+)-tartrate salt of the compound of Formula I can be made by the following processes which includes processes known in the chemical arts for the production of compounds. Certain processes for the manufacture of the L-(+)-tartaric acid salt of the compound of Formula I are provided as further features of the invention and are illustrated by the reaction scheme, shown below.
[0062] The compound of the instant invention has the absolute and relative configuration shown below:
[0063] which is designated as the 3a-(R), 1-(R) configuration. It can be prepared by the method described hereinbelow.
[0064] The growth hormone releasing (L)-(+)-tartaric acid salt of the compound of Formula I is useful in vitro as a unique tool for understanding how growth hormone secretion is regulated at the pituitary level. This includes use in the evaluation of many factors thought or known to influence growth hormone secretion such as age, sex, nutritional factors, glucose, amino acids, fatty acids, as well as fasting and non-fasting states. In addition, the (L)-(+)-tartaric acid salt of the compound of Formula I can be used in the evaluation of how other hormones modify growth hormone releasing activity. For example, it has already been established that somatostatin inhibits growth hormone release.
[0065] The (L)-(+)-tartaric acid salt of the compound of Formula I can be administered to animals, including humans, to release growth hormone in vivo. The (L)-(+)-tartaric acid salt of the compound of Formula I is useful for treatment of symptoms related to GH deficiency; to stimulate growth or enhance feed efficiency of animals raised for meat production to improve carcass quality; to increase milk production in dairy cattle; for improvement of bone or wound healing and for improvement in vital organ function. The (L)-(+)-tartaric acid salt of the compound of Formula I by inducing endogenous GH secretion, will alter body composition and modify other GH-dependent metabolic, immunologic or developmental processes. For example, the compounds of the present invention can be given to chickens, turkeys, livestock animals (such as sheep, pigs, horses, cattle, etc.), companion animals (e.g., dogs) or may have utility in aquaculture to accelerate growth and improve the protein/fat ratio in fish. In addition, the (L)-(+)-tartaric acid salt of the compound of Formula I can be administered to humans in vivo as a diagnostic tool to directly determine whether the pituitary is capable of releasing growth hormone. For example, the (L)-(+)-tartaric acid salt of the compound of Formula I can be administered in vivo to children. Serum samples taken before and after such administration can be assayed for growth hormone. Comparison of the amounts of growth hormone in each of these samples would be a means for directly determining the ability of the patient's pituitary to release growth hormone.
[0066] Accordingly, the present invention includes within its scope pharmaceutical compositions comprising, as an active ingredient, the (L)-(+)-tartaric acid salt of the compound of Formula I in association with a pharmaceutically acceptable carrier. Optionally, the pharmaceutical compositions can further comprise an anabolic agent in addition to the (L)-(+)-tartaric acid salt of the compound of Formula I or another compound which exhibits a different activity, e.g., an antibiotic growth permittant or an agent to treat osteoporosis or with other pharmaceutically active materials wherein the combination enhances efficacy and minimizes side effects.
[0067] Growth promoting and anabolic agents are well known in the art and include, but are not limited to, TRH, PTH, diethylstilbesterol, estrogens, β-agonists, theophylline, anabolic steroids, enkephalins, E series prostaglandins, compounds disclosed in U.S. Pat. No. 3,239,345, the disclosure of which is hereby incorporated by reference, e.g., zeranol, compounds disclosed in U.S. Pat. No. 4,036,979, the disclosure of which is hereby incorporated by reference, e.g., sulbenox, and peptides disclosed in U.S. Pat. No. 4,411,890, the disclosure of which is hereby incorporated by reference.
[0068] The (L)-(+)-tartaric acid salt of the compound of Formula I in combination with other growth hormone secretagogues such as the growth hormone releasing peptides GHRP-6 and GHRP-1 as described in U.S. Pat. No. 4,411,890, the disclosure of which is hereby incorporated by reference, and publications WO 89/07110, WO 89/07111 and B-HT920 as well as hexarelin and the newly discovered GHRP-2 as described in WO 93/04081 or growth hormone releasing hormone (GHRH, also designated GRF) and its analogs or growth hormone and its analogs or somatomedins including IGF-1 and IGF-2 or adrenergic agonists such as clonidine, xylazine, detomidine and medetomidine (clonidine, which is disclosed in U.S. Pat. No. 3,202,660 the disclosure of which is hereby incorporated by reference, xylazine, which is disclosed in U.S. Pat. No. 3,235,550 the disclosure of which is hereby incorporated by reference and medetomidine, which is disclosed in U.S. Pat. No. 4,544,664 the disclosure of which is hereby incorporated by reference) or serotonin 5HTID agonists such as sumitriptan or agents which inhibit somatostatin or its release such as physostigmine and pyridostigmine, are useful for increasing the endogenous levels of GH in mammals. The combination of the (L)-(+)-tartaric acid salt of the compound of Formula I with GRF results in synergistic increases of endogenous growth hormone.
[0069] As is well known to those skilled in the art, the known and potential uses of growth hormone are varied and multitudinous [See “Human Growth Hormone”, Strobel and Thomas, Pharmacological Reviews, 46, pg. 1-34 (1994); T. Rosen et al., Horm Res, 1995; 43: pp. 93-99; M. Degerblad et al., European Journal of Endocrinology, 1995, 133: pp. 180-188; J. O. Jorgensen, European Journal of Endocrinology, 1994, 130: pp. 224-228; K. C. Copeland et al., Journal of Clinical Endocrinology and Metabolism, Vol. 78 No. 5, pp. 1040-1047; J. A. Aloi et al., Journal of Clinical Endocrinology and Metabolism, Vol. 79 No. 4, pp. 943-949; F. Cordido et al., Metab. Clin. Exp., (1995), 44(6), pp. 745-748; K. M. Fairhall et al., J. Endocrinol., (1995), 145(3), pp. 417-426; R. M. Frieboes et al., Neuroendocrinology, (1995), 61(5), pp. 584-589; and M. Llovera et al., Int. J. Cancer, (1995), 61(1), pp. 138-141]. Thus, the administration of the (L)-(+)-tanaric acid salt of the compound of Formula I for purposes of stimulating the release of endogenous growth hormone can have the same effects or uses as growth hormone itself. These varied uses of growth hormone may be summarized as follows: stimulating growth hormone release in elderly humans; treating growth hormone deficient adults; preventing catabolic side effects of glucocorticoids; treating osteoporosis; stimulating the immune system; accelerating wound healing; accelerating bone fracture repair; treating growth retardation; treating congestive heart failure as disclosed in PCT publications WO 95/28173 and WO 95/28174 (an example of a method for assaying growth hormone secretagogues for efficacy in treating congestive heart failure is disclosed in R. Yang et al., Circulation, Vol. 92, No. 2, p. 262, 1995); treating acute or chronic renal failure or insufficiency; treating physiological short stature, including growth hormone deficient children; treating short stature associated with chronic illness; treating obesity; treating growth retardation associated with Prader-Willi syndrome and Tumer's syndrome; accelerating the recovery and reducing hospitalization of bum patients or following major surgery such as gastrointestinal surgery; treating intrauterine growth retardation, skeletal dysplasia, hypercortisonism and Cushings syndrome; replacing growth hormone in stressed patients; treating osteochondrodysplasias, Noonans syndrome, sleep disorders, Alzheimer's disease, delayed wound healing, and psychosocial deprivation; treating of pulmonary dysfunction and ventilator dependency; attenuating protein catabolic response after a major operation; treating malabsorption syndromes; reducing cachexia and protein loss due to chronic illness such as cancer or AIDS; accelerating weight gain and protein accretion in patients on TPN (total parenteral nutrition); treating hyperinsulinemia including nesidioblastosis; adjuvant treatment for ovulation induction and to prevent and treat gastric and duodenal ulcers; stimulating thymic development and preventing age-related decline of thymic function; adjunctive therapy for patients on chronic hemodialysis; treating immunosuppressed patients and enhancing antibody response following vaccination; improving muscle strength, increasing muscle mass, mobility, maintenance of skin thickness, metabolic homeostasis, renal homeostasis in the frail elderly; stimulating osteoblasts, bone remodeling, and cartilage growth; treating neurological diseases such as peripheral and drug induced neuropathy, Guillian-Barre Syndrome, amyotrophic lateral sclerosis, multiple sclerosis, cerebrovascular accidents and demyelinating diseases; stimulating the immune system in companion animals and treating disorders of aging in companion animals; growth promotant in livestock; and stimulating wool growth in sheep.
[0070] It will be known to those skilled in the art that there are numerous compounds now being used in an effort to treat the diseases or therapeutic indications enumerated above. Combinations of these therapeutic agents, some of which have also been mentioned above, with the growth promotant, exhibit anabolic and desirable properties of these various therapeutic agents. In these combinations, the therapeutic agents and the (L)-(+)-tartaric acid salt of the compound of Formula I may be independently and sequentially administered or co-administered in dose ranges from one one-hundredth to one times the dose levels which are effective when these compounds and secretagogues are used singly. Combined therapy to inhibit bone resorption, prevent osteoporosis, reduce skeletal fracture, enhance the healing of bone fractures, stimulate bone formation and increase bone mineral density can be effectuated by combinations of bisphosphonates and the (L)-(+)-tartaric acid salt of the compound of Formula I. See PCT publication WO 95/11029 for a discussion of combination therapy using bisphosphonates and GH secretagogues. The use of bisphosphonates for these utilities has been reviewed, for example, by Hamdy, N. A. T., Role of Bisphosphonates in Metabolic Bone Diseases, Trends in Endocrinol. Metab., 1993, 4, pages 19-25. Bisphosphonates with these utilities include but are not limited to alendronate, tiludronate, dimethyl-APD, risedronate, etidronate, YM-175, clodronate, pamidronate, and BM-210995 (ibandronate). According to their potency, oral daily dosage levels of the bisphosphonate of between 0.1 mg and 5 g and daily dosage levels of the (L)-(+)-tartaric acid salt of the compound of Formula I of between 0.01 mg/kg to 20 mg/kg of body weight are administered to patients to obtain effective treatment of osteoporosis.
[0071] The (L)-(+)-tartaric acid salt of the compound of Formula I may be combined with a mammalian estrogen agonist/antagonist. Any estrogen agonist/antagonist may be used as the second compound of this aspect of this invention. The term estrogen agonist/antagonist refers to compounds which bind with the estrogen receptor, inhibit bone turnover and prevent bone loss. In particular, estrogen agonists are herein defined as chemical compounds capable of binding to the estrogen receptor sites in mammalian tissue, and mimicking the actions of estrogen in one or more tissue. Estrogen antagonists are herein defined as chemical compounds capable of binding to the estrogen receptor sites in mammalian tissue, and blocking the actions of estrogen in one or more tissues. Such activities are readily determined by those skilled in the art according to standard assays including estrogen receptor binding assays, standard bone histomorphometric and densitometer methods (see Eriksen E. F. et al., Bone Histomorphometry, Raven Press, New York, 1994, pages 1-74; Grier S. J. et. al., The Use of Dual-Energy X-Ray Absorptionmetry In Animals, Inv. Radiol., 1996, 31(1):50-62; Wahner H. W. and Fogelman I., The Evaluation of Osteoporosis- Dual Energy X-Ray Absorptionmetry in Clinical Practice., Martin Dunitz Ltd., London 1994, pages 1-296). A variety of these compounds are described and referenced below, however, other estrogen agonistslantagonists will be known to those skilled in the art. A preferred estrogen agonist/antagonist is droloxifene: (phenol, 3-[1-[4[2-(dimethylamino)ethoxy]-phenyl]-2-phenyl-1-butenyl]-, (E)-) and associated compounds which are disclosed in U.S. Pat. No. 5,047,43, the disclosure of which is hereby incorporated by reference.
[0072] Another preferred estrogen agonist/antagonist is tamoxifen: (ethanamine,2-[-4-(1,2-diphenyl-1-butenyl)phenoxy]-N,N-dimethyl, (Z)-2-, 2-hydroxy-1,2,3-propanetri-carboxylate (1:1)) and associated compounds which are disclosed in U.S. Pat. No. 4,536,516, the disclosure of which is hereby incorporated by reference. Another related compound is 4-hydroxy tamoxifen which is disclosed in U.S. Pat. No. 4,623,660, the disclosure of which is hereby incorporated by reference.
[0073] Another preferred estrogen agonist/antagonist is raloxifene: (methanone, [6-hydroxy-2-(4-hydroxyphenyl)benzo[b]thien-3-yl][4-[2-(1-piperidinyl)ethoxy]phenyl]-,hydrochloride) and associated compounds which are disclosed in U.S. Pat. No. 4,418,068, the disclosure of which is hereby incorporated by reference.
[0074] Another preferred estrogen agonist/antagonist is idoxifene: pyrrolidine, 1-[-[4-[[1-(4-iodophenyl)-2-phenyl-1-butenyl]phenoxy]ethyl] and associated compounds which are disclosed in U.S. Pat. No. 4,839,155, the disclosure of which is hereby incorporated by reference.
[0075] Other preferred estrogen agonistlantagonists include compounds as described in commonly assigned U.S. Pat. No. 5,552,412, the disclosure of which is hereby incorporated by reference. Especially preferred compounds which are described therein are:
[0076] cis-6-(4-fluoro-phenyl)-5-[4-(2-piperidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0077] (-)-cis-6-phenyl-5-[4-(2-pyrrolidin- 1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0078] cis-6-phenyl-5-[4-(2-pyrrolidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0079] cis-1-[6′-pyrrolodinoethoxy-3′-pyridyl]-2-phenyl-6-hydroxy-1,2,3,4-tetrahydronaphthalene;
[0080] 1-(4′-pyrrolidinoethoxyphenyl)-2-(4″-fluorophenyl)6-hydroxy-1,2,3,4-tetrahydroisoquinoline;
[0081] cis-6-(4-hydroxyphenyl)-5-[4-(2-piperidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol; and
[0082] 1-(4′-pyrrolidinotethoxyphenyl)-2-phenyl-6-hydroxy-1,2,3,4-tetrahydroisoquinoline.
[0083] Other estrogen agonist/antagonists are described in U.S. Pat. No. 4,133,814 (the disclosure of which is hereby incorporated by reference). U.S. Pat. No. 4,133,814 discloses derivatives of 2-phenyl-3-aroyl-benzothiophene and 2-phenyl-3-aroylbenzothiophene-1-oxide.
[0084] The following paragraphs provide preferred dosage ranges for various anti-resorptive agents.
[0085] The amount of the anti-resorptive agent to be used is determined by its activity as a bone loss inhibiting agent. This activity is determined by means of an individual compound's pharmacokinetics and its minimal maximal effective dose in inhibition of bone loss using a protocol such as those referenced above.
[0086] In general an effective dosage for the activities of this invention, for example the treatment of osteoporosis, for the estrogen agonists/antagonists (when used in combination with (L)-(+)-tartaric acid salt of the compound of Formula I of this invention) is in the range of 0.01 to 200 mg/kg/day, preferably 0.5 to 100 mg/kg/day.
[0087] In particular, an effective dosage for droloxifene is in the range of 0.1 to 40 mg/kg/day, preferably 0.1 to 5 mg/kg/day.
[0088] In particular, an effective dosage for raloxifene is in the range of 0.1 to 100 mg/kg/day, preferably 0.1 to 10 mg/kg/day.
[0089] In particular, an effective dosage for tamoxifen is in the range of 0.1 to 100 mg/kg/day, preferably 0.1 to 5 mg/kg/day.
[0090] In particular, an effective dosage for
[0091] cis-6-(4-fluoro-phenyl)-5-[4-(2-piperidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0092] (-)-cis-6-phenyl-5-[4-(2-pyrrolidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0093] cis-6-phenyl-5-[4-(2-pyrrolidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol;
[0094] cis-1-[6′-pyrrolodinoethoxy-3′-pyridyl]-2-phenyl-6-hydroxy-1,2,3,4-tetrahydronaphthalene;
[0095] 1-(4′-pyrrolidinoethoxyphenyl)-2-(4′-fluorophenyl)-6-hydroxy-1,2,3,4-tetrahydroisoquinoline;
[0096] cis-6-(4-hydroxyphenyl)-5-[4-(2-piperidin-1-yl-ethoxy)-phenyl]-5,6,7,8-tetrahydro-naphthalene-2-ol; or
[0097] 1-(4′-pyrrolidinolethoxyphenyl)-2-phenyl-6-hydroxy-1,2,3,4-tetrahydroisoquinoline is in the range of 0.0001 to 100 mg/kg/day, preferably 0.001 to 10 mg/kg/day.
[0098] In particular, an effective dosage for 4-hydroxy tamoxifen is in the range of 0.0001 to 100 mg/kg/day, preferably 0.001 to 10 mg/kg/day.
[0099] Assay for Stimulation of GH Release From Rat Pituicytes
[0100] Compounds that have the ability to stimulate GH secretion from cultured rat pituitary cells are identified using the following protocol. This test is also useful for comparison to standards to determine dosage levels. Cells are isolated from pituitaries of 6-week old male Wistar rats. Following decapitation, the anterior pituitary lobes are removed into cold, sterile Hank's balanced salt solution without calcium or magnesium (HBSS). Tissues are finely minced, then subjected to two cycles of mechanically assisted enzymatic dispersion using 10 U/mL bacterial protease (EC 3.4.24.4, Sigma P-6141, St. Louis, Mo.) in HBSS. The tissue-enzyme mixture is stirred in a spinner flask at 30 rpm in a 5% CO 2 atmosphere at about 37° C. for about 30 min., with manual trituration after about 15 min. and about 30 min. using a 10 mL pipet. This mixture is centrifuged at 200 x g for about 5 min. Horse serum (35% final concentration) is added to the supematant to neutralize excess protease. The pellet is resuspended in fresh protease (10 U/mL), stirred for about 30 min. more under the previous conditions, and manually triturated, ultimately through a 23-gauge needle. Again, horse serum (35% final concentration) is added, then the cells from both digests are combined, pelleted (200 x g for about 15 min.), resuspended in culture medium (Dulbecco's Modified Eagle Medium (D-MEM) supplemented with 4.5 g/L glucose, 10% horse serum, 2.5% fetal bovine serum, 1% non-essential amino acids, 100 U/mL nystatin and 50 mg/mL gentamycin sulfate, Gibco, Grand Island, N.Y.) and counted. Cells are plated at 6.0-6.5×10 4 cells per cm 2 in 0.48-well Costar™ (Cambridge, Mass.) dishes and cultured for 3-4 days in culture medium.
[0101] Just prior to GH secretion assay, culture wells are rinsed twice with release medium, then equilibrated for about 30 minutes in release medium (D-MEM buffered with 25 mM Hepes, pH 7.4 and containing 0.5% bovine serum albumin at 37° C.). Test compounds are dissolved in DMSO, then diluted into pre-warmed release medium. Assays are run in quadruplicate. The assay is initiated by adding 0.5 mL of release medium (with vehicle or test compound) to each culture well. Incubation is carried out at about 37° C. for about 15 minutes, then terminated by removal of the release medium, which is centrifuged at 2000 x g for about 15 minutes to remove cellular material. Rat growth hormone concentrations in the supernatants are determined by a standard radioimmunoassay protocol described below.
[0102] Measurement of Rat Growth Hormone
[0103] Rat growth hormone concentrations were determined by double antibody radioimmunoassay using a rat growth hormone reference preparation (NIDDK-rGH-RP-2) and rat growth hormone antiserum raised in monkey (NIDDK-anti-rGH-S-5) obtained from Dr. A. Pariow (Harbor-UCLA Medical Center, Torrence, Calif.). Additional rat growth hormone (1.5 U/mg, #G2414, Scripps Labs, San Diego, Calif.) is iodinated to a specific activity of approximately 30 μCi/μg by the chloramine T method for use as tracer. Immune complexes are obtained by adding goat antiserum to monkey IgG (ICN/Cappel, Aurora, Ohio) plus polyethylene glycol, MW 10,000-20,000 to a final concentration of 4.3%; recovery is accomplished by 30 centrifugation. This assay has a working range of 0.08-2.5 μg rat growth hormone per tube above basal levels.
[0104] Assay for Exocenously-Stimulated Growth Hormone Release in the Rat After Intravenous Administration of Test Compounds
[0105] Twenty-one day old female Sprague-Dawley rats (Charles River Laboratory, Wilmington, Mass.) are allowed to acclimate to local vivarium conditions 24° C., 12 hr light, 12 hr dark cycle) for approximately 1 week before compound testing. All rats are allowed access to water and a pelleted commercial diet (Agway Country Food, Syracuse N.Y.) ad libitum. The experiments are conducted in accordance with the NIH Guide for the Care and Use of Laboratory Animals.
[0106] On the day of the experiment, test compounds are dissolved in vehicle containing 1% ethanol, 1 mM acetic acid and 0.1% bovine serum albumin in saline. Each test is conducted in three rats. Rats are weighed and anesthetized via intrapertoneal injection of sodium pentobarbital (Nembutol®, 50 mg/kg body weight). Fourteen minutes after anesthetic administration, a blood sample is taken by nicking the tip of the tail and allowing the blood to drip into a microcentrifuge tube (baseline blood sample, approximately 100 μl). Fifteen minutes after anesthetic administration, test compound is delivered by intravenous injection into the tail vein, with a total injection volume of 1 mL/kg body weight. Additional blood samples are taken from the tail at 5, 10 and 15 minutes after compound administration. Blood samples are kept on ice until serum separation by centrifugation (1430 x g for 10 minutes at 10° C.). Serum is stored at −80° C. until serum growth hormone determination by radioimmunoassay as described above.
[0107] Assessment of Exogenously-Stimulated Growth Hormone Release in the Dog After Oral Administration
[0108] On the day of dosing, the test compound is weighed out for the appropriate dose and dissolved in water. Doses are delivered at a volume of 0.5-3 mL/kg by gavage to 2-4 dogs for each dosing regimen. Blood samples (5 mL) are collected from the jugular vein by direct vena puncture pre-dose and at 0.17, 0.33, 0.5, 0.75, 1, 2, 4, 6, 8 and 24 hours post dose using 5 mL vacutainers containing lithium heparin. The prepared plasma is stored at −20° C. until analysis.
[0109] Measurement of Canine Growth Hormone
[0110] Canine growth hormone concentrations are determined by a standard radioimmunoassay protocol using canine growth hormone (antigen for iodination and reference preparation AFP-1983B) and canine growth hormone antiserum raised in monkey (AFP-21452578) obtained from Dr. A. Pardow (Harbor-UCLA Medical Center, Torrence, Calif.). Tracer is produced by chloramine T-iodination of canine growth hormone to a specific activity of 20-40 μCi/μg. Immune complexes are obtained by adding goat antiserum to monkey IgG (ICN/Cappel, Aurora, Ohio) plus polyethylene glycol, MW 10,000-20,000 to a final concentration of 4.3%; recovery is accomplished by centrifugation. This assay has a working range of 0.08-2.5 μg canine GH/tube.
[0111] Assessment of Canine Growth Hormone and Insulin-Like Growth Factor-1 Levels in the Dog after Chronic Oral Administration
[0112] The dogs receive test compound daily for either 7 or 14 days. Each day of dosing, the test compound is weighed out for the appropriate dose and dissolved in water. Doses are delivered at a volume of 0.5-3 ml/kg by gavage to 5 dogs for each dosing regimen. Blood samples are collected at days 0, 3, 7, 10 and 14. Blood samples (5 ml) are obtained by direct venipuncture of the jugular vein at pre-dose, 0.17, 0.33, 0.5, 0.754, 1, 2, 3, 6, 8, 12 and 24 hours post administration on days 0, 7 and 14 using 5 ml vacutainers containing lithium heparin. In addition, blood is drawn pre-dose and 8 hours on days 3 and 10. The prepared plasma is stored at −20° C. until analysis.
[0113] Female Rat Study
[0114] This study evaluates the effect of chronic treatment with a GHRP mimetic on weight, body composition and non-fasting plasma concentrations of glucose, insulin, lactate and lipids in estrogen-deficient and estrogen-replete female rats. Acute responsiveness of serum GH levels to i.v. administration of the GH releasing agent was assessed on the last day of dosing. Body weight was monitored weekly throughout the treatment period; additionally, body composition and plasma levels of glucose, insulin, lactate, cholesterol and triglycerides were assessed at the end of treatment.
[0115] Virgin female Sprague-Dawley rats were obtained from Charles River Laboratories (Wilmington, Mass.) and underwent bilateral ovariectomy (Ovx) or sham-surgery (Sham) at approximately 12 weeks of age. For sham surgeries, ovaries were exteriorized and replaced into the abdominal cavity. Following surgery the rats were housed individually in 20 cm×32 cm×20 cm cages under standard vivarium conditions (about 24° C. with about 12 hours light/12 hours dark cycle). All rats were allowed free access to water and a pelleted commercial diet (Agway ProLab 3000, Agway Country Food, Inc., Syracuse, N.Y.). The experiment was conducted in accordance with NIH Guidelines for the Care and Use of laboratory Animals.
[0116] Approximately seven months post-surgery, Sham and Ovx rats were weighed and randomly assigned to groups. Rats were dosed daily by oral gavage with 1 mL of either vehicle (1% ethanol in distilled-deionized water), 0.5 mg/kg or 5 mg/kg of a growth hormone releasing agent for 90 days. Rats were weighed at weekly intervals throughout the study. Twenty-four hours after the last oral dose, the acute response of serum growth hormone (GH) to test agent was assessed by the following procedure. Rats were anesthetized with sodium pentobarbital 50 mg/kg. Anesthetized rats were weighed and a baseline blood sample (˜100 μl) was collected from the tail vein. Test agent (growth hormone releasing agent or vehicle) was then administered intravenously via the tail vein in 1 mL. Approximately ten minutes after injection, a second 100 μl blood sample was collected from the tail. Blood was allowed to clot at about 4° C., then centrifuged at 2000 x g for about 10 minutes. Serum was stored at about −70° C. Serum growth hormone concentrations were determined by radioimmunoassay as previously described. Following this procedure, each anesthetized rat underwent whole body scanning by dual-energy X-ray absorptiometry (DEXA, Hiologic QDR 1000/W, Waltham Mass.). A final blood sample was collected by cardiac puncture into heparinized tubes. Plasma was separated by centrifugation and stored frozen as described above.
[0117] Plasma insulin is determined by radioimmunoassay using a kit from Binax Corp. (Portland, Me.). The interassay coefficient of variation is ≦10%. Plasma triglycerides, total cholesterol, glucose and lactate levels are measured using Abbott VP™ and VP Super System® Autoanalyzer (Abbott Laboratories, Irving, Tex.), using the A-Gent™ Triglycerides, Cholesterol and Glucose Test reagent systems, and a lactate kit from Sigma, respectively. The plasma insulin, triglycerides, total cholesterol and lactate lowering activity of a growth hormone releasing peptide (GHRP) or GHRP mimetic such as a compound of Formula I, are determined by statistical analysis (unpaired t-test) with the vehicle-treated control group.
[0118] The (L)-(+)-tartaric acid salt of the compound of Formula I can be administered by oral, parenteral (e.g., intramuscular, intraperitoneal, intravenous or subcutaneous injection, or implant), nasal, vaginal, rectal, sublingual, or topical routes of administration and can be formulated with pharmaceutically acceptable carriers to provide dosage forms appropriate for each route of administration.
[0119] Solid dosage forms for oral administration include capsules, tablets, pills, powders and granules. In such solid dosage forms, the (L)-(+)-tartaric acid salt of the compound of Formula I is admixed with at least one inert pharmaceutically acceptable carrier such as sucrose, lactose, or starch. Such dosage forms can also comprise, as is normal practice, additional substances other than such inert diluents, e.g., lubricating agents such as magnesium stearate. In the case of capsules, tablets and pills, the dosage forms may also comprise buffering agents. Tablets and pills can additionally be prepared with enteric coatings.
[0120] Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups, the elixirs containing inert diluents commonly used in the art, such as water. Besides such inert diluents, compositions can also include adjuvants, such as wetting agents, emulsifying and suspending agents, and sweetening, flavoring and perfuming agents.
[0121] Preparations according to this invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions, or emulsions. Examples of non-aqueous solvents or vehicles are propylene glycol, polyethylene glycol, vegetable oils, such as olive oil and corn oil, gelatin, and injectable organic esters such as ethyl oleate. Such dosage forms may also contain adjuvants such as preserving, wetting, emulsifying, and dispersing agents. They may be sterilized by, for example, filtration through a bacteria-retaining filter, by incorporating sterilizing agents into the compositions, by irradiating the compositions, or by heating the compositions. They can also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, or some other sterile injectable medium immediately before use.
[0122] Compositions for rectal or vaginal administration are preferably suppositories which may contain, in addition to the active substance, excipients such as coca butter or a suppository wax.
[0123] Compositions for nasal or sublingual administration are also prepared with standard excipients well known in the art.
[0124] The dosage of the (L)-(+)-tartaric acid salt of the compound of Formula I in the compositions of this invention may be varied; however, it is necessary that the amount thereof be such that a suitable dosage form is obtained. The selected dosage depends upon the desired therapeutic effect, on the route of administration, and on the duration of the treatment. Generally, dosage levels of between 0.0001 to 100 mg/kg of body weight daily are administered to humans and other animals, e.g., mammals, to obtain effective release of growth hormone.
[0125] A preferred dosage range is 0.01 to 5.0 mg/kg of body weight daily which can be administered as a single dose or divided into multiple doses.
[0126] The following scheme illustrates the synthesis of the (L)-(+)-tartaric acid salt of the compound of Formula I. The symbol *″ indicates a stereochemical center. In the scheme “Prt” is used to indicate any suitable amine protecting group that will be known to those skilled in the art.
[0127] The following describes the steps of the reactions illustrated in the foregoing scheme. In the following description, the amine protecting group Prt is illustrated with the preferred amine protecting group BOC.
[0128] Step a: To a solution of compound A in a reaction inert polar aprotic solvent such as acetone, methyl ethyl ketone or preferably DMF (dimethylformamide) at about 0° C. to room temperature, preferably 0° C., is added picolyl chloride hydrochloride, a carbonate such as Li 2 CO 3 , CsCO 3 or preferably potassium carbonate and potassium iodide or tetrabutylammonium iodide. After stirring at about −20° C. to about 70° C., preferably 0° C. for about 2 to 16 hours, preferably for about 2 hours, the ice bath is removed and DABCO (1,4-diazobicyclo[2.2.2]octane) is added. The reaction mixture is stirred for about 15-30 min. and poured into a mixture of water and a non-polar organic solvent such as toluene, diethyl ether or preferably IPE (isopropyl ether). The organic layer is separated and worked-up using standard methods known in the art to yield compound B.
[0129] Step b: A 70% aqueous solution of CF 3 CH 2 NHNH 2 is used as an aqueous solution in ethanol, water or toluene, preferably the 70% aqueous solution of CF 3 CH 2 NHNH 2 is extracted with toluene. To a solution of compound B in an organic solvent such as ethanol or preferably toluene, is first added the toluene extracts containing the anhydrous 2,2,2-trifluoroethyl hydrazine, followed by acetic acid. The reaction mixture is heated at about 60°-110° C., preferably 70 ° C., for about 30 minutes to 12 hours, preferably 2 hours. The reaction mixture is cooled to room temperature and neutralized with an aqueous base such as NaHCO 3 . The organic layer is separated and worked-up using standard methods known in the art to yield compound C.
[0130] Step c: An acid such as HCI in IPE or ethanol, triflic acid or an alkyl sulfonic acid such as methanesulfonic acid is added to a solution of compound C in a reaction inert organic solvent such as EtOH, IPE or preferably CH 2 Cl 2 . The mixture is stirred for about 1-2 hours, then cooled to about 0° C. to room temp., preferably 0° C., and then an amine base, such as triethylamine, or NH 4 OH is added to the mixture. The mixture is allowed to warm to room temperature, diluted with additional organic solvent and worked-up using standard methods known in the art to yield compound D.
[0131] Step d: (D)- or (L)-Tartardc acid, preferably (D)-tararic acid, is added to Compound D in acetone/water (about 8:1 to about 9:1) at about room temperature. The mixture is stirred at room temperature for about 15 minutes to overnight, preferably overnight, the solid is filtered, collected and washed with cold acetone, to yield the compound of formula E, preferably compound E is the (D)-tartrate of a single enantiomer.
[0132] Step e: To a solution of N-BOC-serine, preferably N-BOC-(D)-serine, (compound F) in THFIDMF (about 1:1 to about 2:1) at about 0° C. is added n-BuLi or a potassium tert-butoxide solution. The reaction mixture is stirred at about 0° C. for about 10-30 min. preferably 20 min., then 2,4difluorobenzyi bromide is added. After warming to room temperature and stirring for about 6-24 hours, the reaction mixture is concentrated in vacuo to remove the THF and an aqueous acid such as 1 N HCl is added to adjust the mixture to pH of about 3. The reaction mixture is then partitioned between water and an organic solvent such as CH 2 Cl 2 or IPE. The organic solution is worked-up using standard methods known in the art to yield compound G, preferably having the R-configuration at the stereocenter, also known as the (D)-enantiomer.
[0133] Step f: To a solution of compound G in an organic solvent such as THF, CH 2 Cl 2 , IPE or a mixture thereof, preferably CH 2 Cl 2 /IPE (about 1:1), is added an alkyl sulfonic acid such as methanesulfonic acid. The solid is filtered and washed with a CH 2 Cl 2 /IPE mixture (1:1) to afford compound H, preferably having the R-configuration at the stereocenter, also known as the (D)-enantiomer.
[0134] Step g: To a solution of compound H in THF/water (about 4:1) is added 2-tert-butoxycarbonylamino-2-methyl-propionic acid-2,5-dioxo-pyrrolidin-1-yl ester and an alkyl amine such as triethylamine. The reaction mixture is stirred at room temperature for about 1-24 hours and quenched with an aqueous acid such as 10% aqueous citric acid solution. The mixture is partitioned with an organic solvent such as ethyl acetate and the organic layer is separated and worked-up using standard methods known in the art to yield compound X, preferably having the R-configuration at the stereocenter also known as the (D)-enantiomer. Compound X can be an acid, alkyl ester or acid halide (X is OH, —O(C 1 -C 4 )alkyl or halo), the acid is preferred.
[0135] Step h: (a) Compound E, preferably the (D)-tartrate of a single enantiomer, is added at about −35° to 0° C., preferably at about −6° C. to ethyl acetate. The solution is cooled to about −30 to −50° C., then an alkyl amine such as triethylamine is added. The reaction mixture is stirred for about 30-90 min. at a temperature between about −78° C. and about −20° C., and filtered to give a solution of the free base of compound E.
[0136] (b) When X in compound X is OH, compound X, preferably having the R-configuration at the stereocenter, is added at about −78° C. to −20° C., preferably −35° C. to a reaction inert organic solvent such as ethyl acetate solution containing the free base of compound E from step h(a), an alkyl amine such as triethylamine and PPAA (1-propane phosphonic acid cyclic anhydride) (50% in ethyl acetate). The reaction mixture is stirred for about 1-24 hours, and worked-up using standard methods known in the art to yield compound J, preferably having the absolute and relative 3a-(R), 1-(R) configuration.
[0137] When X in compound X is Cl, compound X is added at about −78° C. to a reaction inert solvent such as dichioromethane solution containing the free base of compound E and an alkyl amine such as triethylamine. The reaction mixture is stirred for about 1-24 hours at about 0-30° C. and then worked up using standard methods known in the art to yield compound J, preferably having the absolute and relative 3a-(R), 1-(R) configuration.
[0138] When X in compound X is —O(C 1 -C 4 )alkyl, where methyl is preferred, compound X is added to a solution of the free or conjugate base of E (the conjugate base of compound E (—NM where M=Li, Na, K, Mg or Al, preferably aluminum) is prepared by reacting the free amine base with the appropriate reagent (i.e. M=Li, butyl lithium or LDA, M=Na, NaH or NaN(SiMe 3 ) 2 or M=K, KH or KN(SiMe 3 ) 2 , or M=Mg, any alkyl Grignard reagent, preferably diethyl magnesium bromide, or M=Al any trialkyl aluminum reagent, preferably trimethyl aluminum)), preferably aluminum, in a reaction inert solvent such as dichloromethane and the resulting reaction mixture is stirred for about 1-24 hours at about −20-110° C. and worked-up using standard methods known in the art to yield compound J, preferably having the absolute and relative 3a-(R), 1-(R) configuration.
[0139] Step i: An acid such as HCl in EtOH, methanesulfonic acid or triflic acid in CH 2 Cl 2 is added at about 0° C. to room temperature to compound J in CH 2 Cl 2 , IPE or THF. The mixture is stirred for about 40 minutes to about 4 hours at room temperature, then a saturated aqueous base such as NaHCO 3 is added until the solution is at neutral pH. The organic layer is separated and worked-up using standard methods known in the art to yield compound K, preferably having the absolute and relative 3a-(R), 1-(R) configuration.
[0140] Step j: To a solution of compound K in an alcohol preferably methanol is added L-(+) tartaric acid. The reaction mixture is stirred for about 1-12 hours, filtered and concentrated. The crude residue is diluted with an organic solvent such as ethyl acetate, heated and slowly allowed to cool to room temperature. The solid is filtered and dried to give the L-(+) tartaric acid salt of the compound of Formula I as white crystals, preferably having the absolute and relative 3a-(R), 1-(R) configuration.
[0141] The following example is provided for the purpose of further illustration only and is not intended to be a limitation on the disclosed invention.
[0142] Silica gel was used for column chromatography. Melting points were taken on a Buchi 510 apparatus and are uncorrected. Proton NMR spectra were recorded on a Varian XL-300, Bruker AC-300, Varian Unity 400 or Bruker AC-250 at 25° C. Chemical shifts are expressed in parts per million down field from trimethylsilane.
EXAMPLE 1
2-Amino-N-{1-(2,4-difluoro-benzyloxymethyl)-2-oxo-2-[3-oxo-3a-pyridin-2-ylmethyl-2-(2,2.2-trifluoro-ethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridin-5-yl]-ethyl}-2-methyl-propionamide L-(+) tartrate
[0143] A. 4Oxo-3-pyridin-2-ylmethyl-piperidine-1,3-dicarboxylic acid 1-tert-butyi ester 3-ethyl ester
[0144] To a solution of 4-oxo-piperidine-1,3-dicarboxylic acid 1-tert-butyl ester 3-ethyl ester (10.34 g, 38.2 mmol) in DMF (40 mL) at about 0° C. was added picolyl chloride hydrochloride (5.7 g, 34.7 mmol), potassium carbonate (14.4 g, 104.1 mmol) and potassium iodide (5.76 g, 34.7 mmol). After stirring at about 0° C. for about 2 hours, the ice bath was removed and DABCO (973 mg, 8.68 mmol) was added. The reaction mixture was stirred for about 30 min. and poured into a mixture of water and IPE. The organic layer was separated and washed with saturated aqueous NaHCO 3 and saturated aqueous NaCl, dried over Na 2 SO 4 and concentrated in vacuo. The crude residue was crystallized from hexanes to give a white solid (8.19 g, yield 65%). 1 H-NMR (CDCl 3 ) δ 1.17 (t, 3H), 1.48 (s, 9H), 1.55 (s, 2H), 2.61 (m, 1H), 2.71 (m, 1H), 3.31-3.50 (m, 3H), 4.11 (d, 2H), 4.49 (d, 1H), 7.06 (brs, 1H), 7.17 (d, 1H), 7.54 (m, 1H), 8.40 (s, 1H).
[0145] B. 3-Oxo-3a-pyridin-2-ylmethyl-2-(2,2,2-trifluoro-ethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridine-5-carboxylic acid tert-butyl ester
[0146] A 70% aqueous solution of CF 3 CH 2 NHNH 2 (325 mL, 1.986 mol) (obtained from Aldrich) was extracted with toluene (3×1200 mL). To a solution of the product made according to step A (600 g, 1.655 mol) in toluene (900 mL) was first added the combined toluene extracts containing the anhydrous 2,2,2-trifluoroethyl hydrazine, followed by acetic acid (121.4 g, 1.986 mol). The reaction mixture was heated at about 70° C. for about 2 hours , then another toluene extraction of 70% aqueous 2,2,2-trifluoroethyl hydrazine (50 g) was added. The reaction mixture was heated at about 80° C. for about 3.5 hours, cooled to room temperature and diluted with saturated aqueous NaHCO 3 (2 L). The toluene layer was separated and washed with saturated aqueous NaCl, dried over Na 2 SO 4 and concentrated in vacuo to give an oil (754.8 g). Crystallization from methanol/water afforded the desired product as a white solid (609.5 g). 1 H-NMR (CDCl 3 ) δ 1.50 (s, 9H), 2.53 (d, 1H), 2.70 (br s, 2H), 2.88 (br s, 1H), 3.31 (m, 2H), 3.97 (m, 1H), 4.19 (m, 1H), 4.46 (br s, 1H), 4.63 (br s, 1H), 7.06 (m, 2H), 7.51 (m, 1H), 8.34 (m, 1H).
[0147] C. 3a-Pyridin-2-ylmethyl-2-(2,2,2-trifluoroethyl)-2.3a,4,5,6,7-hexahydro-pyrazolo[4,3-c]pyridin-3-one
[0148] Methanesulfonic acid (11.6 g, 121 mmol) was added dropwise to a solution of the product from step B (10 g, 24.2 mmol) in CH 2 Cl 2 (100 mL) over about 30 minutes. The reaction mixture was stirred for about 1 hour, then cooled to about 0° C., and then triethylamine (18.6 mL, 133.1 mmol) was added through an addition funnel. The mixture was allowed to warm to room temperature over about 1 hour, diluted with additional CH 2 Cl 2 and washed with saturated aqueous NaCl, dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford the product as a white solid (7.2 g). 1 H-NMR (CDCl 3 ) δ: 2.51-2.72 (m, 4H), 3.35 (m, 2H), 3.49 (m, 2H), 4.03 (m, 1H), 4.25 (m, 1H), 7.08 (d, 2H), 7.51 (t, 1H), 8.37 (d, 1H).
[0149] D. 3a-Pyridin-2-ylmethyl-2-(2,2,2-trifluoroethyl)-2,3a.4,5,6,7-hexahydro-pyrazolo[4,3-c]pyridin-3-one (D)-tartrate
[0150] In a dry and nitrogen purged 5 L round bottom flask equipped with a mechanical stirrer, D-(-) tartaric acid (129 g, 0.86 mol) was added to the compound made according to step C (243 g, 0.78 mol) in acetone/water (9:1, 2430 mL) at about 17° C. The mixture was stirred at room temperature overnight, filtered, the solid was collected and washed with cold acetone and dried under vacuum. The product was obtained as a yellow solid (284 g, yield 78.8%).
[0151] E. 2-tert-Butoxycarbonylamino-3-(2,4-difluoro-benzyloxy)-propionic acid
[0152] To a solution of N-Boc-(D)-serine (452 g, 2.2026 mol) in a mixture of THF (7 L) and DMF (3 L) at about 0° C. was added potassium tert-butoxide solution (515.8 g, 4.5963 mol). The reaction mixture was stirred at about 0° C. for about 30 min., then 2,4-difluorobenzyl bromide (456.5 g, 2.2051 mol) was added. After warming to room temperature, the reaction mixture was concentrated in vacuo to remove the THF. Partitioned the reaction mixture between 4.5 L H 2 O and 4.5 L IPE. Separated the layers and adjusted the pH of the aqueous layer with 1 N HCl to about 3. The aqueous layer was extracted twice with 4 L each of IPE. The organic solution was dried over Na 2 SO 4 , and concentrated in vacuo to yield a yellow waxy solid (518.0 g, yield: 70.9%). 1 H-NMR (CDCl 3 ) δ 1.44 (s, 9H), 3.73 (m, 1H), 3.94 (d, 1H), 4.44 (br s, 1H), 4.54 (s, 2H), 5.34 (m, 1H), 6.78 (m, 1H), 6.84 (m, 1H), 730 (m, 1H).
[0153] F. 2-Amino-3-(2,4-difluoro-benzyloxy)-propionic acid, methanesulfonic acid salt
[0154] To a solution of the product from step E (1.19 g, 3.59 mmol) in CH 2 Cl 2 /IPE (1:1, 12 mL) was added methanesulfonic acid (1.72 g, 17.95 mmol) through a syringe over about 10 minutes. A solid immediately precipitated out of solution. After about 1 hour, the solid was filtered and washed with a CH 2 Cl 2 /IPE mixture (1:1) to afford 939 mg of product (yield 80%).
[0155] G. 2-(2-tert-Butoxycarbonylamino-2-methyl-propionylamino)-3-(2,4-difluoro-benzyloxy)-propionic acid
[0156] To a solution of the product from step F (520 mg, 1.46 mmol) in THF/water (4:1, 10 mL) was added 2-tert-butoxycarbonylamino-2-methyl-propionic acid-2,5-dioxo-pyrrolidin-1-yl ester (438 mg, 1.46 mmol) and triethylamine (369 mg, 3.65 mmol). The reaction mixture was stirred at room temperature for about 1 hour and quenched with a 10% aqueous citric acid solution (10 mL). After about 15 min., ethyl acetate (50 mL) was added and the organic layer was separated and washed with saturated aqueous NaCl, dried over Na 2 SO 4 and concentrated in vacuo to give a foam (534.1 mg, yield 88%). 1 H-NMR (CD 3 OD): δ 1.38 (br s, 15H), 3.77 (d, 1H), 3.92 (d, 1H), 4.52 (m, 3H), 6.92 (m, 1H), 7.41 (m, 1H), 7.58 (d, 1H).
[0157] H. (1-{2,4-Difluoro-benzyloxymethyl-2-oxo-2-[3-oxo-3a-pyridin-2-ylmethyl-2-(2,2,2-trifluoro-ethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridin-5-yl]-ethylcarbamoyl}-1-methyl-ethyl)-carbamic acid tert-butyl ester
[0158] (a) To the compound made according to step D (517 g, 1.12 mol) was added at about −6° C. to ethyl acetate (5170 mL) in a dry and nitrogen purged 12 L round bottom flask equipped with a mechanical stirrer. The solution was cooled to about −40° C., then triethylamine (398 mL, 2.86 mol) was added over about 45 minutes. The reaction mixture was stirred for about 90 min. at a temperature between about −50° C. and about −40° C., filtered into a 22 L round bottom flask purged with nitrogen and washed with ethyl acetate (2068 mL, pre-cooled to about −50° C.) to give the free base as a white solid.
[0159] (b) The compound made according to step G (425 g, 1.02 mol ) was added at about −30° C. to an ethyl acetate solution containing the product from step H (a), triethylamine (654 mL, 4.69 mol) and PPAA (1-propanephosphonic acid cyclic anhydride) (50% in ethyl acetate, 916 mL, 1.53 mol). The reaction mixture was stirred for about 1 hour, washed with water and saturated aqueous NaCl, dried over Na 2 SO 4 and concentrated in vacuo to give the product as an oil (636 g, yield: 87.8%).
[0160] I. 2-Amino-N-{1-(2,4-difluoro-benzyloxymethyl)-2-oxo-2-[3-oxo-3a-pyridin-2-ylmethyl-2-(2,2,2-trifluoro-ethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridin-5-yl]-ethyl}-2-methyl-propionamide
[0161] Methanesulfonic acid (258.3 mL, 3.98 mol) was added dropwise at about 15° C. over about 55 minutes to the product from step H (566 g, 0.796 mol) in CH 2 Cl 2 (11,320 mL) in a dry and nitrogen purged 22 L round bottom flask equipped with a mechanical stirrer. The mixture was stirred for about 40 minutes at about 20° C., then saturated aqueous NaHCO 3 (8,490 mL) was added until the pH was about 7.8. The organic layer was separated, washed with water and saturated aqueous NaCl, dried over Na 2 SO 4 , and concentrated in vacuo to afford an oily product (388.8 g, yield 80%).
[0162] J. 2-Amino-N-{1-(2,4-difluoro-benzytoxymethyl)-2-oxo-2-[3-oxo-3a-pyridin-2-ylmethyl-2-(2,2,2-trifluoro-ethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridin-5-yl]-ethyl}-2-methyl-propionamide L-(+) tartrate
[0163] To a solution of the product from step I (370 g, 0.6 mol) in methanol (4,070 mL) in a 12 L round bottom flask equipped with a mechanical stirrer was added L-(+) tartaric acid (90 g, 0.6 mol). The reaction mixture was stirred for about 90 min. at about 22° C., filtered and concentrated. The crude residue was diluted with ethyl acetate (4,560 mL), heated at about 70° C. and slowly allowed to cool to room temperature over about 17 hours. The solid was filtered and dried to give white crystals, mp 188-189° C. (348.46 g, yield 76%). 1 H NMR (MeOH, d4) δ: 8.28 (d, 1H), 7.59 (t, 1H), 7.41-7.39 (m, 1H), 7.18-7.13 (m, 1H), 6.92 (t, 1H), 5.2 (t, 1H), 4.56 (bs, 3H), 4.36 (s, 2H), 4.31-4.25 (m, 1H), 4.13-4.06 (m, 1H), 3.78 (d, 2H), 3.21 (t, 1H), 3.18-2.96 (m, 2H), 2.65-2.55 (m, 2H), 1.57 (d, 6H). MS: MH+611. [a] 589 +22.03 (c=11.9, MeOH). | This invention is directed to the (L)-tartaric acid salt of 2-amino-N-{1 -(R)-(2,4-difluoro-benzyloxymethyl)-2-oxo-2-[3-oxo-3a-(R)-pyridin-2-ylmethyl-2-(2,2,2-trifluoroethyl)-2,3,3a,4,6,7-hexahydro-pyrazolo[4,3-c]pyridin-5-yl]-ethyl}-2-methyl-propionamide which is a growth hormone secretagogue and as such is useful for increasing the level of endogenous growth hormone. In another aspect, this invention provides certain intermediates which are useful in the synthesis of the foregoing compound. The (L)-tartaric acid salt of the compound of this invention is useful for the treatment and/or prevention of osteoporosis, insulin resistance and other conditions or diseases associated with growth hormone deficiency. The (L)-tartaric acid salt of the compound of the compound of the present invention is also useful in treating osteoporosis when used in combination with: a bisphosphonate compound; estrogen, Premarin, and optionally progesterone; an estrogen agonist or antagonist; or calcitonin. Further, the present invention is directed to pharmaceutical compositions. This invention is further directed to methods comprising administering to a human or other animal a combination of an alpha-2 adrenergic agonist and the (L)-tartaric acid salt of the compound of this invention. | 8 |
BACKGROUND OF THE INVENTION
[0001] There are existing methods and devices for determining aircraft runway landing conditions. Some of these methods and devices rely on pilot perception of current landing conditions. However, pilot perception may be inaccurate and inconsistent. Some of the other methods and devices rely on ground friction measuring vehicles which attempt to predict the runway landing conditions for aircraft. However, these vehicles may provide inconsistent readings when water, slush, or snow is on the runway; they may not measure real-time changing conditions; and their low relative speed to aircraft may not accurately depict the braking performance of landing aircraft at much higher speeds.
[0002] One or more of the existing methods and devices may experience problems taking accurate, consistent, quantitative, definitive, reliable, and/or real-time prediction of runway conditions. This may lead to increased cost, decreased safety, lower runway efficiency, lower braking determination consistency and accuracy, and/or other types of problems.
[0003] A method, apparatus, and aircraft, is needed which may solve one or more problems in one or more of the existing methods and/or devices for determining aircraft runway landing conditions.
SUMMARY OF THE INVENTION
[0004] In one aspect of the invention, a method is disclosed for determining the braking conditions of a runway. In one step braking data is collected from an aircraft which has landed on the runway. In another step, a braking performance measurement of the aircraft is calculated based on the braking data. In yet another step, a normalized braking performance measurement is determined based on the braking performance measurement of the aircraft.
[0005] In another aspect, the invention discloses a landed aircraft on a runway. During landing of the aircraft, braking data was collected, a braking performance measurement of the aircraft was calculated based on the braking data, and a normalized braking performance measurement was determined based on the braking performance measurement of the aircraft.
[0006] In a further aspect of the invention, an apparatus for aircraft is provided. The apparatus collects aircraft braking data, calculates aircraft braking performance measurements, and determines normalized braking performance measurements based on calculated aircraft braking performance measurements.
[0007] These and other features, aspects and advantages of the invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 depicts one embodiment of a method under the invention for determining the braking conditions for a runway; and
[0009] FIG. 2 depicts a perspective view of a landing aircraft in multiple locations as the aircraft touches down and proceeds down a runway.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0011] In one embodiment of the invention, as shown in FIG. 1 , a method 10 for determining the braking conditions for a runway is provided. In one step 12 , braking data may be collected from an aircraft which has landed on the runway. The braking data may include any data regarding braking of the aircraft on the runway. The aircraft may comprise any type of airplane, or other type of device capable of flying in the air.
[0012] As shown in FIG. 2 , which depicts a landing aircraft 15 in multiple locations as it lands on a runway 17 , the collected braking data may comprise an initial touch-down location 14 of the aircraft 15 on the runway 17 . The initial touch-down location 14 may comprise the approximate coordinates on the runway 17 where the aircraft 15 first touches down upon landing. The collected braking data may further comprise an initial aircraft velocity of the aircraft 15 at the initial touch-down runway location 14 . This initial aircraft velocity may comprise the velocity of the aircraft 15 on the runway 17 when the aircraft first touches down at the initial touch-down location 14 .
[0013] Additionally, the collected braking data may comprise a final runway location 18 of the aircraft 15 . The final runway location 18 may comprise the approximate coordinates on the runway 17 where the aircraft 15 has proceeded down the runway upon landing and reached a velocity where the aircraft 15 is ready to taxi off the runway 17 . In another embodiment, the final runway location 18 may comprise the approximate coordinates on the runway 17 where the aircraft 15 has come to a stop and has zero velocity. In yet another embodiment, the final runway location 18 may comprise the approximate coordinates on the runway 17 of a pre-determined location. The pre-determined location may be based in part on the total length of the runway 17 , or other criteria.
[0014] In addition, the collected braking data may comprise a final velocity of the aircraft 15 at the final runway location 18 . The final velocity may comprise the velocity of the aircraft 15 at the final runway location 18 . The final velocity may comprise a velocity on the runway 17 when the aircraft 15 has reached a velocity where it is ready to taxi off the runway 17 . In another embodiment, the final velocity may comprise a zero velocity when the aircraft 15 has come to a stop. In still another embodiment, the final velocity may comprise the velocity of the aircraft 15 on the runway 17 at the above-referenced pre-determined location.
[0015] Referring to FIGS. 1 and 2 , in another step 22 of the method 10 , a braking performance measurement may be calculated for the landed aircraft 15 based on the collected braking data 12 . The braking performance measurement may comprise a measurement of the braking performance of the aircraft on the runway. The step 22 may comprise calculating one or more runway deceleration measurements of the landed aircraft 15 . The runway deceleration measurement may comprise the deceleration of the landed aircraft 15 between the initial touch-down location 14 on the runway 17 and the final runway location 18 . The deceleration measurement may be calculated by using a mathematical formula similar to the formula Deceleration=|((Velocity 2 ) 2 −(Velocity 1 ) 2 )/(2*Distance)|, wherein Velocities 1 and 2 represents the respective velocities of the aircraft 15 at two separate locations along the runway 17 , and the Distance represents the distance along the runway 17 between the respective locations where Velocities 1 and 2 are measured. The deceleration measurement may be taken in feet per second squared. In one embodiment, the deceleration may be calculated between the initial touch-down location 14 and the final runway location 18 by using, in the above Deceleration formula, the initial aircraft velocity as Velocity 1 , the final aircraft velocity as Velocity 2 , and the runway distance between the initial touch-down location 14 and the final runway location 18 as the Distance.
[0016] In other embodiments, the deceleration measurement may comprise calculating the deceleration of the aircraft 15 at several different locations along the runway 17 . This iteration and calculation may be in the order of twenty times per second. In other embodiments, any number of deceleration measurements may be taken. A graph and/or dynamic display may be prepared to show the variation in deceleration of the aircraft 15 after it touches down 14 until it comes to its final runway location 18 . In other embodiments, only one deceleration measurement may be taken. In still other embodiments, the deceleration measurement may be taken along different portions of the runway 17 .
[0017] Again referring to FIGS. 1 and 2 , in yet another step 24 of the method 10 , a normalized braking performance measurement may be determined based on the calculated braking performance measurement 22 of the landed aircraft 15 . The normalized braking performance measurement may comprise a normalized value of the braking performance measurement. The normalized braking performance measurement may comprise the expected braking performance on the runway 17 of a standard aircraft on a standard day. The term “standard aircraft” may represent a generic, non-descript aircraft of no particular type, while the term “standard day” may represent a day having normal landing conditions. In one embodiment, a standard day may comprise a day where the temperature is 59 degrees Fahrenheit, having a 29.92 Altimeter setting, with no wind, and at sea level. The normalized braking performance measurement may represent a normalization of one or more deceleration rates of the aircraft 15 on the runway 17 . The normalized braking performance measurement may comprise an index, coefficient, or value used to represent the expected braking ability of a generalized aircraft on the runway 17 .
[0018] In determining the normalized braking performance measurement 24 , a variety of factors may be taken into account in order to normalize the calculated braking performance measurement 22 to that of a standard aircraft. Some of these factors may include consideration of wind speed, wind direction, weight of the aircraft, type of the aircraft, air temperature, configuration of the aircraft, Minimum Equipment List (MEL) conditions, thrust reverse conditions, non-normal conditions, initial aircraft velocity at the initial touch-down runway location, final aircraft velocity at the final runway location, and/or other factors.
[0019] In another embodiment, the method 10 for determining the braking conditions for a runway 17 may further include the step of displaying on the aircraft 15 the braking performance measurement 22 and/or the normalized braking performance measurement 24 . This may be displayed on an apparatus on the aircraft 15 such as a computer monitor or other device. The method 10 may further include the step of communicating the braking performance measurement 22 and/or the normalized braking performance measurement 24 to air traffic control and/or other uses of this information—i.e., arriving aircraft, airline dispatch offices, airport operations, military operations, corporate flight departments, departing aircraft, and/or others using braking action reports as an element in making rejected takeoff decisions. This may be accomplished by the pilot radioing air traffic control, or through other means such as data link, Automatic Dependent Surveillance-Broadcast (ADS-B) or other automatic networking communication.
[0020] In yet another embodiment, the method 10 may further comprise the step of determining an expected braking performance of a particular type of aircraft on the runway based on the normalized braking performance measurement 24 . This may be achieved by taking into account the configuration, weight, and performance capabilities of the particular aircraft. In such manner, the expected braking performance of a whole host of different aircraft may be determined.
[0021] In still another embodiment, the method 10 may further comprise the step of preparing, for one or more aircraft, one or more graphs and/or dynamic displays showing at least one of the braking performance measurement 22 and/or the normalized braking performance measurement 24 at particular locations over the runway. These graphs and/or dynamic displays may allow air traffic control to determine the runway deceleration conditions on a continuing time spectrum along various portions of the runway 17 for varying numbers and types of aircraft.
[0022] In still another embodiment, the method 10 may additionally comprise the step of assigning a minimum standard sustainable deceleration rate for continued operation of the runway 17 in hazardous weather conditions. The method 10 may further comprise the step of determining whether the runway 17 should be shut down due to hazardous conditions by comparing at least one of the braking performance measurement 22 and the normalized braking performance measurement 24 to the assigned minimum sustainable deceleration rate. If the braking performance measurement 22 and/or the normalized braking performance measurement 24 is below the assigned minimum sustainable deceleration rate for the runway 17 , the runway 17 may be shut down until conditions improve.
[0023] Any of the above referenced steps for any of the disclosed embodiments of method 10 may utilize one or more apparatus located on the aircraft 15 . Such aircraft apparatus may comprise one or more computers, aircraft auto-braking apparatus, or other types of devices.
[0024] In another embodiment, the invention may comprise a landed aircraft on a runway. During landing of the aircraft, braking data may have been collected, a braking performance measurement may have been calculated based on the braking data, and a normalized braking performance measurement may have been determined based on the braking performance measurement. Any of the embodiments disclosed herein may have been utilized during landing of the aircraft to collect the braking data, calculate the braking performance measurement, and determine the normalized braking performance measurement.
[0025] In yet another embodiment, the invention may comprise an apparatus for aircraft which collects aircraft braking data, calculates aircraft braking performance measurements, and determines normalized braking performance measurements based on calculated aircraft braking performance measurements. Such aircraft apparatus may comprise one or more computers, an aircraft auto-braking apparatus, or other type of device. Any of the embodiments disclosed herein may be used as part of the apparatus to collect the aircraft braking data, calculate the aircraft braking performance measurement, and determine the normalized braking performance measurement.
[0026] One or more embodiments of the disclosed invention may solve one or more problems in existing methods, aircraft, and apparatus for determining the landing conditions of a runway. One or more embodiments of the invention may provide a substantially real-time, quantitative, definitive, reliable measure of runway landing conditions in such manner, the invention may decrease cost, increase safety, increase runway efficiency, increase braking determination consistency and accuracy, and/or address other problems known in the art. For instance, the invention may aid in the determination of runway/airport plowing and closure decisions, may aid in rejected takeoff decisions, may aid in airline dispatch, may aid in flight crew divert decisions, and/or may aid in other problem areas.
[0027] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | The invention discloses differing embodiments of methods, aircraft, and apparatus for determining the landing conditions of a runway. In one embodiment, braking data may be collected from an aircraft which has landed on the runway; a braking performance measurement of the aircraft may be calculated based on the braking data; and a normalized braking performance measurement may be determined based on the braking performance measurement. The invention may be utilized to predict the expected braking performance of various types of aircraft on the runway. The invention may provide landing performance information to a broad host of users, and/or may be used as a basis for the development of a new aviation standard for the reporting of runway braking action. | 6 |
FIELD OF THE INVENTION
This invention relates to a device for securing and organizing golf clubs.
BACKGROUND OF THE INVENTION
Up to the present, one of the most common problems golfers constantly faced was having to struggle with all the other clubs in their golf bag while searching for the correct club to use on the next golf shot. Products currently on the market that made an attempt to organize or protect golf clubs have limited practical benefits and unsubstantiated product longevity.
The most prominent product golfers find in today's market consists of many long tubes inserted into a golf bag. One example of a golf club protector consisting of many tubes is shown in U.S. Pat. No. 4,194,547 (the '547 Patent), issued Mar. 25, 1980. This prior art design uses a combination of tubes and spring clips to hold the golf clubs in place. Although there are racks suited to suspend the golf club heads, it is the chips which grip the golf club shafts that hold the golf clubs in place. Although this combination of tubes, spring clips and racks may be effective, it is also heavy and expensive to produce. In contrast, the present invention eliminates the need for tubes completely and combines the rack and spring clip into one securing device.
Another solution to this problem of lack of organization within a golf club bag, has been to suspend the heads of the golf club from a rack. U. S. Pat. No. 3,503,518 (the '518 Patent) granted Mar. 31, 1970, provided a solution to make the clubs immobile. The '518 Patent disclosed a peripheral upper blade holder portion of resilient material which wedgably engaged the lower portion of the head of the golf club. To provide immobility, a second, lower shaft holder portion was used in conjunction with the blade holder rack. The invention claimed herein eliminates the necessity of two separate devices, one to suspend the club and the other to keep the club secure.
U.S. Pat. No. 1,849,610 (the '610 Patent), granted Mar. 15, 1932, attempts to use a single system to both keep the club secure and to suspend the club. The solution disclosed includes both an inner and outer ring which contain notches upon which the heads of the golf clubs are rested. When the golf bag is tilted over or used for travel, however, the clubs may easily fall out of their notches. This is because the notches do not hold the club securely enough to prevent the club from escaping.
U.S. Pat. No. 2,436,687 (the '687 Patent), granted Feb. 24, 1948, also attempts to use a single device to both suspend the golf club and to secure the golf club in position. The '687 Patent discloses a wedge-like rack with finger-like upward extensions. The golf clubs are supported by these fingers which have been tapered to fit the head of the golf club. Although these fingers provide adequate support for securing the clubs during usage, a guard rail or a strap is needed to eliminate club disengagement in the event that the golf club bag is upended or used for transporting the golf clubs.
Accordingly, a principal object of the present invention is to provide an improved golf club securer and organizer. The invention suspends golf clubs from their heads so that either the butt or handle portions of the clubs rest at the bottom of the golf bag. Alternatively, using the rod and clamp configuration to adjust the height of the frame, the clubs are suspended to relieve the handle portions from weight tending to warp them. The head of each club is secured in place by a single securing device which, unlike the prior art, is able to hold the golf clubs so that even if the bag is upended or used for travel the clubs will remain in place. Since the golf club head securing devices may be individually formed for securing a specific golf club, each club is easily located in its proper position within the frame. The stem-like formation of the frame has two major advantages. The first is that all the clubs may be seen at a glance. Another advantage is the attractive formation of the club heads aloha the perimeter of the bag. The central holding unit holds clubs such as the woods and the putter. By holding these clubs in the center of the unit the golf bag always remains in balance. Finally, for attachment to the rim of the golf bag a series of clamps and rods may be used. This has the advantage of being adjustable to fit any size bag and any size set of golf clubs.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, a universal golf club securer and organizer includes a peripheral frame upon which are attached devices for securing the head of a single golf club. Each golf club head securer is made of a strong yet resilient material which both holds the golf club firmly in place and allows easy insertion and extraction of a golf club head. Further, the golf club head securer is molded to fit a specific numbered golf club. The minor variations between sets of golf clubs in size and contour are accommodated by the flexible nature of the resilient securing device.
In the preferred embodiment of the invention, the frame is made of a relatively stiff material which has been molded into a ring having a series of steps of increasing height. Each step has a securing device attached to it. In this configuration, when the golf clubs are inserted into their proper securing device, the golfer is able to see each club at a glance.
In accordance with one feature, across the central opening of the frame, a central holding unit made of the same relatively stiff material as the frame may be provided. This central holding unit has openings which may be used to hold additional golf clubs such as the woods and the putter. This arrangement protects the woods and the putter from damage and keeps the golf club bag in balance.
Another aspect of the present invention may include a system designed to attach the frame of the invention to a golf club bag. This system can be used to attach the frame to golf club bags of varying sizes. Additionally, the system is adjustable to the height of any set of golf clubs.
The preferred embodiment of the invention may also include the following additional features:
1. The frame and the securing devices may come in a variety of different colors.
2. The frame and the securing devices may be incorporated into a golf club bag as one unit.
3. The securing devices may have numbers imprinted thereon which correspond to the specific golf club number.
4. A series of extension rings may be used instead of the clamp and rod system to adjust the frame to accommodate the heights of various sets of golf clubs.
5. The frames may be made in different sizes and shapes to accommodate non-standard golf club bag openings.
Advantages of the present invention include the fact that the golf clubs are secured and held in a manner that protects the clubs both during usage and during travel. Since the clubs are suspended either on the periphery of the bag or in the central holder, the bag is always kept in balance. Another advantage is the organization the invention provides. This organization, combined with the physical step-like form, allows for easy location and easy inventory of the clubs within the golf bag. The method of attaching the frame to the golf club bag has the advantage of fitting any size golf club bag and any length of a set of golf clubs. Finally, since the clubs are suspended either on the periphery of the bag or in the central holder, the bag is always kept in balance.
Other objects, features and advantages of the present invention will become apparent from a consideration of the following detailed description, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the golf club securer and organizer in place in a golf bag and containing a set of golf clubs;
FIG. 2 is a top view of the golf club securer and organizer in place in a golf bag and containing a set of golf clubs;
FIG. 3 is a perspective view of the golf club securer and organizer looking down and from one side of the bag attachment devices;
FIG. 4 is a view of the under side of the golf club securer and organizer; and
FIG. 5 is a side cross-sectional view of a golf club head securer used to secure an individual head of a golf club.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, FIG. 1 is a depiction of a universal golf club securer and organizer 8 attached by means of rods 50 (best seen in FIG. 3 and FIG. 4) and clamps 52 to the upper rim 12 of the golf bag 10. Putting the shafts 13 of the irons into the inner recesses of the golf club bag 10 and the heads of the golf club irons 16 into the golf club head securer 40, the irons 14 are neatly spaced around the perimeter of the golf club bag so that the irons 14 are held securely in place at all times.
Securing the clubs in place has several advantages. First, if the golf bag 10 is upset or used for travel, the clubs will remain secure and in place. Second, the club heads 15 are protected from scratching and chipping. Third, the clubs 14 are easy to find and return because each has a proper position in the universal golf club securer and organizer 8. This also helps with keeping a constant inventory of the clubs and reduces the likelihood that clubs will be lost.
The frame 20 of the universal golf club securer and organizer 8, as can be seen from FIG. 1, has a step-like configuration. Each step 24 has a golf club head securer 40 mounted upon it. This formation allows the user to see all the clubs at one time. Additionally, this configuration puts the heads in a diagonal ring-like formation which is particularly attractive.
Spanning the frame is a central inner holder 30 with openings 32 (as seen in FIG. 2, FIG. 3 and FIG. 4) into which golf clubs such as the woods 18 and the putter 19 may be inserted. FIG. 1 shows the golf club woods 18 held in the openings 32 of the central inner holder 30 and extending above the irons 16.
FIG. 2 is a perspective view of the universal golf club securer and organizer 8 in place in the golf bag 10 and containing a set of golf clubs 14, 18, and 19. The irons 14 are held in place by claw-like securers 40 around the periphery of the golf bag 10. The woods 18 and putter 19 are situated within the openings 32 of the central inner holder 30. The central inner holder 30 is mounted to extend across the central opening 22 of the golf bag 10. The typical diameter of a rim of a golf bag opening 12 may be approximately seven to nine inches. The frame 20 of this invention preferably has a diameter of approximately eight inches. By using several rods 50 and clamps 52 (as best seen in FIG. 3 and FIG. 4) this frame may be used to fit any standard size golf bag 10. The rods 50 and clamps 52 will be discussed in greater detail in conjunction with FIG. 4.
FIG. 3 is a more detailed showing of the universal golf club securer and organizer 8. The frame 20 of the golf club securer and organizer is made of a relatively stiff material. In its preferred embodiment, the frame is molded out of a firm plastic or rubber material. Other materials which could be effectively used to make a frame include, for example, a lightweight metal or fiberglass. These materials are merely examples and are not intended to limit the scope of the invention.
The frame 20 in the preferred embodiment would have a ring-like shape defining a central opening 22. The ring-like shape may be symmetrically divided into two halves of graduated steps 24 which meet at a lower portion 23 and at an upper portion 25. The width of each step may be determined by the size of the base of each golf club head securer 40. Each step 24 may have at least one bore 26 (as best seen in FIG. 5) through which a locking device 44, at the bottom of each golf club head securer 40, may be inserted. Further, both the outer and the inner edge of each step may have a small ridge 41 (as best seen in FIG. 5). The bore 26 and the ridge 41 both serve to prevent the golf club head securer 40 from rotating.
Each step 24 of the frame 20 has a golf club head securer 40 mounted upon it. By inserting the locking device 44 through the bore 26 (as best seen in FIG. 5) the golf club head securer 40 is fastened to the frame 20. Alternatively, other methods of mounting, such as glues or screws or mating recesses, known to those skilled in the art, could be used by way of illustrative examples.
Extending across the central opening 22 is a central inner holder 30. The central inner holder is attached to the lower portion 23 of the frame 20 and to the upper portion 25 of the frame 20. The central inner holder 30, like the frame 20, has a step-like formation. In the preferred embodiment, each horizontal inner step 31, has an essentially circular opening 32. These circular openings 32 are meant to accommodate golf clubs such as the woods 18 and the putter 19 (as best seen in FIG. 2). The diameter of these openings, therefore may be approximately 11/4 inches. The horizontal inner steps 31 are connected by vertical inner surfaces 33 of approximately 11/2 to 2 inches. In the preferred embodiment, the vertical inner surfaces 33 are partially cylindrical. The central inner holder 30 is preferably formed of the same stiff material as the frame 20. The central inner holder 30 and the frame 20 may be a single unit or may be formed separately and secured together.
The frame 20 is attached to the rim of a golf bag 12 by means of a series of rods 50 and clamps 52. In the preferred embodiment, the rods 50 are made of a sturdy material such as steel or aluminum. The rods consist of two perpendicular portions separated by a 90° bend in the rod. This gives the rods an L-shape formation. The portions of the rod should be long enough to allow for both the varied width of the openings of a golf bag 12 and for the varying heights of golf club sets. A set of essentially flattened hook-shape clamps 52 are provided to secure the rod 50 to the rim of the golf club bag 12. FIG. 3 and FIG. 4 show these clamps 52 from several different angles. The clamps are made of a sturdy high-strength metallic material such as engineered plastic, steel, or aluminum.
As shown in FIG. 4 the clamp can be considered as including three sections. The long section 64 of the clamp has a bore or partial bore 51 through which the rod 50 is inserted. To accommodate the rod 50, a longitudinally-extending, semi-circular protrusion 53 may be included in the center of the long section 64 of the clamp 52. To keep the rod 50 from slipping within the bore 51 of the long side 64 of the clamp 52 a set screw 58 is provided. This long section 64 of the clamp 52 is situated inside of the golf club bag 10 when the frame 20 is in place. In the preferred embodiment the long side 64 of the clamp 52 is approximately 21/2 to 3 inches in length.
The inner surface of the top portion 63 of the clamp 52 rests on the rim of the golf bag 12 when the frame 20 is in place. This top portion 63 on its upper exposed surface may be approximately 1 inch to 11/2 inches thick. Its inner surface, the side touching the rim of the golf bag 12, is approximately 1/2 to 1/4 of an inch wide.
The short portion 62 of the clamp 52 is on the outer portion of the golf bag 10 when the frame 20 is in place (as best seen in FIG. 1 and FIG. 2). This portion may be approximately 1 inch to 11/2 inches long. On the side touching the golf bag 10, there is a gripping surface 54 (as best seen in FIG. 3). Additionally, to keep the clamp 52 in place, one or two set screws 56 may be provided.
A frame and rod joining mechanism 60, as seen in FIG. 4, is provided to attach the rods 50 to the frame 20. This device 60 may be an integral block with two bores 61 through which the rods 50 are inserted. Alternatively, the mechanism 60 may involve a shallow block with two grooves to receive the short ends of the rods 50, with an overlying plate secured in position by one or more screws.
This rod 50 and clamp 52 system of joining the golf club securer and organizer 8 to the golf bag 10 is only meant to be exemplary. Another method could involve the use of extension rings in which either several rings of uniform size or rings of the height desired are provided to be secured between the frame 20 and the rim of the golf bag 12. In addition, the frame 20 could be permanently attached to the golf bag 10.
FIG. 5 is a longitudinal cross-sectional view of a golf club head securer 40 and the adjacent portion of the frame 20. The securer is made of a resilient material which, in the preferred embodiment, is a plastic or rubber material. The securer 40 has a generally trapezoidal exterior perimeter. The lower diagonal portion of the securer 40 is a solid wedge 49 of the resilient material. The upper diagonal portion of the securer 40 is an opening 46 of the general shape of the head of a golf club iron 16 (not shown in FIG. 5).
The golf club is held within the opening 46 by two claw-like prongs 42 and 43. At the top point of the wedge of resilient material 49 is a shorter claw-like prong 42 which extends for a short distance vertically relative to the step 24 of the frame 20. This is the upward portion of the short prong 34. The claw-like prong 42 then makes a sharp, approximately 90°, angle 35 into a portion which extends horizontally and parallel to the step 24 of the frame 20.
Opposite the solid wedge of plastic 49 is a long claw-like prong 43. This claw-like prong 43 has an upward extension 37 at a step angle from the step 24 of the frame 20. From this long upward appendage 37 a horizontal portion 39 extends substantially horizontally. This horizontal element 39 of the long claw-like prong 43 is substantially parallel to the step 24 of the frame 20.
The horizontal portion 36 of the shorter prong 42 and the horizontal portion 39 of the longer prong 43 may be at substantially the same height above the step 24 of the frame 20. These horizontal portions (38 and 39) extend toward each other and meet at the gap 48. The gap 48 is provided to allow the head of a golf club 16 to be inserted and extracted from the golf club head opening 46. The size of the gap 48 in the preferred embodiment is approximately one quarter of an inch. This however is merely exemplary. A gap of an 1/80 inch or no gap at all or even an overlapping could be employed.
At the bottom of the golf club head securer 40 is at least one locking device 44. In the preferred embodiment (as shown in FIG. 5) two such locking devices 44 are provided. These elements 44 are extensions with a mushroom-like protrusion at the center thereof to lock the unit in place. Each locking device 44 is inserted through a bore 26 of a step 24 of the frame 20. In the preferred embodiment the locking device may extend beyond the frame 20 (also seen in FIG. 4). After securing, the end of the element 44 may be clipped off.
One purpose of the locking element 44 is to guard against rotation of the golf club head securer 40, as well as the basic securing function of the elements 44. An additional safeguard to prevent rotation is the small ridge 41 on the inner and outer edges of each step 24 of the frame 20. The ridge in FIG. 5 is larger than that which would actually be necessary, but is represented as such for illustrative purposes.
In conclusion, it is to be understood that the present invention is not to be limited to that precisely as described hereinabove and as shown in the accompanying drawings. More specifically, the frame could take shapes other than circular (such as a square or hexagonal) in order to accommodate unusual golf club bags. Further, the frames and holders can be of any color. The materials discussed are meant to be exemplary and could easily be exchanged with any other material suitable for the intended purpose. Numbering corresponding to the numbers of the specific golf club for which the holder is molded could be added to the exterior or top surface of the holders. Extension rings can be used in place of the rod and clamp system discussed above. Accordingly, the present invention is not limited to the arrangements precisely as shown and described hereinabove. | A universal golf club securer and organizer including a relatively stiff peripheral frame, The frame is molded into a ring having a series of steps of increasing height. Mounted to each step is a strong resilient device for firmly securing the head of a single golf club to the frame. Each golf club head securer has an opening molded to fit a specific golf club surrounded by two claw-like prongs which allows easy insertion and extraction of the golf club head. Spanning the central opening of the frame is a central holding unit which has openings suited to holding additional golf clubs. The frame is attached to a golf club bag by means of a rod and clamp system which is adjustable to the height of any set of golf clubs. | 0 |
This application claims priority to provisional application number 60/012416, filed Feb. 28, 1996
This application claims priority to provisional application number 60/012416, filed Feb. 28, 1996
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to new substituted ω phenoxy, phenylthio, phenylsulfinyl, phenylsulfonyl! alkyl, alkenyl or alkynyl!amine carboxamides, sulfonamides and phosphonylamides which are useful as antiarrhythmic agents.
2. Background of the Invention
Antiarrhythmic agents are classified in one of four categories, sodium channel blockers (Class I), calcium channel blockers (Class II), potassium channel blockers (Class III) and β-adrenergic blockers (Class IV) based upon their ability to exhibit clearly definable pharmacological actions. Compounds contained in the present invention produce a homogenous prolongation of repolanzation and refractoriness which is indicative of Class III antiarrhythmic activity. The electrophysical mechanism underlying the prolongation of repolarization is known to be the blockade of currents through cardiac potassium channels. In contrast, Class I antiarrhythmic agents mediate their pharmacological effect through sodium channel blockade. In canine Purkinje fibers and papillary muscle preparations, the Class III antiarrhythmic action of quinidine is manifested by the prolongation of action potential duration (APD). The prolongation of the APD and the effective refractory period (ERP) has also been shown with other Class III antiarrhythmic agents such as d-sotalol (N- 4- 1-hydroxy-2- (1-methylethyl)amino!ethyl!phenyl!methanesulfonamide), dofetilide (4'-(2- methyl 4-(methylsulphonylamino)phenethyl!amino!ethoxy)methanesulphonanilide), and E-4031 (1- 2-(2-methylpyridin-6-yl)ethyl!-4-(4-methanesulfonylamino-benzoyl)-piperidine) which have shown pharmacological effects in clinical studies. The increase in APD in cardiac muscle has thus become an in vitro standard measure for putative Class III antiarrhythmic agents.
Class III antiarrhythmic activity is established as a viable therapeutic strategy for the management of ventricular arthythmias and the prevention of sudden cardiac death. Some recent reviews of Class III agents include: Gibson and Kersten, Drug Dev. Res., 1990, 19: 173-185; Carmeliet, Fundam. Clin. Pharniacol. 1993, 7: 19-28; Harrison and Bottorff, Advances in Pharmacology, 1992, 23: 179-215; Cimini and Gibson, Ann. Reports in Medicinal Chem. 1992, 27: 89-98.
Racemic sotalol is a structural prototype antiarrhythmic drug whose pharmacological activity stems from the blockade of the delayed rectifier subclass of potassium channels. Sotalol is a phenethanolamine derivative containing a methylsulfonamide moiety. Structural variations of this compound in which either chain extension by carbon or oxygen atoms or the addition of a second aryl moiety such as 4-phenoxyimidazole, have been achieved. However, the presence of a basic amine moiety within the original phenethyl chain has been retained. A general pharmacophore model for this class of compounds is defined and a generalized structure is proposed (Prog. Med. Chem. 1992, 29, 65) linking the structural ##STR1## variations; where Q is an electron withdrawing group, A is a one to four atom link between the aryl group and the nitrogen atom and the R 1 and R 2 substituents are selected from hydrogen, alkyl, arylalkyl or heteroarylalkyl groups.
The current invention is a departure from general Structure I, in that a carbonyl, sulfonyl or phosphoryl group is attached to the nitrogen (NH) atom. The current substituents change the physical chemical characteristics of the nitrogen atom (and therefore the pharmacophore) from one which is basic as in Structure I to one that has either neutral or acidic properties. This novel departure from the general pharmacophore defines a series of compounds which possess significant activity in the action potential prolongation procedure indicative of antiarrhythmic activity.
SUMMARY OF THE INVENTION
This invention relates to new derivatives selected from those of general formula I: ##STR2## wherein R 1 is ##STR3## R 3 is C 1 -C 3 straight chain alkyl; X is O, S, SO or SO 2 ;
D is ##STR4## n is an integer from 3 to 10; k is an integer from 1 to 4;
m is an integer from 1 to 4;
Y is ##STR5## R 2 is ##STR6## Z, Z 1 and Z 2 are independently selected from H, C 1 -C 4 straight or branched alkyl, --CF 3 , --NO 2 , --NHCOR 3 , --OR 4 , --CN, Cl, Br, F, or I; R 4 is C 1 -C 4 straight or branched alkyl; and A is oxygen or a bond; or a pharmaceutically acceptable salt thereof.
A pharmaceutically acceptable salt is an addition salt formed between an invention compound having a basic nitrogen and a pharmaceutically acceptable acid such as one of the inorganic acids hydrochloric, hydrobromic, sulfuric, or phosphoric acid, or an organic acid such as acetic, citric, maleic, fumaric, tartaric, succinic, methanesulfonic, or benzoic acid
Within the group of compounds defined by Formula I, the most preferred compounds are those wherein R 1 is ##STR7## X is O and Y is SO 2 R 2 .
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds of the present invention may be readily prepared in accordance with the following reaction schemes. Unless stated otherwise, all variable values are as previously defined. ##STR8##
The compounds of formula I wherein D is --(CH 2 ) n --may be prepared as described in Scheme I by dissolving a base such as sodium methoxide in a lower alkanol solvent and adding 1, or dissolving 1 in N,N-dimethylformamide and treating with sodium hydride to give 2. Reaction of 2 with the 2-(ω-bromoalkyl) derivative of 1H-isoindole-1,3(2H)-dione 3, in a lower alkanol solvent followed by stirring from room temperature to the reflux temperature of the solvent for 12-16 hours gives intermediate 4. The product is isolated by cooling, collecting the solid, washing the solid with water and drying. Alternatively, reaction of 2 with 3 in N,N-dimethylformamide at or between room temperature and 95° C. on a steam bath gives 4 which is isolated by dilution with 5-10 volumes of water and collecting the product by filtration or by evaporating the N,N-dimethylformamide at reduced pressure and collecting the residue by filtration. Conversion of 4 to the free amine 6 or amine salts 5 is conducted by dissolving or suspending 4 in refluxing ethanol containing either hydrazine or monomethylamine for 12-18 hours, cooling and collecting the insoluble precipitate. The precipitate is washed with 2-5 equivalents of 1N HCl and the filtrate saved. The ethanol filtrate is concentrated to dryness and the residue is suspended 1N aqueous HCl solution. Insolubles are removed by filtration. The combined 1N HCl solutions are evaporated to give the HCl salt 5. Alternately, the filtrate can be rendered alkaline with NaOH, cooled to 0° C. and the free base 6 is collected by filtration. Additionally, reaction of 2 with 7 where n is 3 to 10 using conditions similar to those used in the reaction of 2 and 3 affords 8. Reduction of 8 using either hydrogen and a metal catalyst such as 10% palladium-on-carbon or a complex metal hydride such as lithium aluminum hydride upon isolation gives 6.
The hydrochloride salt 5 is added to water and 2.5 equivalents of sodium hydroxide is added. Sulfonyl chloride 9 where Y is --SO 2 R 2 is dissolved in an ether solvent such as diethyl ether and added dropwise to 6. After stirring for 2-16 hours the precipitate is collected, washed with water and ether, dried and crystallized to give 10, where Y is --SO 2 R 2 .
Alternatively, 6 is dissolved in pyridine and a slight molar excess of 9 is added where Y is --SO 2 R 2 . The reaction mixture is stirred at between room temperature and steam bath temperature for 8-16 hours. The pyridine is removed at reduced pressure and the residue is washed with water, dried and crystallized to give 10.
Additionally, 6 is dissolved in dichloromethane containing an excess of triethylamine or N,N-diisopropylethylamine followed by the addition of 9 where Y is --SO 2 R 2 . The reaction mixture is stirred at or between room temperature and the reflux temperature of the solvent for 2-18 hours. The solvent is concentrated at reduced pressure and the residue is washed with water, dried and crystallized to give 10 where Y is --SO 2 R 2 .
Additionally, 5 or 6 are reacted with 9 where Y is ##STR9## and to give 10 using the conditions to prepare 10 where Y is --SO 2 R 2 .
Furthermore, 5 or 6 are reacted with 9 where Y is ##STR10## and A is oxygen or a bond to give 10 using the conditions described to prepare 10 where Y is --SO 2 R 2 .
Oxidation of 10 wherein X is S with one equivalent of an aryl or alkyl carboxylic peracid produces sulfoxide 11a or the sulfone 11b when an excess of the oxidizing reagent is present. ##STR11## The compounds of formula I wherein D is ##STR12## are prepared as described in Scheme II by reaction of olefins 12a and 12b wherein W is Br or Cl with potassium salts of 1H-isoindole-1,3(2H)-dione in N,N-dimethylformamide at or between room temperature and the reflux temperature of the solvent for 12 to 16 hours to give intermediates 13a and 13b. Treatment of 13c with sodium hydride or sodium methoxide in N,N-dimethylformamide followed by reaction with 13a and 13b gives 14a and 14b. Reaction of 14a and 14b with hydrazine or monomethylamine in refluxing ethanol affords the free amines 15a and 15b or the acid addition salts such as hydrochloric, hydrobromic, hydroiodic, phosphoric, nitric or sulfate 15c and 15d. Sulfonyl chloride 9 where Y is --SO 2 R 2 is dissolved in an ether solvent such as diethyl ether and added dropwise to 15a and 15b. After stirring for 2-16 hours the precipitate is collected, washed with water, ether, dried and crystallized to give 16a and 16b, where Y is --SO 2 R 2 .
Alternatively, 15c and 15d are dissolved in pyridine and a slight molar excess of 9 is added where Y is --SO 2 R 2 . The reaction mixture is stirred at or between room lo temperature and the reflux temperature of the solvent for 8-16 hours. The pyridine is removed at reduced pressure and the residue is washed with water, dried and crystallized to give 16a and 16b.
Additionally, 15c and 15d are dissolved in dichloromethane containing an excess of triethylamine or N,N-diisopropylethylamine followed by the addition of 9 where Y is --SO.sub. R 2 . The reaction mixture is stirred at or between room temperature and the reflux temperature of the solvent for 2-18 hours. The solvent is concentrated at reduced pressure and the residue is washed with water, dried and crystallized to give 16a and 16b where Y is --SO 2 R 2 .
Additionally, 15a, 15b, 15c, or 15d are reacted with 9 where Y is ##STR13## and R 2 is hereinbefore defined to give 16a and 16b using the conditions to prepare 10 where Y is --SO 2 R 2 .
Furthermore, 15a, 15b, 15c, or 15d are reacted with 9 where Y is ##STR14## to give 16a and 16b using the conditions described to prepare 10 where Y is --SO 2 R 2 . ##STR15##
The compounds of formula I wherein D is ##STR16## may be prepared as described in Scheme III by reaction of alkyne 17 wherein W is Br or Cl and k and m are hereinbefore defined with the potassium salt of 1H-isoindole-1,3-(2H)-dione in N,N-dimethylformamide at room temperature to give intermediate 18. Treatment of 13c with sodium hydride or sodium methoxide in N,N-dimethylformamide followed by reaction with 18 gives 19. Reaction of 19 with hydrazine or monomethylamine in refluxing ethanol affords the free amine 20 or the acid addition salt 21 such as hydrochloric, hydrobromic, hydroiodic, phosphoric, nitric or sulfate. Sulfonyl chloride 9 where Y is --SO.sub. R 2 is dissolved in ether and is added to 20. After stirring for 2-16 hours the precipitate is collected, washed with water, ether, dried and crystallized to give 22, where Y is --SO 2 R 2 .
Alternatively, 20 is dissolved in pyridine and a slight molar excess of 9 is added where Y is --SO 2 R 2 . The reaction mixture is stirred at or between room temperature and the reflux temperature of the solvent for 8-16 hours. The pyridine is removed at reduced pressure and the residue washed with water, dried and crystallized to give 22.
Additionally, 21 is dissolved in dichloromethane containing an excess of triethylamine or N,N-diisopropylethylamine followed by 9 where Y is --SO 2 R 2 . The reaction mixture is stirred at or between room temperature and the reflux temperature of the solvent for 2 to 18 hours. The solvent is concentrated at reduced pressure and the residue washed with water, dried and crystallized to give 22 where Y is --SO 2 R 2 .
Additionally, 20 or 21 are reacted with 9 where Y is ##STR17## to give 22 using the conditions to prepare 10 where Y is --SO 2 R 2 .
Furthermore, 20 or 21 are reacted with 9 where Y is ##STR18## to give 22 using the conditions described to prepare 10 where Y is --SO 2 R 2 . ##STR19##
Referring to Scheme IV, sulfonamide 23 prepared by Schemes I, II and III where Y ##STR20## is reacted with hydrogen sulfide to give product 24. Reaction of 24 with α-bromoacetophenone 25 yields the thiazole 26.
Additionally, reaction of 23 where Y is ##STR21## with sodium azide in N,N-dimethylformamide at 120°-130° C. in the presence of ammonium chloride gives tetrazole 27.
As shown in Scheme V, 28 prepared by Schemes I, II and III wherein is reacted with tris(formamido)methane and formamide at 160°-165° C. to give pyrimidine 29. Additionally, reaction of 28 with dimethylfornamide dimethylacetal gives eneaminone 30. Reaction of 30 is treated with hydrazine in refluxing ethanol to give pyrazole 31 or with formamidine to afford 29.
Reaction of 31 with 9 gives 32.
Cleavage of 29 by hydrazine or dimethylamine gives amine 33. Reaction of 33 with 9 gives 34. ##STR22##
As shown in Scheme VI, benzenesulfonamide 35a, prepared by Schemes I, II and III, wherein Y is ##STR23## reduced to benzenesulfonamide 35 which is reacted with 2,5-dimethoxytetrahydrofuran in acetic acid to give pyrrolo compound 36. ##STR24##
As shown in Scheme VII, 37a prepared by Schemes I, II and III is reduced to 37, which is then reacted with triethylorthoformate in the presence of sodium azide to give tetrazole 38. ##STR25## where Y is hereinbefore defined gives 40. Cleavage of 38 with hydrazine or methylamine gives amine 39. Reaction of 39 with YCl where Y is as defined previously gives a compound of formula 40.
The invention will be described in greater detail in conjunction with the following specific examples which are included for illustrative purposes. The reagents and intermediates used are either commercially available or can be synthesized by standard literature procedures by those skilled in the art of organic synthesis.
EXAMPLE 1
2- 4- 4-(1H-Imidazol-1-yl)phenyoxy!butyl!-1H-isoindole-1,3(2H)-dione
To a solution of 4.0 g of sodium methoxide in 100 ml of dimethylformamide is added 10.0 g of 4-(1H-(imidazol-1-yl)phenol. After a few minutes 18.2 g of 2-(4-bromobutyl)-1H-isoindole-1,3(2H)-dione is added, and the reaction mixture stirred and heated in the steam bath for 16 hours. Addition to two liters of cold water gives a precipitate which is collected, washed with one liter of cold water, and dried. Recrystallization from methylene chloride-hexane gives 14.7 g of a solid melting at 105°-107° C.
EXAMPLE 2
4- 4-(1H-Imidazol-1-yl)phenoxy!butaneamine
To a solution of 13.0 g of 2- 4- 4-1H-imidazol-1-yl)phenoxy!butyl!-1H-isoindole-1,3(2H)-dione (Example 1) in 250 ml of refluxing ethanol is added a 1.6 ml portion of anhydrous hydrazine. The mixture is stirred at reflux for 16 hours and taken to dryness in vacuo. The residue is mixed with 200 ml of ethanol and 25 ml of concentrated hydrochloric acid, and the mixture stirred at reflux for two hours. The hot reaction mixture is filtered and the precipitate is then washed with 100 ml of hot water. The combined filtrates are then taken to dryness in vacuo, leaving 8.4 g of the dihydrochloride salt of the title compound, mp 195°-200° C.
The title compound is obtained by dissolving the above dihydrochloride salt in H 2 O, treating with excess 10N NaOH, and extraction with dichloromethane. After drying and removal of the dichloromethane, the base is obtained as a low melting solid.
EXAMPLE 3
4-(t-Butyl)-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
A solution of 3.0 g of 4- 4-(1H-imidazol-1-yl)phenoxy!butaneamine dihydrochloride (Example 2) is dissolved in 100 ml H 2 O and while stirring 3.5 ml of 10N NaOH, and then 2.6 g of 4-(t-butyl)benzenesulfonyl chloride in 100 ml of diethyl ether are added. The mixture is stirred at room temperature for 4 hours. The precipitate is collected, washed with 50 ml of water and 50 ml of diethyl ether, and air dried. Recrystallization from 50% aqueous ethanol gives 2.6 g of the title compound, m.p. 138°-140° C.
EXAMPLE 4
4-Bromo-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
Utilizing the procedure of Example 3, employing 3.0 g of 4-bromobenzenesulfonyl chloride, 0.6 g of the desired product is obtained as a white solid, m.p. 134°-136° C.
EXAMPLE 5
4-Chloro- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The procedure of Example 3 is followed using 2.4 g of 4-chlorobenzenesulfonyl chloride. A yield of 1.6 g of the desired compound is obtained as a white solid, m.p. 122°-123° C.
EXAMPLE 6
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-2-naphthalenesulfonamide
The procedure of Example 3 is employed using 2.6 g of 2-naphthalenesulfonyl chloride. A yield of 1.9 g of the title compound is obtained as a white solid, m.p. 157°-158° C.
EXAMPLE 7
4-Methyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
Following the procedure of Example 3, using 2.2 g of 4-methylbenzenesulfonyl chloride, 0.8 g of the desired compound is obtained as a white solid, m.p. 96°-98° C.
EXAMPLE 8
4-Iodo-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzensulfonamide
Employing the procedure of Example 3, using 3.0 g of 4-iodobenzenesulfonyl chloride, 3.2 g the desired compound is obtained as a white solid, m.p. 150°-152° C.
EXAMPLE 9
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!buty!benzenemethanesulfonamide
Following the procedure of Example 3, and using 2.1 g of benzenemethanesulfonyl chloride, 0.3 g the desired compound is obtained as a white solid, m. p. 123°-124° C.
EXAMPLE 10
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-8-quinolinesulfonamide
Utilizing the procedure of Example 3 and employing 2.4 g of 8-quinolinesulfonyl chloride, 1.8 g of the desired compound is obtained as a white solid, m.p. 131°-3° C.
EXAMPLE 11
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-2-thiophenesulfonamide
The title compound is prepared by the procedure of Example 3 and employing 2.0 g of 2-thiophenesulfonyl chloride; 1.9 g the desired compound is obtained as a solid, m.p. 121°-122° C.
EXAMPLE 12
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-1,2-dihydro-1-methyl-2-oxobenz cd!indole-6-sulfonamide
1,2-Dihydro-1-methyl-2-oxobenz cd!indole is dissolved in chlorosulfonic acid at room temperature. After eighteen hours at room temperature, the solution is added to crushed ice, precipitating the 6-sulfonyl chloride. This solid is collected, washed with water, and dried in vacuo at room temperature.
A solution of 2.8 g of the above sulfonyl chloride in 200 ml of dichloromethane is added to a stirred mixture of 3.0 g of 4- 4-(1H-imidazol-1-yl)-phenoxy!butaneamine dihydrochloride (Example 2) and 3.5 ml of 10N NaOH. After 6 hours, the dichloromethane layer is separated, washed with water, and dried over Na 2 SO 4 . Addition of an equal volume of hexane gives a yellow precipitate which is purified by recrystallization from ethanol; yield, 0.8 g; m.p. 177°-179° C.
EXAMPLE 13
2,5-Dichloro-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The procedure of Example 3 is followed utilizing 2.6 g of 2,5-dichlorobenzenesulfonyl chloride. The desired compound is obtained as a white solid, m.p. 144°-146° C.; yield, 1.5 g.
EXAMPLE 14
4-Trifluoromethyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 0.01 mole of 4-trifluoromethylbenzenesulfonyl chloride. The desired compound is obtained as a solid, 119°-120° C; yield, 1.0 g.
EXAMPLE 15
4-Nitro-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared by the method of Example 3 utilizing 2.4 g of 4-nitrobenzenesulfonyl chloride. The desired compound is obtained in 0.5 g yield as a solid m.p. 156°-157° C.
EXAMPLE 16
4-Acetamido-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title product is prepared by the procedure of Example 3, utilizing 4-acetamidobenzenesulfonyl chloride. The desired product is obtained as a solid, m.p. 101°-103° C.; yield, 1.9 g.
EXAMPLE 17
4-Methoxy- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 0.011 mole of 4-methoxybenzenesulfonyl chloride. The desired product is obtained as a solid, m.p. 106°-107° C.; yield, 1.6 g.
EXAMPLE 18
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-1-octanesulfonamide
The procedure of Example 3 is followed, utilizing 2.3 g of octanesulfonyl chloride. The desired compound is obtained as a solid, m.p. 99°-100° C.; yield, 2.0 g.
EXAMPLE 19
2,4,6-Trimethyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 2.4 g of 2,4,6-trimethylbenzenesulfonyl chloride. The desired compound is collected as a solid, m.p. 130°-131° C.; yield, 0.8 g
EXAMPLE 20
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-2,1,3-benzothiadiazole-4-sulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 2.6 g of 2,1,3-benzothiadiazole-4-sulfonyl chloride. The desired compound is obtained as a solid, m.p. 112°-114° C.; yield, 0.8 g.
EXAMPLE 21
4-Cyano-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 2.2 g of 4-cyanobenzenesulfonyl chloride. The desired compound is obtained as a solid, m.p. 148°-149° C.; yield 2.0 g.
EXAMPLE 22
4-Butoxy-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The compound is prepared by the method of Example 3 using 2.8 g of 4-butoxybenzenesulfonyl chloride. The desired compound is collected as a solid, m.p. 103°-105° C.; yield, 1.5 g.
EXAMPLE 23
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 1.4 ml of benzenesulfonyl chloride. The desired compound is collected as a solid, m.p. 110°-111° C.; yield 1.5 g.
EXAMPLE 24
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-2,1,3-benzoxadiazole-4-sulfonamide
The title compound is prepared by the procedure of Example 3, utilizing 2.0 g of 2,1,3-benzoxadiazole-4-sulfonyl chloride. The desired compound is collected as a white solid, m.p. 125°-126° C.; yield, 1.0 g.
EXAMPLE 25
5-Aminomethyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!-2-thiophenesulfonamide
A solution of 3.0 g of 5-benzoylaminomethyl-2-thiophenesulfonyl chloride, in 100 ml of dichloromethane, is added to a stirred mixture of 3.0 g of 4- 4-(1H-imidazol-1-yl)phenoxy!butaneamine dihydrochloride (Example 2) and 3.5 ml of 10N NaOH in 100 ml of water. The mixture is stirred at room temperature for 3 hours, a tacky precipitate being formed. The precipitate is mixed with 100 ml of concentrate HCl, and the mixture is stirred at reflux for 12 hours, solution taking place. The solution is taken to dryness in vacuo, and the dihydrochloride salt of the title compound was recrystallized from aqueous ethanol, m.p. 230°-232° C. (dec.); yield, 0.5 g.
EXAMPLE 26
2- 5- 4-(1H-imidazol-1-yl)phenoxy!pentyl-1H-isoindole-1,3-(2H)-dione
The title compound is prepared essentially by the procedure of Example 1, 2-(5-bromopentyl)-1H-isoindole-1,3(2H)-dione replacing the 4-bromobutyl intermediate. Recrystallization of the collected solid from dichloromethane-hexane gives the desired product m.p., 105°-106° C.
EXAMPLE 27
5- 4-(1H-imidazol-1-yl)phenoxy!pentaneamine
2- 5- 4-(1H-imidazol-1-yl)phenoxy!butyl!-1H-isoindole-1,3-(2H)-dione (Example 26) is cleaved by hydrazine in refluxing ethanol by the procedure of Example 2. The crude hydrochloride salt is dissolved in 20 parts of water, made basic with 10N NaOH, and the mixture then extracted with 30 parts of dichloromethane. After drying with Na 2 SO 4 , the dichloromethane is removed in vacuo to give the desired compound as a clear oil, with the correct molecular weight as determined by mass spectrometry.
EXAMPLE 28
4-Bromo-N- 5- 4-(1H-imidazol-1-yl)phenoxy!pentyl!benzenesulfonamide
5- 4-(1H-imidazol-1-yl)phenoxy!pentaneamine (Example 27) is converted to the title compound by the procedure of Example 4, to give the desired compound as a solid, m.p. 137°-138° C.
EXAMPLE 29
N- 5- 4-(1H-Imidazol-1-yl)phenoxy!pentyl!hexanesulfonamide
The desired product is obtained by utilizing 5- 4-(1H-imidazol-1-yl)phenoxy!pentaneamine (Example 27) and hexanesulfonyl chloride by the procedure of Example 3, which gives the title compound as a solid.
EXAMPLE 30
(E)-2- 4- 4-(1H-Imidazol-1-yl)phenoxy!-2-buten-1-yl!-1H-isoindole-1,3(2H)-dione
(E)-1,4-Dichloro-2-butene and potassium phthalimide are added to dimethylformamide, and the mixture stirred at room temperature for 18 hours. The reaction mixture is taken to dryness in vacuo. The residue is shaken with cold water, precipitating (E)-2-(4-chloro-2-buten-1-yl)-1H-isoindole-1,3(2H)-dione, which is purified by recrystallization from hexane; m.p. 100°-101 ° C.
A solution of 16.0 g of 4-(1H-imidazol-1-yl)phenol in 250 ml of dimethylformamide, is treated with 4.2 g of 60% NaH. To the suspension of the sodium salt, 23.5 g of (E)-2- 4-chloro-2-buten-1-yl)-1H-isoindole-1,3(2H)-dione is added, and the reaction mixture stirred and heated on the steam bath for 16 hours. The dimethylformamide is removed in vacuo, and the residue stirred with 250 ml of water. The insolubles are collected, washed with water, and dried. Recrystallization from ethanol gives the desired product as a solid, m.p. 170°-171° C.
EXAMPLE 31
(E)-4- 4-(1H-Imidazol-1-yl)phenoxy!-2-buten-1-amine
A solution of 26.2 g of (E)2- 4- 4-(1H-imidazol-1-yl)phenoxy!-2-buten-1-yl!-1H-isoindole-1,3(2H)-dione (Example 30) in 1 liter of ethanol is treated with 5 ml of anhydrous hydrazine, and the mixture stirred at reflux for 18 hours. To the reaction mixture is added 25 ml of concentrated HCl and the mixture cooled to room temperature. The precipitate is collected and washed with 2 portions of 300 ml of water. The filtrate and aqueous washes are combined and taken to dryness in vacuo. The solid is treated with 25 ml of 10N NaOH, the mixture saturated with solid K 2 CO 3 , and then extracted with 500 ml of dichloro-methane. Removal of the dichloromethane in vacuo leaves a viscous oil that solidifies at room temperature. A portion is purified by recrystallization from hexane, and dried; m.p. 81°-83° C.; yield, 0.5 g.
EXAMPLE 32
(E)-4-Methyl-N- 4- 4-(1H-imidazol-1l-yl)phenoxyl-2-buten-1yl!benzenesulfonamide
A suspension of 3.4 g of (E)-4- 4-(1H-imidazol-1-yl)phenoxy!-2-butene-1-amine (Example 31) in 300 ml of diethylether and 5 ml of triethylamine is treated with a solution of 3.0 g of 4-methyltoluenesulfonyl chloride in 100 ml of diethyl ether. The mixture is stirred at room temperature for 12 hours, refluxed for two hours, and filtered hot. The precipitate is washed with 50 ml of H 2 O and 100 ml of ether, and air-dried. Recrystallization from ethanol gives the pure title compound, m.p. 140°-142° C.; yield 2.4 g.
EXAMPLE 33
2- 4-(4-Nitrophenoxy)butyl!-1H-isoindole-1,3 (2H)-dione
A solution of 14.0 g of 4-nitrophenol in 250 ml of dimethylformamide is treated with 6.0 g of sodium methoxide. After 15 minutes, 28.2 g of 2-(4-bromobutyl)-1H-isoindole-1,3(2H)-dione is added, and the mixture then stirred at room temperature for 16 hours. The reaction mixture is diluted with 1500 ml of cold water, the precipitated solid collected, washed with water, and dried. Recrystallization from ethanol gives the desired compound, m.p. 112°-114° C.
EXAMPLE 34
4- 4-Nitrophenoxy!butaneamine
A suspension of 62.6 g of 2- 4-(4-nitrophenoxy)butyl!-1H-isoindole-1,3(2H)-dione (Example 33) in one liter of ethanol is treated with 6.5 ml of hydrazine, and the mixture then stirred at reflux for 18 hours. After cooling to room temperature, the precipitate is collected, washed with 250 ml of hot 2.5N HCl, and 200 ml of hot H 2 O. The combined acid and water washes are taken to dryness to obtain the hydrochloride salt of the title compound. Mass spectrometry shows the presence of the title compound. The compound is utilized directly without further purification.
EXAMPLE 35
4-Methyl-N- 4-(4-nitrophenoxy)butyl!benzenesulfonamide
A solution of 8.8 g of 4-(4-nitrophenoxy)-butaneamine hydrochloride (Example 34) in 200 ml of water is treated successively with 9 ml of 10N NaOH, and a solution of 7.5 g of 4-methylbenzenesulfonyl chloride in 200 ml of diethylether. The reaction is stirred at room temperature for 3 hours, the precipitate collected, washed with water and diethylether, and air dried. Recrystallization from 50% aqueous ethanol gives the desired product as a solid, m.p. 87°-88° C.; yield, 1.2 g.
EXAMPLE 36
4-Methyl-N- 4-(4-aminophenoxy)butyl!benzenesulfonamide
5.0 g of 4-methyl-N- 4-(4-nitrophenoxy)-butyl!benzenesulfonamide (Example 35) is dissolved in 500 ml of ethanol, 1.5 ml of anhydrous hydrazine and 500 mg of 10% palladium on carbon are added, and the mixture is then stirred under reflux for four hours. The reaction mixture is filtered hot. Cooling the filtrate to room temperature produces a precipitate, which is collected. The filtrate is reheated to boiling and utilized to re-extract the palladium-carbon residue, and after filtration, cooled to room temperature, the precipitate being collected. The process is repeated until no further precipitate is formed on cooling to room temperature. After drying at 60° in vacuo, the combined precipitates weigh 3.3 g; m.p. 176°-178° C.
EXAMPLE 37
2- 4-(4-Aminophenoxy)butyl!-1H-isoindole-1,3(2H)-dione
A suspension of 6.8 g of 2- 4-(4-nitro-phenoxy)butyl!-1H-isoindole-1,3(2H)-dione (Example 33) in 200 ml of ethanol is treated with 500 mg of 10% Pd on carbon, and reduced in a Parr hydrogenator. After filtration, concentration of the filtrate gives the desired product, m.p. 119°-121° C.; yield 4.3 g.
EXAMPLE 38
2- 4- 4-(1H-Tetrazol-1-yl)phenoxy!butyl!-1H-isoindole-1,3(2H)-dione
To a solution of 17.7 g of 2- 4-(4-amino-phenoxy)butyl!-1H-isoindole-1,3(2H)-dione (Example 37) in a mixture of 250 ml of acetic acid and 80 ml of triethylorthoformate is added 7.0 g of sodium azide and the mixture then stirred and heated on the steam bath for 4 hours. Concentration to dryness in vacuo leaves a residue that is triturated with 250 ml of water. The insolubles are collected, washed with water, and dried. Recrystallization from ethanol gives the title compound, m.p. 143°-145° C.
EXAMPLE 39
4- 4-(1H-Tetrazol-1-yl)phenoxy!butaneamine
A suspension of 19.4 g of 2- 4- 4-(1H-tetrazol-1-yl)phenoxy!butyl!-1H-isoindole-1,3(2H)-dione (Example 38) in 400 ml boiling ethanol is treated with 3 ml of anhydrous hydrazine, and the mixture stirred at reflux for 16 hours. The precipitate is collected, washed with 200 ml of hot 1.5N HCl, and 50 ml of H 2 O. The combined ethanol, hydrochloric acid, and water filtrates are taken to dryness in vacuo to give the hydrochloride salt of the title compound. A portion of the salt was recrystallized from hot ethanol, m.p. 197°-198° C. (dec.).
EXAMPLE 40
4-Bromo-N- 4- 4-(1H-tetrazol-1-yl)phenoxy!butyl!benzenesulfonamide
A solution of 2.7 g of 4- 4-(1H-tetrazol-1-yl)phenoxy!butaneamine hydrochloride (Example 39) in 100 ml of water is treated successively with 3.5 ml of 10N NaOH and a solution of 2.7 g of 4-bromobenzenesulfonyl chloride in 100 ml of diethyl ether. The mixture is stirred at room temperature for 1.5 hours, the precipitate collected, washed with diethyl ether and water, and air dried. Recrystallization from ethanol gives the pure compound, m.p. 109°-110° C.; yield, 1.6 g.
EXAMPLE 41
4-Methyl-N- 4- 4-(1H-tetrazol-1-yl)phenoxy!butyl!benzenesulfonamide
The subject compound is prepared essentially by the procedure of Example 40, 4-methylbenzenesulfonyl chloride replacing the 4-bromobenzenesulfonyl chloride. The desired compound is collected as a solid, m.p. 127°-128° C.
EXAMPLE 42
2- 4-(4-Acetylphenoxy)butyl!-1H-isoindole-1,3(2H)-dione
The subject compound is prepared essentially by the procedure of Example 33, 1-(4-hydroxyphenyl)-ethanone replacing the 4-nitrophenol. Recrystallization of the collected solid from ethanol gives the desired product, m.p. 112°-114° C.
EXAMPLE 43
1- 4-(4-Aminobutoxy)phenyl!ethanone
A suspension of 13.5 g of 2- 4-(4-acetyl-phenoxy)butyl!-1H-isoindole-1,3(2H)-dione in 500 ml of ethanol is treated with 1.4 ml of anhydrous hydrazine, and the mixture stirred at reflux for 9 hours. After cooling to room temperature, the precipitate is collected. Concentration of the filtrate gives the crude title compound, which is used directly for further synthesis.
EXAMPLE 44
1- 4- 4-(4-Bromobenzene-sulfonamido)butoxy!phenyl!ethanone
The desired product is prepared using the conditions of Example 40, using 1- 4-(4-aminobutoxy)phenylethanone in place of 4- 4-(1H-tetrazol-1-yl)-phenoxy!butaneamine; m.p. 129°-130° C.
EXAMPLE 45
2- 4- 4-(Pyrimidin-4-yl)phenoxy!butyl!-1H-isoindole-1,3(2H)-dione
A mixture of 10.0 g of 2- 4-(4-acetylphenoxy!-butyl!-1H-isoindole-1,3(2H)-dione (Example 42) 10.0 g of tris(formamido)methane, and 20 ml of formamide are combined and the mixture stirred and heated at 160°-165° C. for 8 hours. After dilution with 100 ml of water, the mixture is rendered basic with 10N NaOH, the precipitate collected, washed with water, and air dried. Recrystallization from ethanol gives the pure compound, m.p. 100°-102° C.; yield, 5.0 g.
EXAMPLE 46
4- 4-(Pyrimidin-4-yl)phenoxy!butaneamine
A suspension of 4.6 g of 2- 4- 4-(pyrimidin-4-yl)phenoxy!butyl!-1H-isoindole-1,3(2H)-dione (Example 45) in 200 ml of boiling ethanol is treated with 0.8 ml of anhydrous hydrazine, and the mixture then refluxed for 9 hours. The hot suspension is filtered. The precipitate is washed with 125 ml of 1.5N HCl. The combined HCl and ethanolic filtrates are taken to dryness in vacuo to obtain the hydrochloride salt of the title compound. Mass spectrometry shows the residue to be the tide compound and the salt is utilized for synthesis without further purification, m.p. 208°-210° C. (dec.).
EXAMPLE 47
4-Bromo-N- 4- 4-(pyrimidin-4-yl)phenoxy!butyl!benzenesulfonamide
The subject compound is prepared essentially by the procedure of Example 4, 4- 4-(pyrimidin-4-yl)phenoxy!butaneamine hydrochloride (Example 46) replacing the 4- 4-(1H-imidazol-1-yl)phenoxy!butaneamine hydrochloride. The desired compound is obtained as a solid after recrystallization from 50% aqueous ethanol, m.p. 131°-133° C.
EXAMPLE 48
(E)-2- 4- 4- 3-(dimethylamino)-1-oxo-2-propenyl!phenoxy!butyl!-1H-isoindole-1,3(2H)-dione
A solution of 25 g of 2- 4-(4-acetylphenoxy)butyl!-1H-isoindole-1,3(2H)-dione (Example 42) and 25 ml of dimethylformamide dimethylacetal in 50 ml of dioxane is heated in the steam bath for 16 hours. The volatile components are removed in vacuo, a tacky reddish-brown solid being obtained. A portion is recrystallized from dichloromethane/hexane; m.p. 109°-111° C.
EXAMPLE 49
4- 4-(1H-Pyrazol-3-yl)phenoxy!butaneamine
A suspension of 21.2 g of (E)-2- 4- 4- 3-(dimethylamino)-1-oxo-2-propenyl!phenoxy!butyl!-1H-isoindole-1,3(2H)-dione (Example 48) in 300 ml of boiling ethanol is treated with 6 ml of anhydrous hydrazine. A suspension quickly develops, necessitating addition of 200 ml more ethanol to permit stirring. While stirring 35 ml of concentrated HCl is then added, the mixture refluxed a further hour, and filtered hot. The insolubles are washed with 200 ml of boiling water. The combined filtrates are taken to dryness in vacuo, leaving the hydrochloride salt of the title compound as shown by mass spectrometry. The product is utilized for synthesis without further purification.
EXAMPLE 50
4-Bromo-N- 4- 4-(1H-pyrazol-3-yl)phenoxy!butyl!benzenesulfonamide
The title compound is prepared essentially by the procedure of Example 40, 4- 4-(1H-pyrazol-3-yl)phenoxy!butaneamine hydrochloride (Example 49) replacing the 4- 4-(1H-tetrazol-1-yl)phenoxy!butane amine hydrochloride. The resulting compound is recrystallized from 50% aqueous ethanol, m.p. 157°-158° C.
EXAMPLE 51
2- 4-(4-Cyanophenoxy)butyl!-1H-isoindole-1,3(2H)-dione
The title compound is prepared essentially by the procedure of Example 33, 4-hydroxybenzonitrile replacing the 4-nitrophenol. The resulting solid is collected, m.p. 129°-130° C.
EXAMPLE 52
4-(4-Aminobutoxy)benzonitrile
A suspension of 48.0 g of 2- 4-(4-cyano-phenoxy)butyl!-1H-isoindole-1,3(2H)-dione (Example 51) in one liter of refluxing ethanol is treated with 10 ml of anhydrous hydrazine. The mixture is stirred at reflux for 14 hours. After cooling to room temperature, the precipitate is filtered off and washed with 100 ml of ethanol. The ethanol filtrates are combined and taken to dryness in vacuo. The oil is dissolved in 100 ml of ethanol containing 15 ml of concentrated hydrochloric acid. Concentration of the solution in vacuo gives the crude hydrochloride salt of the tide compound, purified by recrystallization from ethanol; m.p. 144°-145° C.; yield, 7.2 g.
EXAMPLE 53
4-Methyl-N- 4-(4-cyanophenyloxy)butyl!benzenesulfonamide
A solution of 3.4 g of 4-(4-aminobutoxy)benzonitrile hydrochloride (Example 52) is in 100 ml of water is treated successively with 3.5 ml of 10N NaOH and 3.5 g of 4-methylphenylsulfonyl chloride in 100 ml of diethyl ether. The mixture is stirred at room temperature for two hours, a precipitate forming. The solid is collected, washed with water and diethyl ether, dried, and recrystallized from 50% aqueous ethanol; m.p. 107°-108° C.; yield, 3.5 g.
EXAMPLE 54
4-Methyl-N- 4- 4-(1H-tetrazol-5-yl)phenoxy!butyl!benzenesulfonamide
A mixture of 3.4 g of 4-methyl-N- 4-(4-cyanophenoxy)butyl!benzenesulfonamlde (Example 53), 1.3 g of sodium azide, 1.5 g of ammonium chloride, and 25 ml of dimethylformamide is stirred at 120°-130° C. (oil bath) for 16 hours. The reaction mixture is added to 200 ml of water and the resultant solution then acidified to pH 4-5 with acetic acid. The precipitate that forms is collected, washed with water, dried and recrystallized from boiling ethanol. Cooling gives the pure compound, m.p. 180°-182° C.; yield, 2.4 g.
EXAMPLE 55
4-Methyl-N- 4-(4-(thiocarbamylphenoxy)butyl!benzenesulfonanide
A solution of 3.5 g of 4-methyl-N- 4-(4-cyanophenoxy)butyl!benzenesulfonamide (Example 53) in a mixture of 30 ml of pyridine and 5 ml of triethylamine is gassed with a slow stream of hydrogen sulfide for 30 minutes and placed in a stoppered flask. After 7 days, the volatile components are removed in vacuo. The oily residue is recrystallized from 50% aqueous ethanol, yielding the pure compound as yellow crystals, m.p. 140°-141° C.; yield, 3.0 g.
EXAMPLE 56
N-Dimethylaminomethylidene-4- (4-methyl!phenyl-sulfonamido)butyoxy!thiobenzamide
3.6 g of 4-methyl-N- 4-(4-thiocarbamyl-phenoxy)butyl!benzenesulfonamide is added to 30 ml of dimethylformamide dimethylacetal, and the mixture is stirred at room temperature for one hour. The precipitate is collected, washed with diethyl ether, and dried in vacuo at 40° C. The yield of title compound is 3.9 g; m.p. 115°-117° C.
EXAMPLE 57
4-Methyl-N- 4- 4- (4-chlorophenyl)thiazol-2-yl!phenoxy!butyl!benzenesulfonamide
A solution of 1.5 g of 2-bromo-1-(4-chlorophenyl)ethanone and 2.5 g of 4-methyl-N- 4- 4-(thiocarbamylphenoxy!butyl!benzenesulfonamide Example 55) in 100 ml of ethanol is stirred at reflux for 17 hours. Cooling the solution gives a precipitate which is collected, washed with ethanol and dried. The precipitate is slurried in 200 ml of saturated NaHCO 3 solution for 30 minutes. The insolubles are collected, washed with water, and dried. Recrystallization from ethanol gives the pure compound, m.p. 158°-159° C.; yield, 2.2 g.
EXAMPLE 58
2- 4-(4-Phenylphenoxy)butyl!-1H-isoindole-1,3(2H)-dione
The subject compound is prepared by the procedure of Example 33, 4-phenylphenol replacing the 4-nitrophenol. The resulting solid is collected, m.p. 110°-111° C.
EXAMPLE 59
4-(4-Phenylphenoxy)butaneamine
The title compound is prepared essentially by the procedure of Example 34, 2- 4-(4-phenylphenoxy)-butyl!-1H-isoindole-1,3(2H)-dione (Example 58) replacing the 2- 4-(4-nitrophenoxy)butyl!-1H-isoindole-1,3(2H)-dione. The crude isolated hydrochloride salt has the expected molecular weight as shown by mass spectrometry, and is utilized directly in further synthesis.
EXAMPLE 60
4-Methyl-N- 4-(4-(phenylphenoxy)butyl!benzenesulfonamide
The subject compound is prepared essentially by the procedure of Example 35, 4-(4-phenylphenoxy)butaneamine hydrochloride replacing the 4- 4-nitro-phenoxy)butaneanine hydrochloride. After recrystallization from 50% aqueous ethanol, the pure compound is obtained as a solid, m.p. 119°-120° C.
EXAMPLE 61
2- 4-(4-Phenylcarbonylphenoxy)butyl!-1H-isoindole-1,3(2H)-dione
The subject compound is prepared essentially by the procedure of Example 33, (4-hydroxyphenyl)phenylmethanone replacing the 4-nitrophenol. Recrystallization of the crude product from methanol gives white crystals, m.p. at 53°-55° C.
EXAMPLE 62
4- (4-Phenylcarbonylphenoxy!butaneamine
The hydrochloride salt of the title compound is prepared essentially by the procedure of Example 34, 2- 4-(4-phenylcarbonyl-phenoxy)butyl!-1H-isoindole-1,3(2H)-dione (Example 61) replacing the 2- 4-(4-nitrophenoxy)butyl!-1H-isoindole-1,3(2H)-dione. The resulting solid is collected, m.p. 188°-190° C.
EXAMPLE 63
4-Bromo-N- 4-(4-phenylcarbonylphenoxy)butyl!benzenesulfonamide
To a solution of 2.0 g of 4- (4-phenylcarbonylphenoxy!butaneamine hydrochloride (example 62) in a mixture of 40 ml of pyridine and 3 ml of triethylamine is added 2.0 g of 4-bromobenzenesulfonyl chloride. The reaction mixture is stirred at room temperature for 18 hours, heated on the steam bath for one hour, and then added to 250 ml of water. Cooling at 0° C. gives an oil which is dissolved in 100 ml of dichloromethane. Addition of 150 ml of hexane is followed by concentration to turbidity (steam bath), and the mixture cooled at -10° C. An oily solid is precipitated and fine white crystals are produced in the supernatant solvent. These are carefully separated and dried; m.p. 71°-73° C.; recovery, 0.2 g.
EXAMPLE 64
3-Chloro-N- 4-(4-phenylcarbonylphenoxy)butyl!benzenesulfonamide
The tide compound is prepared essentially by the procedure of Example 53 with 3-chlorophenylsulfonyl chloride replacing the 4-methylphenylsulfonyl chloride to give the desired product.
EXAMPLE 65
2- 10- 4-(1H-Imidazol-1-yl)phenoxy!decyl!-1H-isoindole-1,3(2H)-dione
The title compound is prepared essentially by the procedure of Example 1, 2-(10-bromodecyl)-1H-isoindole-1,3(2H)-dione replacing the 4bromobutyl intermediate. After recrystallization from dichloromethane-hexane, the desired compound is collected, m.p. 90°-91° C.
EXAMPLE 66
10- 4-(1H-Imidazol-1-yl)phenoxy!decaneamine
2- 10- 4-(1H-imidazol-1-yl)phenoxy!decyl!-1H-isoindole-1,3(2H)-dione (Example 65) is converted to the free amino derivative by treatment with hydrazine in a refluxing ethanol solution. A portion is converted to its dihydrochloride salt by treatment with concentrated hydrochloric acid in ethanol to give the desired compound, m.p. 190°-192° C. The free base is obtained by treatment with excess 10N NaOH.
EXAMPLE 67
N- 10- 4-(1H-Imidazol-1-yl)phenoxy!decyl!-2-naphthalenesulfonamide
A suspension of 2.5 g of 10- 4-(1H-imidazol-1-yl)phenoxy!decaneamine (Example 66) in 250 ml of diethyl ether containing 3 ml of triethylamine is stirred while 2.0 g of 2-naphthalenesulfonylchloride is added. The reaction mixture is stirred at room temperature for 72 hours and 50 ml of H 2 O added. The solvents are decanted, leaving a viscous solid. The solid is dissolved in 100 ml of 50% aqueous ethanol. Careful concentration under a gentle stream of air gives a crystalline solid. The solid is collected washed with water and dried in vacuo at room temperature; m.p. 112°-115° C.; yield, 0.2 g.
EXAMPLE 68
4-Methyl-N- 4-(4-methanesulfonamido)phenyloxy)butyl!benzenesulfonamide
A solution of 3.2 g of 4-methyl-N- 4-(4-aminophenyl-oxy)butyl!benzenesulfonamide (Example 36) in 50 ml of pyridine is stirred and treated with 1.5 g of methanesulfonyl chloride. The reaction mixture is stirred and heated on the steam bath for 4 hours, and then taken to dryness in vacuo. The residue is stirred with 50 ml of water and acidified to pH <2 with concentrated hydrochloric acid. The precipitate is collected, washed with water, and air dried. Recrystallization from 50% aqueous ethanol, followed by cooling at -10° C. gives 2.0 g of the desired compound, m.p. 121°-122° C. Concentration of the mother liquor gives an additional 0.4 g of product.
EXAMPLE 69
2- 4-(4-Acetamido)phenylthio!butyl-1H-isoindole-1,32-(2H)-dione
To a solution of 5.6 g of 95% sodium methoxide in 400 ml of ethanol is added 16.7 g of 4-acetaniido-benzenethiol and the mixture stirred at room temperature for 15 minutes while 28.2 g of 2-(4-bromobutyl)-1H-isoindole-1,3(2H)-dione is added. The reaction mixture is stirred and heated under reflux for 6 hours and 100 ml of water added. The solution is concentrated to about a 250 ml volume, and stirred at room temperature overnight. The precipitate present is collected, washed with water and air dried. Recrystallization from 50% aqueous ethanol gives the desired product, m.p. 113°-114° C.; yield 33.0 g.
EXAMPLE 70
4- 4-(Acetaindo)phenylthio!butaneamine
To a solution of 26.0 g of 2- 4-(4-acetamidophenylthio)butyl!-1H-isoindole-1,3(2H)-dione (Example 69) in 500 ml of boiling ethanol is added 4 ml of anhydrous hydrazine and refluxing continued for 20 hours. After cooling to room temperature, the precipitate present is collected and washed with 100 ml of ethanol. The ethanolic filtrate is taken to dryness in vacuo. The viscous oily residue is shaken with 200 ml of 1N hydrochloric acid and the insolubles are filtered off. The filtrate is rendered alkaline with 10N sodium hydroxide to give an oil which crystallizes when the mixture is cooled to 0° C. The crystals are collected, washed with cold water, and air dried; yield, 13.3 g. Mass spectroscopy of the product gives a molecular weight of 238, consistent with that expected for 4- 4-(acetamidophenylthio!butaneamine. Treatment with concentrated hydrochloride in ethanol solution gives the hydrochloride salt, m.p. 167°-169° C.
EXAMPLE 71
4-Methyl-N- 4- 4-(acetamido)phenylthio!butyl!benzenesulfonamide
To a solution of 7.2 g of 4- 4-(acetamido)phenylthio!butaneamine (Example 70) in 100 ml of dichloromethane containing 8 ml of triethylamine is added 6.2 g of 4-methylbenzenesulfonyl chloride. The mixture is then stirred under reflux for six hours. The solvents are removed in vacuo. The residue is triturated with 2 portions of 100 ml of water. The insoluble portion is recrystallized from aqueous ethanol. Initially, the product precipitates as an oil, but after standing, crystals are obtained, m.p. 104°-105° C.; yield, 6.6 g.
EXAMPLE 72
4-Methyl-N- 4-(4-ainnophenylthio)butyl!benzenesulfonamide
A mixture of 5.3 g of 4methyl-N- 4-(4-acetamidophenylthio)butyl!benzenesulfonamide, (Example 71) 25 ml of concentrated hydrochloric acid, and 100 ml of ethanol are combined and stirred under reflux for 20 hours. The reaction mixture is taken to dryness in vacuo. The residue is shaken with 200 ml of water and rendered alkaline to pH>14 with 10N sodium hydroxide. The resultant precipitate is collected, washed with water, and dried, 140°-142° C.; yield 2.8 g.
EXAMPLE 73
4-Methyl-N- 4-(4-methanesulfonamidophenylthio)butyl!benzenesulfonamide
A solution of 2.4 g of 4-methyl-N- 4-(4-aminophenylthio)butyl!benzenesulfonamide (Example 72) in 50 ml of pyridine is treated with 1.05 g of methane-sulfonyl chloride, and the solution stirred and heated on the steam bath for 6 hours. The pyridine is then removed in vacuo. The residue is shaken with 100 ml of water, and the mixture acidified below pH=2 with concentrated hydrochloric acid. The precipitate is collected, washed with water and dried. Recrystallization from 50% aqueous ethanol gives shiny white crystals after drying, m.p. 95°-96° C.; yield, 1.2 g.
EXAMPLE 74
4-Methyl-N- 4-(4-acetamidophenylsulfonyl)butyl!benzenesulfonamide
A solution of 2.0 g of 4-methyl-N- 4-(4-acetamidophenyl-thio)butyl!benzenesulfonamide (Example 71) in 100 ml of acetic acid is heated at 90°-95° C. After addition of 10 ml of 30% hydrogen peroxide, the mixture is stirred at steam bath temperature for 16 hours. Dilution with 300 ml of cold water produces an oily precipitate which is collected on a diatomaceous earth filter pad. Extraction of the filter pad with 250 ml of boiling acetone, followed by concentration to dryness in vacuo gives an oily residue. Recrystallization from 50% aqueous ethanol gives the desired compound, m.p. 93°-95° C.; yield, 0.3 g.
EXAMPLE 75
4-Methyl-N- 4- 4-(pyrrol-1-yl)phenyloxy!butyl!benzenesulfonamide
A mixture of 3.2 g of 4-methyl-N- 4-(4-aminophenyl-oxy)butyl!benzenesulfonamide (Example 36), 1.5 g of 2,5-dimethoxytetrahydrofuran, and 50 ml of acetic acid is stirred and heated on the steam bath for 16 hours. The reaction mixture is taken to dryness in vacuo. The residue is shaken with 150 ml of dichloromethane and 150 ml of saturated sodium bicarbonate solution. The dichloromethane layer is separated, dried over Na 2 SO 4 , and diluted with 100 ml of hexane. The solution is concentrated until turbid, then cooled at -10° C. The precipitate that forms is collected, washed with hexane, and air dried; m.p. 124°-126° C.; yield, 0.2 g.
EXAMPLE 76
4-Chloro-N- 4- 4-(1H-imidazol-1-yl)phenyloxy!butyl!benzamide
A solution of 2.8 g of 4- 4-(1H-imidazol-1-yl)phenoxy!butylamine hydrochloride (Example 2) in 50 ml of water is treated successively with 4 ml of 10N NaOH and 2.0 g of 4-chlorobenzoyl chloride in 100 ml of diethyl ether. Stirring at room temperature for 3 hours gives a precipitate which is collected, washed with diethylether and water, and air dried. Recrystallization from 33% aqueous ethanol gives the desired product, m.p. 138°-139° C.; yield, 1.3 g.
EXAMPLE 77
4-Bromo-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
The tide compound is prepared essentially by the procedure of Example 76, 4-bromobenzoyl chloride replacing the 4-chlorobenzoyl chloride; m.p. 140°-141° C.
EXAMPLE 78
2-Bromo-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
The title compound is prepared by the procedure of Example 76, 2-bromobenzoyl chloride replacing the 4-chlorobenzoyl chloride. Recrystallization from 50% aqueous methanol gives the desired product, m.p. 138°-139° C.
EXAMPLE 79
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!benzamide
The title compound is prepared by the procedure of Example 76, benzoyl chloride replacing the 4-chlorobenzoyl chloride. After recrystallization from 33% aqueous ethanol, the compound has m.p. of 117°-118° C.
EXAMPLE 80
4-Methyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
4- 4-(1H-Imidazol-1-yl)phenoxy!butaneamine dihydrochloride (Example 2) is treated with 10N NaOH (mixture pH >12). The oil present is extracted with dichloromethane. Removal of the dichloromethane in vacuo gives the 4- 4-(1H-imidazol-1-yl)phenoxy!butanearnine as a viscous oil which is used directly for further synthesis. A solution of 2.3 g of 4- 4-(1H-imidazol-1-yl)phenoxy!butaneamine in 25 ml of pyridine is treated with 1.8 g of 4-methylbenzoyl chloride. After heating at steam bath temperature for one hour, the reaction mixture is added to 400 ml of water precipitating a viscous oil. The aqueous phase is decanted. A solution of the oil in 200 ml of hot 50% aqueous methanol, followed by cooling at -10° C. gives a tacky precipitate, but a white crystalline precipitate develops in the supernatant solvent. The crystals are carefully collected, washed with cold H 2 O and dried in vacuo at room temperature, m.p. 128°-130° C.; yield, 0.7 g.
EXAMPLE 81
4-Methoxy-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
A solution of 2.3 g of 4- 4-(1H-imidazol-1-yl)phenoxy!butaneamine (Example 2) in 50 ml of dichloromethane containing 2 ml of pyridine is treated with 2.0 g of 4-methoxybenzoyl chloride. The reaction mixture is allowed to stand at room temperature for 18 hours, and is then heated at reflux for one hour. The volatiles are removed in vacuo. The residue is partitioned between 100 ml of dichloromethane and 100 ml of water. The dichloromethane layer is dried over Na 2 SO 4 , and then heated to gentle boiling. Hexane is then added to turbidity and the mixture cooled at -10° C. A tacky precipitate results and crystals develop in the supernatant solvent. These are collected, washed with hexane, and dried in vacuo at room temperature; m.p. 125°-126° C.; yield, 0.4 g.
EXAMPLE 82
N- 4- 4-(1H-Imidazol-1-yl)phenoxy!butyl!-1-naphthalenecarboxamide.
The preparation of the title compound is carried out essentially in the procedure of Example 81, 1-naphthoyl chlorine replacing the 4-methoxybenzoylchloride. After removal of the volatiles, the residue is treated with 100 ml of 1N NaOH and 100 ml of diethyl ether, and mixture then cooled at 0° C. overnight. The precipitate is collected and recrystallized from 50% aqueous ethanol and dried; m.p.157°-159° C.
EXAMPLE 83
4-Fluoro-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
The title compound is prepared essentially by the procedure of Example 81, 4-fluorobenzoyl chloride replacing the 4-methoxybenzoylchloride. The crude product is recrystallized from diethyl ether and dried m.p. 122°-123° C.
EXAMPLE 84
4-Iodo-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
The title compound is prepared essentially by the procedure of Example 76, 4-iodobenzoyl chloride replacing the 4-chlorobenzoyl chloride. The pure compound is obtained after recrystallization from 50% aqueous ethanol, m.p. 143°-145° C.
EXAMPLE 85
N-(4-Bromophenyl)-N'- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!urea
Solutions of 4- (4-(imidazol-1-yl)-phenoxy!-butaneamine (Example 2) in diethyl ether (1.6 g in 400 ml) and 4-bromophenylisocyanate in diethyl ether (1.4 g in 100 ml) are mixed. A white precipitate forms immediately. After 30 minutes, the title compound is collected, washed with diethyl ether, and dried m.p. 157°-159° C.; yield, 1.7 g.
EXAMPLE 86
4-Bromo-N- 5- 4-(1H-imidazol-1-yl)phenoxy!pentyl!benzamide
A solution of 2.9 g of 5- 4-(1H-imidazol-1-yl)phenoxy!pentaneamine (Example 27) in 150 ml of dichloromethane and 100 ml 1N NaOH are combined and stirred vigorously as 2.8 g of 4-bromobenzoyl chloride is added. The reaction mixture is stirred at room temperature for 20 hours, the dichloromethane layer separated and dried over Na 2 SO 4 . The dichloromethane solution is diluted with 200 ml of hexane, and the solution concentrated to turbidity. Cooling the mixture at room temperature gives the desired product as white crystals, m.p. 150°-151° C.; yield, 1.4 g.
EXAMPLE 87
O,O'-Diphenyl-N- 4- 4-(1H-imidazol-1-yl)phenyloxy!butyl!phosphoramide
A solution of 3.0 grams of 4- 4-(1H-imidazol-1-yl)phenoxy!butaneamine hydrochloride (Example 2) in 100 ml of water is stirred and treated with 3.3 ml of 10N sodium hydroxide. A solution of 2.9 g of O,O', diphenylphosphoryl chloride in 100 ml of diethyl ether is added, and the mixture stirred at room temperature for six hours. The diethyl ether is removed in a stream of air, leaving a viscous solid in the aqueous phase. The mixture is cooled to 0° C., and the water decanted. The solid is dissolved in 100 ml of ethyl acetate and the solution then dried over Na 2 SO 4 . The ethyl acetate solution is cooled to 0° C. and diluted with 300 ml of hexane. Cooling at -10° C. leads to the formation of a precipitate which is collected, washed with hexane, and dried in vacuo at 40° C. to give 1.5 g of the title compound, m.p. 110°-112° C.
EXAMPLE 88
P,P-Diphenyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!phosphinamide
A mixture consisting of 3.0 g of 4- 4-(1H-imidazol-1-yl)phenoxy!butanearine dihydrochloride (Example 2) is triturated with 3.5 ml of 10N sodium hydroxide. To the mixture is added 150 ml of methylene chloride followed by 20 g of sodium sulfate. After stirring for 25 minutes, the solids are removed by filtration. To the filtrate are added, with stirring, 3 ml of triethylamine and then 2 ml of diphenylphosphinic chloride. The reaction mixture is stirred at room temperature for 2 hours, washed with 100 ml of water and dried over sodium sulfate. Removal of the methylene chloride in vacuo leaves a viscous oil which crystallizes on stirling with 25 ml of diethyl ether. The precipitate is collected, washed with 75 ml of diethyl ether, and dried in vacuo at room temperature. The melting pointis 106°-107° C.
EXAMPLE 89
N- 4- 4-(1H-Tetrazol-1-yl)phenoxy!butyl!-2,1,3-benzothiadiazole-4-sulfonamide
A mixture consisting of 0.9 g of 4- 4(1H-tetrazol-1-yl)phenoxy!butaneamine hydrochloride (Example 39) and 1 ml of 10N sodium hydroxide is stirred until all solid has disappeared. The suspension is stirred with 150 ml of dichloromethane and 7 g of anhydrous sodium sulfate for 30 minutes. The insolubles are removed by filtration. The filtrate is then treated with 1.5 ml of triethylamine followed by a solution of 0.93 g of 2,1,3-benzothiadiazole-4-sulfonyl chloride in 25 ml of dichloromethane. The reaction mixture is stirred at room temperature for 16 hours. It is then washed with an equal volume of water. After drying with anhydrous Na 2 SO 4 , the dichloromethane is removed in vacuo, leaving a yellow solid. Recrystallization from a mixture of dichloromethane/diethyl ether gives 0.7 g of pure product, m.p. 142°-143° C.
EXAMPLE 90
3-Bromo-N- 4- 4-(1H-imidazol-1-yl)phenoxy!butyl!benzamide
The title compound is prepared by the procedure of Example 76, 3-bromobenzoyl chloride replacing the 4-chlorobenzoyl chloride. Recrystallization from methanol gives the desired product, m.p. 89°-91° C.
EXAMPLE 91
2- 3- 4-(1H-Imidazol-1-yl)phenoxy!proply!-1H-isoindole-1,3(2H)-dione
To 100 ml of absolute ethyl alcohol is added 1.01 g of sodium followed by stirring for 30 minutes and adding 10.7 g of N-(3-bromopropyl)phthalimide. After refluxing for 4 hours, the mixture is cooled to room temperature, methylene chloride added and filtered to remove insolubles. The filtrate is dried (MgSO 4 ) and evaporated in vacuo to give 13.5 g of residue. A sample is crystallized from ethyl alcohol to give tan solid, m.p. 113°-117° C.
EXAMPLE 92
3- 4-(1H-Imidazol-1-yl)phenoxy!propanamine
A mixture of 17.0 g of 2- 3- 4-(1H-imidazol-1-yl)phenoxy!propyl!-1H-isoindole-1,3(2H)-dione (Example 91) and 2.8 ml of hydrazine hydrate in 150 ml of ethyl alcohol is refluxed for 3 hours. The reaction mixture is cooled and 225 ml of 3N HCl added followed by refluxing for 2 hours and standing at room temperature for 18 hours. The reaction mixture is filtered and the filtrate evaporated in vacuo to a residue which is washed with ethyl alcohol and ether, dried in a vacuum oven to give 12.0 g of the dihydrochloride salt of the title compound as a tan solid, m.p. 208°-220° C.
EXAMPLE 93
4-Bromo-N- 3- 4-(1H-imidazol-1-yl)phenoxy!propyl!benzamide
A mixture of 2.04 g of 3- 4-(1H-imidazol-1-yl)phenoxy!propanamine dihydrochloride (Example 92) in 70 ml of methylene chloride is treated with 21 ml of 1N NaOH followed by 1.54 g of 4-bromobenzoyl chloride with stirring at room temperature for 18 hours. Additional methylene chloride and 5 ml of 1N NaOH is added and the organic layer separated, washed with water and filtered. The organic layer is evaporated in vacuo to a residue which is washed with ether and dried to give 1.3 g of off-white solid, m.p. 183°-185° C.
EXAMPLE 94
N- 4- 3-(1,3-Dihydro-1,3-dioxo-2H-isoindol-2-yl)propoxy!phenyl!acetamide
To a solution of 15.1 g of 4-acetanidophenol is 150 ml of N,N-dimethylformamide is added 4.0 g of 60% sodium hydride in mineral oil followed by stirring until gas evolution ceases. A 26.8 g portion of N-(3-bromopropyl)phthalimide is added and the reaction mixture heated on a steam bath for 16 hours. The reaction mixture is poured into 1 liter of cold water and the resulting solid collected and washed with 1 liter of cold water and the solid vacuum dried. A 5 g sample is crystallized from 25 ml of ethanol to give 1.5 g of solid, m.p. 155°-157° C. The remaining sample is crystallized from ethanol to give 23.4 g of solid, m.p. 154°-156° C.
EXAMPLE 95
2- 3-(4-Aminophenoxy)propyl!-1H-isoindole-1,3(2H)-dione
A solution of 10.0 g of N- 4- 3-(1,3-dihydro-1,3-dioxo-2H-isoindol-2-yl)propoxy!phenyl!acetamide (Example 94) in 500 ml of ethanol is treated with 100 ml of HCl and refluxed for 8 hours and allowed to stand at room temperature for 18 hours. The precipitate is collected, washed with 50 ml of ethanol and air dried to give 8.6 g of solid as the hydrochloride salt. A 1.5 g sample is crystallized from ethanol: water to give 1.2 g of the HCl salt of the title compound, m.p. 250°-260° C.
EXAMPLE 96
N- 4- 3-(1,3-Dihydro-1,3-dioxo-2H-isoindol-2-yl)propoxy!phenyl!methanesulfonamide
A 7.0 g sample of 2- 3-(4-aminophenoxy)-propyl!-1H-isoindole-1,3(2H)-dione monohydrochloride (Example 95) is added to 100 ml of pyridine, 2.2 ml of 10N NaOH and 2.5 g methanesulfonyl chloride. The mixture is stirred at room temperature for 6 hours and 1 hour on a steam bath. The reaction mixture is poured into 900 ml of cold water and stored at 0° C. for 18 hours. The precipitate is collected, washed with 200 ml of water and dried to give 6.5 g of solid. A 1.0 g sample is crystallized from 100 ml of boiling ethanol after treatment with activated carbon to give 0.6 g of solid, m.p. 176°-178° C.
EXAMPLE 97
3- 4-(Methanesulfonylamino)phenoxy!propaneamine
A suspension of 5.5 g of N- 4- 3-(1,3-dihydro-1,3-dioxo-2H-isoindol-2-yl)propoxy!phenyl!methanesulfonamide in 200 ml of ethanol is treated with 1.5 ml of hydrazine hydrate and the mixture stirred and refluxed for 6 hours. A precipitate forms in 1 hour. After 6 hours, 5 ml of HCl is added and the mixture refluxed for 1 hour and allowed to stand at room temperature for 18 hours. The precipitate is collected, stirred with 50 ml of hot water and the insolubles washed with 50 ml of water. The combined water washes are evaporated in vacuo to a dry residue. The residue is dissolved in 100 ml of saturated sodium bicarbonate, treated with activated carbon, filtered and the filtrate acidified with acetic acid and concentrated in vacuo to 100 ml. The precipitate is collected, washed with 25 ml of cold water and dried to give a solid, m.p. 200° C.
EXAMPLE 98
4-Bromo-N- 3- 4-(methylsulfonylamino)phenoxy!propyl!benzamide
A 1.6 g sample of Example 97, 4- 4-(methanesulfonylamino)-phenoxy!propaneamine is dissolved in 50 ml of water and 3 ml of 100N NaOH. While stirring, a solution of 1.7 g of 4-bromobenzoyl chloride in 100 ml of diethyl ether is added. After stirring for 5 hours, a precipitate forms and 2 ml of acetic acid is added. The precipitate is collected, washed with 50 ml of water and air dried to a residue(A). The filtrate is air evaporated to a residue(B). Residue A is crystallized from ethanol:water to give 1.1 g of solid, m.p. 209°-210° C. Residue B is crystallized from ethanol: water to give 0.4 g of solid, m.p. 208°-209° C.
EXAMPLE 99
4Methyl-N- 4- 4-(1H-imidazol-1-yl)phenoxy!-2-butyn-1-yl!benzenesulfonamide
Following the procedures of Examples 30, 31, and 32 and substituting 1,4-dichloro-2-butyne for (E)-1,4-dichloro-2-butene in the procedure of example 30, the title compound is obtained.
PHARMACOLOGY
1. Action Potential Duration Prolongation Test Description
Preparation of Cardiac Muscle
Male Hartley guinea-pigs (Charles River, N.Y.) weighing between 120 and 160 grams are anesthetized intraperitoneally with Pentothal. After thoracotomy, the heart is removed and immediately placed in oxygenated (100% O 2 ) Tyrode's-HEPES solution of the following composition: NaCl 140.0 mM, KCl 4.0 mM, MgCl 2 1.0 mM, CaCl 2 1.8 mM, Glucose 10.0 mM, and HEPES pH 7.4, 5.0 mM. Thin (less than 1 mm) papillary muscle is excised from the right ventricle and mounted in a 1.5 ml plexiglas chamber (BSC chamber, Medical Systems Corp., Greenvale, N.Y.). The chamber is constantly perfused at a rate of 2.5 ml/min. with oxygenated Tyrode's-HEPES solution at a constant temperature of 37° C.
Measurements of transmembrane action potentials
The stimulating and recording electronics is assembled from Digitimer Neurolog modules (Medical Systems Corp., Greenvale, N.Y.). The isolated papillary muscle is held in place by a bipolar platinum stimulating electrode, which is connected to a Neurolog NL800 Stimulus Isolation Unit. The pair of platinum wires is insulated with teflon except at the tips, and the interelectrode distance is less than 1 mm. Electrical stimulation of the muscle is done with pulses of 1 millisecond in duration delivered from a Neurolog NL510 Pulse Buffer according to signals generated by Neurolog NL304 Period Generator and NL403 Delay-Width units. The stimulus threshold is determined during experiments before drug perfusion and the intensity of the current pulse is set 1.5 times the threshold. The preparation is paced at 0.5 Hz for at least 1 hour for equilibration before measurements are made. Transmembrane action potentials are intracellularly recorded with 3M KCl-filled glass capillary microelectrodes (Dagan Corp., Minneapolis, Minn.), with tip diameters <1 μm and impedances of 20-50 Meghoms. A single impalement is maintained throughout control and drug-superfusing periods. A silver-silver chloride electrode in the bath serves as reference. Signals are amplified with Neurolog NL102 DC PreAmp and NL106 AC-DC Amplifier and displayed on a Tektronix 5110 oscilloscope. Action potentials are plotted on- line by a Hewlett-Packard 7475-A plotter. Signals are also fed to DATA 6100 Universal Waveform Analyzer (Data Precision, Danvers, Mass.) for on-line analyses of action potential waveforms. Experimental timing signals, initialization of DATA 6100, acquisition of analyzed data from DATA 6100, and plotting functions are under the control of custom software which is run on an IBM-AT microcomputer. Action potential parameters computed with DATA 6100 are: maximum upstroke velocity (max dV/dT), action potential amplitude (APA), resting membrane potential (RMP), and action potential duration at 25% (APD25), 50% (APD50), and 90% (APD90) repolarization.
The current series of compounds produced a minimum of 5% increase in action potential duration prolongation using the test conditions described above.
2. Significance of Data
Class III anti-arrhythmic agents prolong the cardiac action potential duration by blocking cardiac potassium channels. This prolongation of the action potential duration causes a prolongation of cardiac tissue refractoriness, namely, a delay in the recovery of tissue from inexcitability. When a re-entrant impulse meets an inexcitable tissue, the impulse is terminated and the arrhythmia disappears. Agents capable of eliciting this effect would be useful in circumventing sudden death due to ventricular tachycardia and fibrillation, the most lethal cardiac disorder which kills almost half a million Americans annually.
Class III anti-arrhythmic agents may also be effective against atrial fibrillation, a condition that afflicts millions of elderly. One unique feature of this class of compounds is the lack of excessive prolongation of the cardiac action potential at slow rhythms. This finding suggests that the compounds would show lesser proarrhythmic tendencies, particularly the type known as "Torsades de Pointes." The existing anti-arrhythmic agents show this pro-arrhythmic tendency.
As potassium channel blockers, the compounds can find other usefulness as memory-enhancers in Alzheimer's disease, neurotransmitter release in depression and insulin release in diabetes.
TABLE I______________________________________ % ACTION POTENTIAL DURATION (APD) 10 μM DrugEXAMPLE NO. 60 Min______________________________________ 3 18.2 4 19.9 5 2.4 6 8 7 35.6 9 11.410 23.110 16.611 16.612 12.913 9.414 13.615 28.716 7.817 18.718 11.619 6.622 14.524 7.325 428 22.232 23.436 3.240 27.641 17.544 3.447 13.350 3.553 11.267 9.168 7.476 -1.377 10.178 6.783 11.584 11.386 2.587 14.390 9.693 4.398 5.3______________________________________
When the compounds, or where applicable as a pharmaceutically acceptable salt, are ties, they may be combined with one or more pharmaceutically acceptable carriers, for example, solvents, diluents and the like, and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs containing, for example, from about 20 to 50% ethanol, and the like, or parenterally in the form of sterile injectable solutions or suspensions containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 25 to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration and the severity of the condition being treated. However, in general, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 0.5 to about 500 mg/kg of animal body weight, preferably given in divided doses two to four times a day, or in a sustained release form. For most large mammals the total daily dosage is from about 1 to 100 mg, preferably from about 2 to 80 mg. Dosage fonns suitable for internal use comprise from about 0.5 to 500 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
These active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of phannaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin E, ascorbic acid, BHT and BHA.
The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hard-filled or liquid-filled capsules. Oral administration of the compounds is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid, polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exits. It must be stable under conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacterial and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oil.
In particular, the antiairhythmlc compounds of this invention are therapeutically useful in the treatment and as a viable therapeutic strategy for the management of ventricular arrhythmias and the prevention of sudden cardiac death. | The present invention relates to substituted ω- phenoxy, phenylthio, phenylsulfinyl, phenylsulfonyl! alkyl, alkenyl or alkynyl!amine carboxamides, sulfonamides and phosphonylamides which are useful as antiarrhythmic agents. | 2 |
FIELD OF THE INVENTION
[0001] This invention is concerned with compositions, in particular pharmaceutical compositions containing the 1-acetoxyethyl ester of cefuroxime, which has the approved name ‘cefuroxime axetil’.
BACKGROUND TO THE INVENTION
[0002] Cefuroxime, as disclosed in British Patent Specification No. 1453049, is a valuable broad spectrum antibiotic characterised by high activity against a wide range of gram-positive and gram-negative micro-organisms, this property being enhanced by the very high stability of the compound to β-lactamases produced by a range of gram negative micro-organisms. Cefuroxime and its salts are principally of value as injectable antibiotics since they are poorly absorbed from the gastro-intestinal tract.
[0003] Esterification of the carboxyl group of cefuroxime as a 1-acetoxyethyl ester to give cefuroxime axetil improves the effectiveness on oral administration as disclosed in British Patent Specification No. 1571683. The presence of the 1-acetoxyethyl esterifying group results in significant absorption of the compound from the gastrointestinal tract, whereupon the esterifying group is hydrolysed by enzymes present in, for example, serum and body tissues to yield the antibiotically active acid. It is particularly advantageous to employ cefuroxime axetil in an amorphous form as disclosed in British Patent Specification No. 2127401.
[0004] A convenient means of presenting antibiotics for oral administration is in the form of granules which may be administered as a solution or suspension or taken with a draught of water. Solutions or suspensions of granules as, for example, a syrup are particularly convenient for oral administration of antibiotics to children. However, cefuroxime axetil has an extremely bitter taste which is long lasting and which cannot be adequately masked by the addition of sweeteners and flavours to conventional granule presentations.
[0005] Another problem arises from the tendency of cefuroxime axetil, both in crystalline form and the amorphous form to form a gelatinous mass when contacted with aqueous media. This gelling effect is temperature dependent but does occur at temperatures of about 37° C., i.e. at the physiological temperatures at which the disintegration of an orally administered granule would take place. Where there is a relatively slow dispersion of cefuroxime axetil into the surrounding aqueous medium following ingestion there is still the risk that the cefuroxime axetil present in the composition may gel. Such gel formation would lead to the poor dissolution of the cefuroxime axetil and hence poor absorption from the gastrointestinal tract—ie—low bioavailability. In the case of granule formulations the use of particles of small diameter and high surface area is desirable to avoid such gelling.
[0006] In the formulation of cefuroxime axetil into granules it is important to avoid the release of the drug into any liquid medium in which it is suspended or indeed into the mouth when administering. Such problems may be minimised by formulating the cefuroxime axetil as lipid coated particles.
[0007] GB 2204792 discloses a particulate formulation in which the above problems are addressed. This patent discloses a composition comprising cefuroxime axetil in particulate form, the particles being provided with integral coatings of a lipid or a mixture of lipids which are insoluble in water and which serve to mask the bitter taste of cefuroxime axetil upon oral administration but which disperse or dissolve on contact with gastrointestinal fluid. The formulated coated particles break down upon contact with gastrointestinal fluid, thus allowing rapid dispersion and dissolution in the gastrointestinal tract.
[0008] WO 94/25006 discloses a method of masking the flavour of bitter tasting drugs in particulate form by mixing the drug with a lipid at a temperature below that where significant drug degradation occurs. To the drug and lipid mixture is added an emulsifier and surfactant, a polymer solution, and a dilution solution to form the stable taste-masked drug composition.
[0009] WO 00/076479 discloses taste masked compositions comprising a bitter tasting active, such as cefuroxime axetil, and two enteric polymers, namely methacrylic acid copolymer and phthalate polymer which are dissolved in a solvent system and subsequently dried to form a “solid solution” matrix in which the drug is kept in a finely dispersed state within the polymers, preventing the exposure of the bitter tasting drug to the taste buds.
[0010] The applicants currently market an oral suspension composition comprising cefuroxime axetil, the particles being provided with integral coatings of a lipid in the UK under the tradename Zinnat™ and in the US under the tradename Ceftin™. This oral suspension composition comprises, in addition to cefuroxime axetil, the inactive ingredients stearic acid, tutti frutti flavour, a binding agent (Povidone K30) and sucrose as a bulk sweetener.
[0011] Although the lipid coating goes some way to mask the bitter taste of the cefuroxime axetil upon oral administration, cefuroxime axetil is so bitter that these suspensions and compositions still have a bitter taste and prove a particular problem for administration to children. In addition, the suspensions may have a “gritty” feeling in the mouth making them less palatable than other antibiotic suspensions. Both of these factors may affect patient compliance because, particularly in children, less palatable antibiotics are likely to be discontinued as soon as the patient is well rather than continuing the course for the prescribed duration. In view of the above, there is a need for improved cefuroxime axetil suspensions to reduce the significant bitter taste and to improve mouth “feel”.
[0012] The present inventors have surprisingly now found a way to further improve the taste of the cefuroxime axetil used to form a suspension such that its unfavourable bitter taste may prove more acceptable. Advantageously, the overall “feel” in the mouth of the cefuroxime axetil suspension formulation is also improved in terms of less grittiness and is more easy to swallow.
SUMMARY OF THE INVENTION
[0013] Accordingly the present invention provides a composition comprising cefuroxime axetil in particulate form, the particles being provided with integral coatings of lipid or mixture of lipids which are insoluble in water and which disperse or dissolve on contact with gastrointestinal fluid characterised in that the composition further comprises a sweetener system and a texture modifier in amounts sufficient to mask the bitter taste of cefuroxime axetil.
[0014] More particularly, the present invention provides a composition comprising cefuroxime axetil in particulate form, the particles being provided with integral coatings of lipid or mixture of lipids which are insoluble in water and which disperse or dissolve on contact with gastrointestinal fluid, a bulk sweetener and a binding agent, characterised in that the composition further comprises a sweetener system and a texture modifier in amounts sufficient to mask the bitter taste of cefuroxime axetil.
[0015] Advantageously, it has been found that the sweetener system and texture modifier act synergistically to overcome both the bitter taste and also improve mouth “feel” thereby aiding patient compliance. As indicated above, the sweetener system overcomes the bitter taste by producing an initial sweet taste in the mouth. However, the simultaneous use of the texture modifier helps to provide a creamier texture improving mouth “feel” and, in addition, reducing the number of lipid coated particles left in the mouth when the preparation is swallowed further reducing the bitter taste effect. Using individual sweeteners or the texture modifier alone, would not produce such a significant improvement in both taste masking and mouth “feel”. Applicants have discovered that these beneficial effects are only produced when the sweeteners are combined and are further improved when the texture modifier is used in a synergistic combination.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Suitable lipid or mixtures of lipid coating for the cefuroxime axetil particles together with methods for preparing lipid coated particles of cefuroxime axetil are described for example in GB 2204792 the contents of which are incorporated herein by reference. A particularly preferred lipid coating is stearic acid in admixture with palmitic acid in a ratio in the range 3:7 to 7:3 by weight, more preferably 1:1 by weight.
[0017] The composition of the invention may contain cefuroxime axetil in crystalline form, in a mixture of crystalline and amorphous forms and more preferably in the amorphous form, for example as described in GB 2127401.
[0018] As described in GB2204792 the cefuroxime axetil particles may be undercoated with a substance with coating properties in order to protect the cefuroxime axetil where it may be chemically sensitive to the lipid with which it is coated. As described in GB2204792 undercoated particles in which the cefuroxime axetil is present at a concentration of 10-30%, for example about 20%, may conveniently be used for coating by the lipid.
[0019] Suitable methods of coating the cefuroxime axetil particles with the lipid or mixture of lipids are disclosed in GB 2204792. The patent also discloses the preferred sizes of the lipid coated particles. When the cefuroxime axetil for dispersion in the lipid is undercoated the lipid coating preferably represents 20-80% by weight, more preferably 35-65% by weight of the coated particles.
[0020] The lipid coated particles according to the invention will preferably contain from 5 to 90%, more preferably from 5 to 50% and still more preferably from 5 or 10 to 30% by weight of cefuroxime axetil. Where the cefuroxime axetil is first undercoated the lipid coated particles most preferably contain from 5 to 15% by weight of cefuroxime axetil; where no undercoating is employed the lipid coated particles most preferably contain from 10 to 30% by weight of cefuroxime axetil.
[0021] By “sweetener system” is meant a sweetener or combination of sweeteners which are added in addition to the bulk sweetener used during the granulation process described below and specifically designed to form an acceptable level of sweetness for the preparation. The sweetener system in the present invention acts to reduce the bitter taste. Preferably artificial or naturally derived sweeteners are used either alone or in admixture. Suitable sweeteners include, but are not limited to, saccharin, sodium saccharin, sodium cyclamate, acesulfame potassium, thaumatin, neohesperidin dihydrochalcone and aspartame.
[0022] Alternatively, the sweeteners include saccharin, sodium saccharin, sodium cyclamate, acesulfame potassium, thaumatin, neohesperidin dihydrochalcone, ammonium glycyrrhizinate and aspartame.
[0023] The sweetener system comprises between about 0.1-10% by weight of the final granule composition, more preferably about 0.3 to 5% by weight. Where there are two sweeteners used in admixture, the ratios between the two sweeteners are in the range of about 1:10 to 10:1 by weight.
[0024] A preferred sweetener system is a mixture of acesulfame potassium and aspartame, preferably in a weight ratio of about 1:1.
[0025] The composition additionally comprises a “texture modifier” comprising one or more thickening agents. The texture modifier is added in addition to any thickeners or binding agents which may optionally form part of the composition and therefore constitutes an essential feature of the invention. By “texture modifier” is meant a thickening agent, or combination of thickening agents, which helps to improve the texture of the cefuroxime axetil formulation when in the mouth so as to produce a desired mouth “feel”.
[0026] The texture modifier employed acts to reduce the bitter taste by suspending the lipid coated granules, resulting in reduced contact in the mouth, a reduced gritty texture and more ease of swallowing. Suitable texture modifiers are selected from polyvinylpyrrolidone (povidone), for example Povidone K30 or Povidone K90, sodium carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, guar gum or xanthan gum.
[0027] Alternatively, the texture modifiers are selected from polyvinylpyrrolidone (povidone), for example Povidone K30 or Povidone K90, sodium carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, guar gum, alginates, carrageenan or xanthan gum.
[0028] Preferably, the texture modifier is xanthan gum.
[0029] Most preferably, the sweetener system is a mixture of acesulfame potassium and aspartame and the texture modifier is xanthan gum.
[0030] The texture modifier is preferably present in a weight ratio of modifier:lipid coated particle between about 1:300 to about 1:3000, more preferably between about 1:500 to about 1:1500. The texture modifier comprises about 0.01 to about 5% by weight of the final granule composition, more preferably about 0.01 to about 1% by weight.
[0031] The weight ratio of texture modifier:sweetener system is between about 1:1 to about 1:1000, more preferably between about 1:10 to about 1:100.
[0032] The weight ratio of lipid coated particle:sweetener system:texture modifier in the final granule composition is between about 300:10:1 to about 3000:100:1, preferably between about 500:10:1, to about 1500:100:1.
[0033] The sweetener/texture modifier particle composition may also optionally contain other excipients such as suspension and binding agents, fillers, thickeners, flavours and bulk sweeteners.
[0034] Suitable suspension and binding agents include, but are not limited to, alkycelluloses such as methylcellulose, hydroxyalkylcelluloses such as hydroxypropylcellulose and hydroxypropylmethylcellulose, sodium carboxymethylcellulose or mixtures thereof, pregelatinised maize starch or polyvinylpyrrolidone.
[0035] Suitable fillers include sucrose, starch, lactose and microcrystalline cellulose.
[0036] Bulk sweeteners which are suitable for the purposes of the present invention include sorbitol, sucrose, or artificial sweeteners such as sodium saccharin or sodium cyclamate.
[0037] Alternatively, bulk sweeteners which are suitable for the purposes of the present invention include sorbitol, mannitol, maltitol, xylitol, fructose, glucose, sucrose, or artificial sweeteners such as sodium saccharin or sodium cyclamate.
[0038] Thickeners which are suitable for the purposes of the present invention include, but are not limited to, lecithin or aluminium stearate.
[0039] Suitable flavourings such as mint, peppermint, strawberry or tutti frutti may additionally be present in the composition.
[0040] In a preferred embodiment, the lipid coated granules of cefuroxime axetil are granulated with sucrose using an aqueous solution of polyvinylpyrrolidone (Povidone) as a binder to form the granule. A suitable flavour, such as tutti frutti flavour, is added and the composition is blended. The sweetener and texture modifier of the present invention may be blended together with the granulated particles in the form of a dry mix using conventional techniques either before, after or at the same time as addition of the flavouring agent to form the final granule composition. Alternatively, the sweetener and texture modifier may be blended with the lipid coated particles during the granulation process. During the blending process it is important to ensure that the sweetener system and texture modifier are evenly in admixture with the cefuroxime axetil lipid coated particles.
[0041] The particulate products according to the present invention may be used in pharmaceutical compositions for oral administration and may be presented as a suspension for administration, as a dry product for constitution with water or other suitable vehicle before use for administration as a suspension, or for direct administration and then washed down with water or other suitable liquid.
[0042] In a further aspect, therefore, the invention provides a pharmaceutical composition for oral administration comprising a composition according to the invention together with one or more pharmaceutical carriers or excipients.
[0043] The pharmaceutical compositions of the invention is preferably formulated as an oral suspension. However, the granules or particles can be formed into a tablet, caplet, and/or lozenge using known tablet/caplet/lozenge processes (e.g. compression or matrix processes) or other standard techniques, if desired. Preferably, such tablets, caplets, lozenges dissolve rapidly in a liquid medium (e.g. about 60% or more (by tablet weight) in 1 hour or less). Most preferably, 75% or more dissolves in less than 1 hour (e.g. in about 30 minutes). The liquid medium generally contains water, is preferably aqueous, but can be comprised of or contain other ingredients (e.g. emulsifiers) such as oils or alcohols.
[0044] The pharmaceutical compositions of the invention, formulated for oral administration as a suspension, may be constituted with a suitable amount of water, for use in oral administration of cefuroxime axetil. The particles will be typically presented so as to give a multidose suspension containing the equivalent of 125 mg to 5 g cefuroxime axetil or a single dose suspension containing the equivalent of 125 to 500 mg cefuroxime axetil.
[0045] Doses employed for human treatment will typically be in the range of 250 to 1000 mg cefuroxime axetil per day for adults and 80 to 500 mg per day for children, although the precise dose will depend on inter alia the frequency of administration.
[0046] The present invention may be further illustrated by the following examples which should not be construed as constituting a limitation thereto.
EXAMPLES
[0047] The cefuroxime axetil used in the Examples was highly pure spray dried amorphous material prepared as described in GB 2127401. The sweetener system and texture modifier were blended together with the cefuroxime axetil granules as a dry mix ensuring that they are evenly in admixture.
Example 1
[0048] Cefuroxime axetil suspension 125 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.150 g 3.55 Stearic acid 0.852 g 20.19 Povidone 0.013 g 0.31 Tutti Frutti flavour 0.100 g 2.37 Sucrose 3.062 g 72.56 Acesulfame Potassium 0.021 g 0.50 Aspartame 0.021 g 0.50 Xanthan gum 0.001 g 0.02 Potable Water to 5 mL
Example 2
[0049] Cefuroxime axetil suspension 125 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.150 g 3.55 Stearic acid 0.852 g 20.19 Povidone 0.013 g 0.31 Tutti Frutti flavour 0.100 g 2.37 Sucrose 3.062 g 72.56 Sodium saccharin 0.021 g 0.50 Aspartame 0.021 g 0.50 Xanthan gum 0.001 g 0.02 Potable Water to 5 mL
Example 3
[0050] Cefuroxime axetil suspension 125 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.150 g 3.55 Stearic acid 0.852 g 20.19 Povidone 0.013 g 0.31 Tutti Frutti flavour 0.100 g 2.37 Sucrose 3.062 g 72.56 Sodium saccharin 0.021 g 0.50 Acesulfame Potassium 0.021 g 0.50 Xanthan gum 0.001 g 0.02 Potable Water to 5 mL
Example 4
[0051] Cefuroxime axetil suspension 125 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.150 g 3.56 Stearic acid 0.852 g 20.24 Povidone 0.013 g 0.31 Tutti Frutti flavour 0.100 g 2.38 Sucrose 3.062 g 72.75 Neophesperidin dihydrochalcone 0.010 g 0.24 Sodium saccharin 0.021 g 0.50 Xanthan gum 0.001 g 0.02 Potable Water to 5 mL
Example 5
[0052] Cefuroxime axetil suspension 125 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.150 g 3.57 Stearic acid 0.852 g 20.29 Povidone 0.013 g 0.31 Tutti Frutti flavour 0.100 g 2.38 Sucrose 3.062 g 72.92 Thaumatin 0.010 mg 2.38 × 10 −4 Sodium saccharin 0.021 g 0.50 Xanthan gum 0.001 g 0.02 Potable Water to 5 mL
Example 6
[0053] Cefuroxime axetil suspension 250 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.300 g 7.50 Stearic acid 1.203 g 30.09 Povidone 0.012 g 0.30 Tutti Frutti flavour 0.102 g 2.55 Sucrose 2.289 g 57.25 Acesulfame Potassium 0.045 g 1.13 Aspartame 0.045 g 1.13 Xanthan gum 0.002 g 0.05 Potable Water to 5 mL
Example 7
[0054] Cefuroxime axetil suspension 250 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.300 g 7.50 Stearic acid 1.203 g 30.09 Povidone 0.012 g 0.30 Tutti Frutti flavour 0.102 g 2.55 Sucrose 2.289 g 57.25 Sodium saccharin 0.045 g 1.13 Aspartame 0.045 g 1.13 Xanthan gum 0.002 g 0.05 Potable Water to 5 mL
Example 8
[0055] Cefuroxime axetil suspension 250 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.300 g 7.50 Stearic acid 1.203 g 30.09 Povidone 0.012 g 0.30 Tutti Frutti flavour 0.102 g 2.55 Sucrose 2.289 g 57.25 Sodium saccharin 0.045 g 1.13 Acesulfame Potassium 0.045 g 1.13 Xanthan gum 0.002 g 0.05 Potable Water to 5 mL
Example 9
[0056] Cefuroxime axetil suspension 250 mg/5 ml
Ingredients 5 mL Dose % w/w Cefuroxime axetil 0.300 g 7.55 Stearic acid 1.203 g 30.28 Povidone 0.012 g 0.30 Tutti Frutti flavour 0.102 g 2.57 Sucrose 2.289 g 57.62 Neophesperidin dihydrochalcone 0.020 g 0.50 Sodium saccharin 0.045 g 1.13 Xanthan gum 0.002 g 0.05 Potable Water to 5 mL
Results
[0057] A taste trial was performed in which 5 volunteers assessed a suspension of the composition of Example 1 reconstituted with potable water according to the following categories:
Initial taste: sweet or bitter Aftertaste: bitter aftertaste present or absent Mouthfeel: creamy or gritty Flavour: pleasant or unpleasant
[0058] The results of the taste trial are tabulated below:
Taste category Volunteer response Initial taste All volunteers appreciated a sweet taste in the preparation Bitter None of the volunteers appreciated a bitter aftertaste in aftertaste the preparation Mouthfeel All volunteers appreciated a creamy mouthfeel in the preparation, although some granules could be detected. Flavour All volunteers appreciated a pleasant Tutti Frutti flavour in the preparation
[0059] Further taste trials were carried out in a number of healthy adult patients comparing a suspension of the composition of Example 1 (125 mg/ml) and of Example 6 (250 mg/5 ml) with a suspension of compositions of cefuroxime axetil which were identical except for the absence of the sweetener system and texture modifier. Formulations in both strengths were assessed in the “fresh” form, ie freshly constituted formulations.
[0060] In a preference test design, the suspensions were compared for sweetness, bitterness, mouthfeel and overall preference. The results demonstrated in the following tables show percentages of patients preference for both a 125 mg/5 ml dose form and a 250 mg/5 ml dose form.
Suspension Sweeter Bitter Better Mouthfeel Preference 125 mg/5 ml taste trials Suspension 1 a 66% 0% 42% 58% Suspension 2 b 17% 67% 16% 17% Equal 17% 33% 42% 25% 250 mg/5ml taste trials Suspension 1 a 75% 0% 42% 92% Suspension 2 b 0% 100% 25% 8% Equal 25% 0% 33% 0%
[0061] The results clearly indicate that suspensions of the present invention which contain added sweeteners and texture modifier is the much preferred formula for both taste and mouthfeel. | A composition comprising cefuroxime axetil in particulate form, the particles being coated with integral coatings of a lipid or mixture of lipids which are insoluble in water in which the composition further comprises a sweetener system and a texture modifier which serves to mask the bitter taste of cefuroxime axetil upon oral administration is disclosed. | 0 |
RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 60/179,997, filed Feb. 3, 2000. U.S. provisional application Ser. No. 60/179,997 is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an apparatus and method for assessing the status of a cellular pathway. Several biotechnology companies are developing DNA-chips which contain printed arrays of hundreds or thousands of genes, or more. However, the DNA sequence of the genes or the level of gene expression do not reflect the actual functional state of the proteins encoded by the genes. The functional state of each protein involves more than simply the amount of the proteins. It includes, for example, post translational modifications (phosphorylation, glycosylation, etc.), binding partners in cellular pathways, conformation, enzymatic function, and state of activation. Moreover, each cell in the body has a pattern of functional proteins which reflects the current biologic working state of the cell (e.g., growing, differentiating, diseased, dying, senescent, etc.). Therefore, there exists a need in the art for a device and method for determining the status of cellular pathways (e.g., the phosphorylation state or binding partners of involved proteins) in tissue samples, including human tissue samples, thus providing the diagnostician or clinician with an early warning of impending or occult toxicity, disease state, response to treatment, differentiated function, and so forth.
SUMMARY OF THE INVENTION
[0003] The present invention provides a molecular detection device having a plurality of binding or reaction sites comprising a series of immobilized recognition molecules or binding reagents selected and arranged to qualitatively or quantitatively assess the status of a series of signal transduction pathway proteins or other protein-protein interactive network, their phosphorylated or activated state, and their binding partners, in a cell sample to determine the status of a selected cellular signal transduction pathway. Knowledge of the pathway status can then be used by the diagnostician or clinician to determine the health of the sampled cells, drug or other treatment efficacy or toxicity. This knowledge can also be used to identify candidates for selected therapies, to aid in therapy selection for a given subject, and to determine drug toxicities.
[0004] Protein interactions are defined herein as the coupling of two or more proteins in a given space and time such that a binding reaction occurs, and/or one protein modifies the other protein. The novel concept of the invention is that the protein networks and pathways, and their changing state in cells, can be recapitulated after the cells are dissolved and the proteins are solubilized. The invention method recapitulates the proteins involved in networks because a) networks are built from proteins binding to other proteins to form larger complexes; and b) phosphorylation events cause specific proteins to interact with (or dissociate from) other proteins in a certain order. Therefore, the upstream and downstream networks emanating from any given point can be elucidated by using the subject invention to find at least two proteins that are phosphorylated and forming complexes with other proteins. This pattern changes with disease state or drug treatment or toxicity.
[0005] In a preferred embodiment, multiple nodes in a signal transduction pathway circuit within a cell are profiled to determine whether the entire pathway is functionally activated and in use by the cell or whether only a portion of the pathway is activated (e.g., upstream or downstream), thus indicating, for example, that the pathway may be regulated at intermediate points along the pathway circuit. Also, the binding partners which complex with individual nodes of the pathway can be identified.
[0006] In still a further aspect, a method of identifying the full repertoire of proteins that could serve as acceptors for phosphorylation comprises treating cells, such as whole tissue specimens grown ex-vivo, or animal tissue treated in vivo with compounds that inhibit protein tyrosine and/or serine/threonine phosphatase activity such as sodium pervanadate, okadaic acid, calyculin A, for acute periods of time (e.g., less than 3 hours), and isolating the cells of interest. The cells of interest are lysed and selected for the phosphorylated proteins using antibodies on an immobilized bait, such as anti-phosphotyrosine, anti-phosphoserine, and/or anti-phosphothreonine antibodies, and so forth. The phosphoproteins in the enriched fraction are separated, e.g., by chromatographic and/or electrophoretic means and the primary amino acid sequence of the proteins is identified by enzymatic digestion or chemically-induced protein fragmentation followed by standard mass spectrometric techniques. Finally, antibodies or binding molecules that specifically bind to the identified proteins are developed.
[0007] In further embodiments, protein pathways which reflect a disease state can be fingerprinted to pinpoint a therapeutic target. In order to select a treatment or determine treatment efficacy, informatics or heuristics can be developed for various pathways, pathological states, therapies, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
[0009] FIG. 1 illustrates a cellular signal transduction pathway profiling device of the present invention.
[0010] FIGS. 2-6 illustrate exemplary pathway profiling methods in accordance with the present invention.
[0011] FIG. 7 illustrates a system and method for identifying therapeutic targets employing trapped lysates from cells of different pathological states.
[0012] FIG. 8 shows a multiplexed embodiment of the molecular detection device in accordance with the present invention.
[0013] FIG. 9 illustrates an exemplary pathway profiling device according to the present invention.
[0014] FIG. 10 illustrates autoradiography results for microdissected erb2+ and erb2−human breast cancer epithelium from tissue sample specimens probed for anti-ERK½ mouse monoclonal antibody using the pathway profiling device according to FIG. 9 .
[0015] FIG. 11 illustrates a method of the present invention for the detection of IFNA stimulation of the JAK-STAT signal pathway.
[0016] FIG. 12 illustrates the use of nitrocellulose engraved by a laser to manufacture raised porous columns that contain and channel the flow of cellular proteins through the zones. In the depicted example, a high sensitivity and dose dependence of protein detection is noted for the intracellular human heart muscle protein troponin.
[0017] FIGS. 13A-13C , 14 A, 14 B, and 15 - 18 illustrate the use of activated glass beads as the flow-through matrix of the present invention.
[0018] FIG. 19 is a flow chart of a signal transduction pathway profiling method in accordance with the present invention.
[0019] FIGS. 20 and 21 illustrate the use of patterns for the identification of a pathway and/or disease state of a cell sample.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to FIG. 1 , a cellular signal transduction pathway profiling device 100 includes a porous support member 110 , such as a porous membrane or the like. support member 110 may be fabricated from any material into which fluids may flow and readily pass through, such as nitrocellulose, cellulose, glass, nylon, or other fibrous material. On the support 110 , two or more, preferably three or more, distinct binding site regions or trapping zones 116 are formed by applying and immobilizing within each region a substance capable of reaction with an analyte contained within the test sample. In a preferred embodiment, each region contains a single purified ligand, such as a protein, peptide, antibody, or drug capable of trapping a specific protein or modification thereof involved in a selected transduction pathway. Alternately, the immobilized materials at the binding sites are complex mixtures (e.g., cellular lysates). By “immobilized” is meant that the substance capable of holding an analyte is applied in a confined area on the surface of the membrane such that it is permanently bound or otherwise incapable of substantial movement to positions elsewhere on the support.
[0021] A lysate application region 114 and a chase application region 112 are provided at one end of the device 100 . In this manner the lysate can be applied to the support 110 , followed by a chase, such as a buffer or other physiological solution, to cause the lysate to flow through the trapping zones 116 to an outflow region 118 . Preferably, the lysate is drawn through the reaction zones via wicking or capillary action, although other methods are contemplated as well, such as gravity, application of a pressure differential, electrical pumping, and so forth. The trapping zones are applied in a manner such that subsequent capillary wicking of material for analysis will pass through the immobilized protein zone and not around it. In one embodiment, the support material 110 forms a strip and the reaction zones 116 are applied in a line traversing the width of the strip.
[0022] When antibodies are used for trapping, they may be from any species, including but not limited to human, goat, rabbit, mouse, etc. The antibodies can be either anti-protein specific (e.g., anti-ERK kinase) or anti-modified protein specific (e.g., anti-phosphorylated ERK kinase).
[0023] For signal transduction profiling, the sequence of the applied antibodies in the multiple reaction zones 116 are preferably ordered such that the protein components of a pathway that are activated last are captured first, although the ordering is otherwise not necessarily critical. For example, the analysis of EGF signaling profiles from cells that are expressing differential amount of the erb receptor family can be analyzed by imprinting antibodies recognizing the phosphorylated forms of proteins in the EGF receptor signaling cascade. The order of imprinting, from first capture zone to last capture zone, is shown below in TABLE 1.
TABLE 1 Capture Zone Antibody 1 anti-phosphorylated c-myc 2 anti-phosphorylated c-jun 3 anti-phosphorylated p70RSK 4 anti-phosphorylated erk 5 anti-phosphorylated AKT 6 anti-phosphorylated c-RAF 7 anti-phosphorylated erb2 8 anti-phosphorylated erb1
[0024] Once the trapping zones 116 have been imprinted on the support 110 , cellular lysates, DNA aptomer libraries, focussed or unfocussed drug libraries, and/or phage display libraries, can be applied to the top of the detection device 100 in the defined application zone 114 and allowed to actively wick through the support 110 by active capillary action using a buffer chase applied to region 112 . Again, other methods of drawing the lysate through the zones 116 are also contemplated.
[0025] Analytes in the material for analysis, such as proteins, drugs, DNA, phages, will, depending on their abundance, specifically bind to a corresponding trapping zone region 116 having a substance capable of reaction therewith. All other components will wick through the zone into the waste outlet region 118 at the bottom of the chip 100 .
[0026] Because these analyses are performed under native conditions, protein complexes, comprising activated proteins (e.g., phosphorylated proteins) and their binding partners will be trapped in each of the subsequent zones, depending on the degree of phosphorylation and the presence of the binding partners.
[0027] Subsequent analysis and/or identification of proteins trapped in the zones 116 is performed by countercurrent extraction, treatment with enzymes (e.g., trypsin), mimetics (e.g., phenylphosphate for the removal of phosphotyrosine-containing proteins), and so forth. Analysis of extracted material can be performed by elution into other trap zones (three-dimensional separation) or by mass spectrometry (e.g., LCQ-MS, CE-ESI-MS) for identification and discovery purposes. Additionally, quantitative analysis of trapped analyte composition can be performed by querying each trap zone with a tagged or detectably labeled antibody (e.g., biotinylated or alkaline phosphatase tagged) to generate a signal. Exemplary methods for detecting the bound proteins are illustrated in FIGS. 2-6 .
[0028] An exemplary embodiment in which each trapping zone 116 is imprinted with lysates from cells of different types or different pathological states is illustrated in FIG. 7 . Phage and/or DNA aptamer libraries 220 , such as random phage and/or random aptamer libraries, can be screened and analyzed by successive rounds of trapping with a plurality of protein lysate zones 216 a - 216 c . For example, in a first binding site 216 a , there is applied and immobilized a normal cell lysate. In a second binding site 216 b , there is applied and immobilized a lysate of cells in a predisease state. In a third binding site 216 c , there is applied and immobilized a lysate of diseased cells. Each round of trapping is followed by amplification. For example, each binding site can be cut out and amplified using PCR (for aptomer libraries) or amplification by infection (e.g., in E. coli for phage display peptide libraries). Alternately, small molecule drugs can be identified by NMR or other like methodologies. The amplified entities 222 can then be used for potential targeting therapies, e.g., as toxin-conjugated vehicles. For example, an amplified entity which selectively binds to a protein representative of a disease state, such as cancer, can be conjugated or linked to a toxin for efficient delivery of the vehicle to the targeted cells. Likewise, an amplified entity can be conjugated to an imaging reagent for diagnostic imaging of the targeted cells, such as x-ray contrast agents, MRI contrast agents, radiopharmaceuticals for nuclear medicine diagnostic imaging, and so forth. These entities can be further screened for DNA or peptide sequences that bind to unique cell-specific or tissue-specific proteins by repanning against immobilized bait trap surfaces.
[0029] Referring now to FIG. 8 , there is shown another embodiment of the present invention in which a molecular detection device 300 comprises a plurality of support members 310 arranged in a multiplexed format. Each support member includes a plurality of binding sites 316 to which is applied and immobilized a series of proteins and modifications thereof involved in a selected signal transduction pathway. Such a format is suitable for high-throughput drug screening using cell lines and/or microdissected tissue cell lysates. A lysate application zone 314 is provided for each strip 310 . In alternate embodiments, the zones 314 are cell growth zones for selected cell lines, in which case an optional lysing buffer application zone 322 is provided such that the cells are lysed prior to reaching the trapping zones 316 . A chase application zone 312 is provided for application of a buffer or other physiological solution to carry the lysate through the trapping regions 316 . Analytes in the lysate will specifically bind to a corresponding trapping zone region 316 having a substance capable of reaction therewith and all other components will wick or otherwise be drawn through the zones into the waste outlet region 118 at the bottom of the device 300 .
[0030] The reduction of this method to practice has been demostrated in the following tests. A pure nitrocellulose membrane (0.45 micron pore size, Shleister and Schuell) was cut as a 6 cm×1 strip beginning and ending with wider 3 cm×3 ends. The following commercially available rabbit polyclonal antibodies (New England Biolabs, Upstate Biotechnology) at 100 microgram/ml concentration were applied undiluted in total applied volume of 2 microliters as traping zone “stripes” perpendicular to the length of the menbrane as shown in FIG. 9 . The antibodies were applied in bands approximately 2-3 mm wide, spaced at repeated 0.5 cm intevals, and ordered from top to bottom as shown in TABLE 2.
TABLE 2 Capture Zone Antibody 1 anti-phosphorylated c-myc 2 anti-phosphorylated p70 SK kinase 3 anti-phosphorylated elk 4 anti-phosphorylated STAT5 5 anti-phosphorylated AKT 6 anti-phosphorylated c-erb2 7 anti-phosphorylated c-erb1 8 anti-phosphorylated erk kinase
[0031] The antibodies were allowed to bind to the membrane overnight, after which the entire strip was immersed in a commercially available casein blocking solution (Superblock, Pierce Chemical ) for 2 hours. The membrane was then washed 3 times for 10 minutes with 20 milliliters of a 50 mM TRIS, 100 mM NaCl, 0.5% Tween−20 solution (TBST). The strip was then allowed to air-dry for 5 hours.
[0032] Lysates comprised of 1500 cells procured via Laser Capture microdissection (LCM) of two human breast cancer specimens, one known to be highly reactive for erb2 (erb2+), and the other known to be weakly reactive (erb2−), were applied to the top of the strip (lysate application region) in a volume of 5 microliters of commercially available lysing buffer (T-PER, Pierce Chemical) with a commercially available protease inhibitor cocktail (Complete Tablets, Boehringer Mannheim) and 1 μl sodium vanadate as a phosphotyrosine phosphatase inhibitor. 25 microliters of the T-PER solution was applied as a chase immediately after the application of the lysate, and the lysates were allowed to actively “wick” through the strip over a period of 60 minutes. An additional volume of 25 microliters of T-PER was applied to the chase zone when the buffer front was approximately ½ of the way through the strip.
[0033] Five minutes after the buffer front had passed through the last antibody trap zone, the entire strip was immersed and washed 3 times for 10 minutes in TBST. The strip was then immersed in TBST+ mouse monoclonal anti-ERK (Transduction Laboratories) at a 1:2000 dilution for 1 hour. The strip was then washed 3 times for 10 minutes each time with TBST, and then incubated for 1 hour with a biotinylated goat anti-mouse IgG antibody (Vector Laboratories) at a 1:5000 dilution.
[0034] The strip was then washed 3 times for 10 minutes each time in TBST, and developed according to the package insert from Vector Laboratories using a commercially available kit (ABC reagent) which generates luminescent output. The strips were then exposed to standard autoradiography for 1 second to 30 second exposures. The results of the autoradiography are illustrated in FIG. 10 .
[0035] The following experimental example demonstrates the recapitulation of the state of a cellular signal pathway using proteins dissociated from lysed human cells treated with a drug known to activate the selected signal pathway.
[0036] The Janus kinase-signal transducer and activator of ranscription (JAK-STAT) signaling pathway is important in he Interferon Alpha (IFNA) cellular response. Binding of FNA induces the following sequence of events:
Fusion of Interferon Alpha Receptor(IFNAR)1 and IFNAR2; Jak1 and Tyk2 are phosphorylated; IFNAR1 is phosphorylated allowing docking of Stat2; Stat2 is phosphorylated allowing Stat1 to dock; Stat1 is phosphorylated; Stat1(Pi)-Stat2(Pi) heterodimer is released.
Interferon Alpha Treatment of Peripheral Blood Lymphocytes
[0043] Peripheral Blood Lymphocytes (PBLs) were isolated using Histopaque-1077 (Sigma). The PBLs were suspended in PBS (0.01 M phosphate buffered saline, 0.138 M NaCl, 0.0027 M KCl), pH 7.4, and allowed to acquiesce overnight at 4° C. The cells were pelleted by centrifugation at 5000×g for 5 minutes. The supernatant was decanted off, and the cells resuspended in RPMI-1640 media (Bio-Whittaker) at approximately 20 million cells/mL. The cells were treated with 13,500 units/mL of recombinant human interferon alpha (BioSource) for 0, 3, 10 or 30 minutes. Once the incubation was complete, cells were pelleted by centrifugation at 5000×g for 5 minutes. Cells were washed with ice-cold PBS and resuspended in lysis buffer ((T-PER, Pierce), 10 mM beta-glycerophosphate, 1 mM sodium molybdate, 2 mM sodium orthovanadate, 2.5 mM AEBSF and 5% glycerol). The cells were vortexed and placed on ice for 5 minutes, repeated. Lysates were clarified by centrifugation at 10,000×g for 5 minutes. The supernatant was snap frozen and stored at −80° C.
Pervanadate Treatment of Peripheral Blood Lymphocytes
[0044] Peripheral Blood Lymphocytes (PBLs) were isolated using Histopaque-1077. The PBLs were suspended in PBS and allowed to acquiesce overnight at 4° C. The cells were pelleted by centrifugation at 5000×g for 5 minutes. The supernatant was decanted off, and the cells resuspended in RPMI-1640 media at approximately 20 million cells/mL. A pervanadate solution was made as follows. 882 μL of 0.10 M sodium orthovanadate was added to a mixture containing 832 μL RMPI-1640 media and 50 μL 30% H 2 O 2 , mixed at room temperature, and let stand for 15 minutes. The cells were treated with pervanadate 1 μL to 500 μL of cells for 30 minutes at 37° C. Cells were pelleted at 5700×g for 5 minutes. Pellets were washed with ice-cold PBS and snap frozen. T-PER (salt concentration was adjusted from 0.150 M to 0.20 M) was added to the pellet and the resulting lysate was vortexed rapidly for 1 minute. The lysate was clarified by centrifugation at 15,000×g for 10 minutes. The supernatant was snap frozen and stored at −80° C.
[0000] Preparation of Flow-Through Trapping Zones.
[0045] FF85 (Schleicher and Schuell) nitrocellulose membranes were cut into approximately 8 cm×1 cm strips. Stat2 antibody (C-20, Santa Cruz Biotechnology) was spotted down at 0.5 μL increments/2.5 μL total across the 1 cm width of the strip at approximately 6.0 cm from the top. Stat1αp91 antibody (C-24, Santa Cruz Biotechnology) was strided down at 0.5 μL increments/2.5 μL total across the 1 cm width of the strip at approximately 7.0 cm from the top. The treated membranes were dried for 45 minutes at room temperature and 6% relative humidity. The strips were blocked in Superblock (Pierce Chemical Company) for 3 hours at room temperature with shaking. The strips were washed 3 times with TBS-T (0.20 M Tris, 0.50 M NaCl, 0.1% Tween20), pH7.5, then dried at 37° C./6% relative humidity.
[0046] p-Stat1 Association Strip Assay
[0047] The IFNA treated PBL lysates (25μL) were placed approximately 1 cm from the top of the strip. The lysate was moved through the strip upon addition of TBS-T to the top of the strip. Every 20 minutes over a period of 3 hours, 50 μL of TBS-T was placed at the top of the strip. Upon completion the entire strip was washed 1 time with TBS-T. The strips were incubated overnight at 4° C. with p-Stat1 (A-2, Santa Cruz Biotechnology) diluted at an appropriate concentration in Superblock. The strips were washed 3 times with TBS-T. The strips were then incubated at room temperature for 3 hours with Goat Anti-Mouse:Alkaline Phosphatase (Fortran, In House Conjugation to AP) diluted in Superblock. The strips were washed 3 times with TBS-T. The strips were incubated with CDP-Star (Tropix) for 5 minutes. Light output/binding of p-Stat1 antibody was recorded using a CCD imager (NightOwl, Berthold Technologies). As shown in FIG. 11 , the invention method was able to detect IFNA stimulation of the JAK-STAT signal pathway in the expected time-dependent manner.
CTNI Example
[0048] The following Example demonstrates how parallel arrays of flow-through binding zones useful for practicing the subject invention can be manufactured by using a laser engraver to build up porous matrix columns. The raised columns on a plastic backing contain and direct the flow of solubilized proteins to be analyzed. The example indicates the quantitative dose-dependent detection of troponin, an intracellular myofibril component of human cardiac muscle cells.
[0049] Nitrocellulose, purchased from Schleicher and Schuell, comprises an inert plastic (Mylar) backing support onto which a layer of directly cast nitrocellulose is deposited. During our investigation of this matrix for flow-through diagnostic applications, it was discovered that it is possible to create channels in the material. This was achieved by using the cutting power of a CO 2 laser. The laser is programmable through a computer software application, which enables the creation of highly complex patterns on the surface of the nitrocellulose. Briefly, the laser vaporizes the cellulose beneath the beam, exposing the underlying mylar surface. One of the simplest applications of this process is to take a 4 cm×4 cm square of nitrocellulose (or any other desired size) and use the laser to cut a series of vertical slots in the material. In this manner, one creates in the nitrocellulose a number of “columns”, each column separated by an inert mylar barrier. Interpreted another way, a series of “usable” ridges are manufactured on the matrix, each ridge usable for a similar or dissimilar diagnostic application. The number of ridges created on the material varies with the width of the ridge and the length of the nitrocellulose piece. The laser action also scores the upper surface of the mylar, allowing for easy detachment of a single column or multiple columns from the sheet.
[0050] A series of columns (3 mm wide) were cut into a 4 cm×4 cm length of nitrocellulose. Seven columns were detached and treated as follows.
[0051] 1 μl of a 1 mg/ml solution of neutravidin (Pierce Chemical Co., Rockford, Ill.) was applied to each ridge. The protein was heat (37*) cured on the matrix for 2 hrs. After washing, a 1 μl aliquot of biotinylated anti-cardiac troponin I antibody was overlayed onto the original neutravidin spot. Thirty minutes later, excess antibody was removed and the whole surface of the matrix blocked in a PEG/PVP solution.
[0052] A series of troponin I calibrators (purified from human heart muscle), ranging in concentration from 0 to 160 ng/ml were reacted individually with an anti-troponin I antibody conjugate. The latter recognizes a site on troponin I, which differs from the site recognized by the neutravidin bound antibody.
[0053] A 1 μl aliquot of each antigen/conjugate reaction was placed onto individual columns. The placement of the liquid was immediately below the neutravidin complex.
[0054] The lower edge of the seven column composite was placed into a buffer allowing the latter to move through the material via capillary action (conventional TLC). The length of time required for the buffer to reach the top of the device was 45 seconds.
[0055] The device was removed and coated in CDP* substrate (Tropix Corporation, Bedford, Massachusetts), light emission was recorded on a NightOwl CCD scanner of light emission.
[0056] The flow-through trapping zones created in nitrocellulose porous matrix columns efficiently retained antibody antigen complexes such that the troponin analyte could be measured in a dose-dependent manner as shown in FIG. 12 and TABLE 3.
TABLE 3 Card Style Troponin Membrane; Dose Curve 1 μL(Sample + Conjugate) Troponin (ng/mL) Light output (cts/sec) 0 0 2.6 4955 5.2 7264 10.4 8477 20.8 13116 41.65 18199 83.5 21415
[0057] The porous matrix material through which the cellular protein flows has been successfully reduced to practice with porous or fibrous materials, such as nylon, cellulose or silica, and can be configured as raised porous interconnecting columns or suitably packed particles or beads.
[0058] The following example demonstrated the use of activated glass beads to construct a flow through matrix of the present invention.
[0059] Controlled pore glass (CPG) is a matrix whose surface is readily modified by reaction with a wide variety of bifunctional silanes. The material exhibits a significant surface area to weight ratio. The rigid nature of the glass, high porosity and non-compressibility lends itself to rapid passage of liquids or biological fluids through the matrix. The present invention employing a series of capture zones having differing specificity for removal and quantitation of phosphorylated and non-phosphorylated protein complexes from stimulated cells can be achieved through the use of CPG.
[0060] By confining specific capture zones of CPG in a micro-capillary tube, each zone separated by either inert glass or an inert cellulose plug, biological fluids can be drawn through each zone (e.g., using a vacuum or positive displacement pump, or the like), to capture the desired entities in the zones. The microenvironment of the capillary minimizes diffusion limitations thereby enhancing acceleration of the rate of binding of the ligand to the capturing agent.
[0061] Accordingly, CPG (Sigma Corporation, St. Louis, Mo.) was reacted with 3-aminopropyl trimethoxysilane (Sigma Corporation, St. Louis, Mo.) using standard published procedures. Subsequently, the amino modified glass was reacted with iminothiolane (Traut's reagent, Pierce Chemical Co., Rockford, Ill.). The latter procedure provides a sulphydryl group (thiol) for further reaction with maleimido modified proteins, drugs, nucleotides and other entities so modified.
[0062] Maleimido horseradish peroxidase was reacted with 20 mg of iminothiolane CPG. After washing, small portions (2 mg×3) of the beads were loaded into a micro-capillary tube. Each zone was separated by an inert glass or plug. A chemiluminescent substrate (Duolux, Lumigen, Southfield, Mich.) was pulled rapidly into the capillary using vacuum. The tube was transferred to a light measuring device (NightOwl CCD light scanner) and the light output read for 1 sec. The results are shown in FIG. 13A . In either case, three illumination zones are indicated, thereby demonstrating the feasibility of the system. In a further iteration, an epitope of cardiac troponin I (P14 cTNI epitope, Research Genetics, Huntsville, Ala.), conjugated to thyroglobulin (porcine thyroglobulin, Sigma Corporation, St. Louis, Mo.) was reacted with CPG. An antibody (P3 cTNI antibody, Fortron Bioscience Inc., Morrisville, N.C.), conjugated to peroxidase or alkaline phosphatase (AP), was introduced into the requisite capillary, excess conjugate was removed through rapid washing and the bound antibody enzyme visualized with an appropriate chemiluminescent substrate. The results are recorded in FIGS. 13B and 13C .
[0063] A single peroxidase bead, 100-200 microns in diameter, was exposed to Duolux and the light output recorded, compared with substrate background. The calculated signal to noise ratio was 3.5, indicating that the system has the potential of being reasonably sensitive. The results are shown in FIG. 14A .
[0064] In order to provide a generic CPG system, maleimido-neutravidin (neutravidin and maleimido peroxidase were purchased from Pierce Chemical Co., Rockford, Ill.) was reacted with iminothiolane glass. Neutravidin binds biotinylated species aggressively. Such biotinylated species include peptides, proteins, drugs, nucleotides and other entities so modified. In this example, biotin containing Stat 1 and phosphorylated Stat 1 antibodies (Stat1{pY 701 } peptide, BioSource International, Camarillo, Calif.) were attached to CPG. Bovine serum albumin (Sigma Corporation, St. Louis, Mo.) containing phosphorylated Stat 1 peptide was drawn into a capillary, in which a zone of each was antibody was deposited. After washing, the zones were probed with RC20-AP (RC20-AP antibody conjugate purchased from Transduction Laboratories, Lexington, Ky.). Following a further wash, substrate was introduced and the light output recorded. In this experiment it was anticipated that the luminescence from the p-Stat 1 zone would be greater than that from the Stat 1 zone. This turned out to be the case. The light output from the Stat1 zone is related to the poor quality of the RC-20 AP conjugate and probably represents non-specific binding to the bound matrix antibody. To demonstrate that binding to a zone is reversible in the presence of a appropriate ligand, p-Stat 1 antibody beads were exposed to p-Stat 1 peptide peroxidase, both in the absence and presence of p-Stat1 peptide albumin (blocking agent). As anticipated, the presence of the peptide reduced the binding of the conjugate, resulting in less light output. The results are shown in FIG. 14B .
[0065] To further demonstrate the utility of our CPG capillary approach, neutravidin beads were reacted with a biotinylated antibody which recognizes a specific epitope on cardiac troponin I (cTNI). A negative serum sample was drawn through the capillary (vacuum). After washing, a secondary AP labeled antibody, with a different specificity for cTNI was introduced and excess conjugate removed immediately by washing. Exposure of the beads to substrate produced the light output shown in FIG. 15 (-⋄-). Using the same capillary and procedure, a positive sample of cTNI (490 pg/ml) was examined for light yield (-□-). The calculated signal to noise ratio of 5 to 1 indicates that the system is capable of extreme sensitivity. An overlay of the light output from the capillary is included in FIG. 15 .
[0066] Peripheral blood lymphocytes (PBLs) were exposed to alpha-interferon. The cells were lysed and cellular debris removed by centrifugation. In a similar fashion, non-treated cells were and lysed and the cell contents collected. Fifty microliters of each lysate were drawn through separate capillaries, each containing Stat 1 antibody CPG beads. The capillaries were probed with RC20-AP. After washing, substrate (CDP*) was drawn into the tubes and the light emission recorded in a tube luminometer (Junior Luminometer, Berthold Technologies) or the Nightowl CCD scanner. The data indicates that stimulation of PBLs with interferon, induces an increase of phosphorylated tyrosine species, which bind to Stat 1 protein. This is indicative of binding of tyrosine phosphorylated Stat 2 to Stat 1, thus forming the recognized heterodimer, known to be part of the alpha-interferon/lymphocyte signaling cascade. The results are illustrated in FIG. 16
[0067] An additional approach to confirm the observations from FIG. 16 is described here and shown in FIG. 17 . Instead of probing with RC20-AP, a non-labeled mouse antibody specific for phosphorylated tyrosine in conjunction with a goat anti-mouse AP conjugate were employed sequentially. Negatively and positively, alpha-interferon stimulated PBL lysates were drawn through individually packed capillaries containing Stat 1 antibody CPG. After washing, etc., and exposure to the primary and secondary antibodies, the beads were exposed to CDP* substrate. The increase in positive light emission supports our contention that stimulation of PBLs with alpha-interferon leads to an increase in phosphorylated Stat2, which in turn binds to Stat 1 protein.
[0068] The phosphatase activity of PBLs is significantly reduced in the presence of pervanadate. Inhibition of phosphatase activity enhances the overall level of phosphorylated proteins within the lymphocyte. The experiment shown and described with reference FIG. 18 illustrates this phenomenon quite nicely. Briefly, CPG Stat 1 antibody beads (10 mg), were placed in a Z-spin well (Z-spin columns were obtained from Fisher Scientific, Pittsburgh, Pa.). As a control, plain neutravidin CPG was used. To each well, 50 μl of pervanadate treated PBL lysate was added. The wells were centrifuged, washed and then exposed sequentially to mouse anti-phosphorylated tyrosine antibody and goat anti-touse AP conjugate. Each addition was followed by a wash/centrifuge cycle. The addition of CDP* substrate induced light emission which was recorded in the NightOwl. The data indicates that inhibition of phosphatase activity enables measurement of the basal level of phosphotyrosine proteins in non stimulated PBLs. In this instance, the data suggest that this type of methodology is capable of discriminating phosphorylated Stat2 from a whole range of known and as yet unknown phosphorylated signaling intermediates.
[0069] The following are experimental examples of more than 20 specific different trapping ligands that were successfully used in the subject invention for protein network profiling. The invention methods led to identification of phosphorylated proteins and assignment of their functional participation in signal pathways. The information derived is relevant to the following: a) identifying specific protein-protein interactions; b) assignment of the specific interactions into larger functional circuits and networks; c) downstream ordering of protein components in a given pathway; d) specific disruptions caused by drug treatments, disease, or toxicity; and e) identifying patterns of protein interactions or phosphorylations that are unique to disease state, drug treatment or toxicity.
[0070] 1. 100,000 primary human lymphocytes and 100,000 primary human monocytes obtained by tangential centrifugal elutriation and differential ficoll-percoll gradient selection were resuspended in 5 ml (each cell type) RPMI-1640 media.
[0071] 2. 1 ml aliquots were placed in eppendorf tubes
[0072] 3. A 100× cocktail (herein referred to as PI or phosphatase inhibitor cocktail) consisting of the following: 2500 nM Okadaic acid (cell-permeable inhibitor of protein phosphatase); 500 micromolar sodium pervandate (membrane soluble form of sodium orthovanadate and an inhibitor of tyrosine phosphatases), 500 nM Calyculin A (cell-permeable inhibitor of protein phosphatase 2A and protein phosphatase); and 2500 micromolar phenylarsine oxide (cell-permeable phosphotyrosine phosphatase inhibitor).
[0073] 4. The following experimental treatment protocol was then set up and performed with each 1 ml cell suspension (20,000 cells/ml):
[0074] i. primary human lymphocytes/monocytes+ vehicle alone (10 microliters DMSO) 1 hour;
[0075] ii. primary human lymphocytes/monocytes+1× PI ½ hour; and
[0076] iii. primary human lymphocytes/monocytes+1× PI ½ hour+10 micromolar SB 203589 (p38 kinase inhibitor) ½ hour.
[0077] 5. Cells were pulse centrifuged at 5000×g for 2. minutes, washed twice in ice cold PBS and the resultant cell pellet lysed in 100 microliters lysing solution (TPER (Pierce Chemical)+2 mM sodium orthovanadate (tyrosine phosphatase inhibitor), 10 mM B-glycerol phosphate (serine phosphatase inhibitor), 300 mM NaCl, 4 NM AEBSF (protease inhibitor)), vortexed rapidly for. 1 minute and clarified by centrifugation for 5 minutes.
[0078] At this point the lysates are analyzed by 4 main methods.
[0079] i. Open faced array of antibodies immobilized on nitrocellulose (see No. 6 list below).
[0080] ii. Flow-through devices striped with trapping zones containing protein binding ligands.
[0081] The analysis was complemented by the following additional standard methods:
[0082] iii. Two-dimensional or one-dimensional gel-based separation technologies.
[0083] iv. Mass-spectrophotometric-based baiting technologies.
[0084] 6. The resultant whole cell lysate was then incubated overnight at 4 degrees C. on an Oncyte multiwell (Grace Biolabs, Inc) nitrocellulose slide that was spotted with rabbit polyclonal phospho-specific antibodies recognizing the following 20 proteins: EGFR (Tyr1173); Tyk2 (Tyr1054/105); ATF-2 (Thr71); eIF2 a (Ser51); eIF4E (Ser209); Cdc2 (Tyr15); p38 (Thr180/Tyr182); Cdk1 (Thr14/Tyr15); CREB (Ser133); Akt (Ser473); eNOS (Ser1177); CREB (Ser133).; c-Jun(Ser63); Elk-1 (Ser383); ErbB2 (Tyr1248); Bad (Ser112); Jak1 (Tyr1022/1023); p70 S6 (Thr421/Ser424); ERK½ (Thr202/Tyr204); and Cdc25 (Ser216).
[0085] 7. The slide was washed 3× with TBC-tween for 5 minutes, then incubated with a horseradish peroxidase-conjugated goat anti-rabbit antibody for 1 hour at 4 degrees C.
[0086] 8. Chemiluminescent detection was performed using the ECL-plus kit from Amersham following recommended manufacturer procedures.
[0087] 9. Proteins whose phosphorylation is dependent upon p38 kinase activity and lie downstream of the p38 kinase are subsequently identified by their inhibition of phosphorylation due to the pre-incubation of the specific p38 kinase inhibitor.
[0088] 10. For 2D-PAGE applications, the lysates are 35 enriched for phosphorylated proteins via:
[0089] i. Affinity chromatography-based or immuno-precipitation-based methods (i.e., using a anti-phosphotyrosine antibody, anti-phosphoserine antibody, etc.); and
[0090] ii. Eluted by a competitive mimetic such as phenylphosphate or sodium pyrophosphate or a specific peptide used as the antigen for the development of the antibody.
[0091] iii. The resultant eluate is then run on the gels directly, and phosphorylated proteins detected by traditional staining procedures compatible with mass spectroscopy-based protein identification (e.g., colloidal coomassie, ponceau S, SYPRO Ruby-red (Molecular Probes, Eugene, OR), and so forth)
[0092] iv. The visualized proteins are identified by mass spectroscopy and proteins whose activity lie downstream and are substrates for the p38 kinase are identified by the absence of the signal on the gel which separated lysates that were pre-treated with the specific kinase inhibitor.
[0093] 11. For flow-through applications see the previous example for IFNA and ERB2.
[0094] 12. For mass-spectrophotometric applications a Ciphergen Inc. mass spec. instrument was employed.
[0095] The resultant phosphoprotein-enriched eluates or whole cell extracts are incubated on bait traps that specifically bind phosphorylated proteins. Such baits may be protein-based (e.g., anti-phosphotyrosine antibody) or chemical (e.g., iron, gallium ion, etc.). The surfaces are then washed and phosphorylated proteins detected and identified by time-of-flight or collision-induced daughter ion spectral analysis.
[0096] Novel circuit profiles and maps were successfully obtained using ligands that recognized the phosphorylated versions of the 20 proteins listed in above.
[0097] 1. The following proteins were identified to lie downstream of p38 kinase: CREB, CD25, cJUN, Cdk1, and e1f2A.
[0098] 2. The following proteins can be activated in primary human monocytes: EGFR, Tyk2, E1F2 a , E1F4E, p38, CDK1, CREB, c-Jun, Elk-1, BAD, Jak1, Erk ½, CD25. The following were specific to monocytes and not found in lymphocytes from the same patient: EGFR, Tyk2, E1F2 a.
[0099] 3. The following proteins are specifically activated in primary human lymphocytes but not monocytes from the same patient: ERB2.
[0100] 4. The following new unknown proteins changed their phosphorylation state in response to treatment with SB203589: mw. 100 kDa; mw. 85 kDa; mw. 35 kDa; mw. 30 kDa; mw.25 kDa; mw. 20 kDa.
[0101] 5. ERB2 positive primary human breast cancer cells show that ERK is interacting and binding with the following proteins to a greater level than ERB2 negative human breast cancer cells: pERB2, pERB1, pELK, p70S6K.
[0102] 6. Fresh human brain and prostate tissue cells can be treated ex vivo with phosphatase inhibitors under the subject invention resulting in the identification of proteins that are phosphorylated in a tissue and disease specific manner.
[0103] FIG. 19 is a flow chart of a molecular detection method in accordance with the present invention. As indicated in step 402 , the method includes arranging a series of recognition molecules or binding reagents which selectively bind to the various proteins, their phosphorylated or activated state, and their binding partners, of a signal transduction pathway to form a signal transduction pathway profiling chip 100 as described above by way of reference to FIG. 1 . The method further includes applying (step 404 ) a cell lysate from a tissue of interest to the profiling chip. Thereafter, the sample is allowed to bind or hybridize with the recognition molecules at the binding sites 116 ( FIG. 1 ) as indicated by step 406
[0104] At step 408 , binding events at the plurality of binding sites 116 are detected. The detection can be performed by a number of labeling or other techniques to produce a detectable signal, such as spectrophotometric, fluorometric, colorimetric, chemiluminescent, radiometric, electrochemical, photochemical, enzymatic, or optical readout techniques, and the like. In one embodiment, the step of detecting the binding events provides a qualitative indication of binding at each binding site. More preferably, however, a quantitative determination of binding at each binding site is made at step 408 , for example, by determining an intensity or magnitude of the detectable signal at each binding site.
[0105] At step 410 , the detected binding events are used to determine a characteristic of the analyzed sample. By identifying at which sites binding events occurred, the status of the selected pathway can be determined. The determination can be made by visual detection of the binding sites. Alternately, the characteristics can be determined automatically, for example, using a binding event sensor and pattern recognition software so that the pathway status can be determined under preprogrammed control. Furthermore, heuristic algorithms are used to correlate binding patterns and/or pathway status with cellular conditions, such as normal, pre-disease, or disease states. The use of patterns for the identification of a pathway and/or disease state of a cell sample is illustrated in FIGS. 20 and 21 .
[0106] Appendix A of 17 pages is incorporated herein by reference. Appendix A presents further exemplary embodiments related to the protein interaction profiling system and method of the present invention.
[0107] The description above should not be construed as limiting the scope of the invention, but as merely providing illustrations to some of the presently preferred embodiments of this invention. In light of the above description and examples, various other modifications and variations will now become apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims. Accordingly, the scope of the invention should be determined solely by the appended claims and their legal equivalents. | An assay device for determining the presence of analytes in a cell lysate comprises a porous support member and a plurality of binding reagents arranged and immobilized at multiple reaction sites on the support member. The binding reagents are selected and arranged to assess the status of a selected cellular signal transduction pathway/protein-protein interactive network. In a further aspect, a method for assessing the status of a signal transduction pathway comprises generating a lysate of cells, the lysate retaining one or more pathway molecules present in one or more states and the pathway molecules reflecting signal transduction events taking place in the cells. The method further includes applying the lysate to an immobilized series of binding reagents which can discriminate the pathway molecules and their states. Binding events between the pathway molecules and the binding reagents are identified and the state of the selected signal pathway is determined. | 6 |
This application is a Continuation of U.S. application Ser. No. 09/979,344, filed Nov. 21, 2001, now U.S. Pat. No. 6,710,190 which is a 371 filing of PCT/US00/11397 filed Apr. 28, 2000, which claims the benefit of U.S. Provisional Application 60/136,491 filed May 28, 1999, the entire contents of which applications are hereby incorporated herein by reference.
Compounds of formula:
wherein R 1 is hydrogen or a lower alkyl radical and n is 4, 5, or 6 are known in U.S. Pat. No. 4,024,175 and its divisional U.S. Pat. No. 4,087,544. The uses disclosed are: protective effect against cramp induced by thiosemicarbazide; protective action against cardiazole cramp; the cerebral diseases, epilepsy, faintness attacks, hypokinesia, and cranial traumas; and improvement in cerebral functions. The compounds are useful in geriatric patients. The patents are hereby incorporated by reference.
SUMMARY OF THE INVENTION
The instant invention is a compound of Formula I and II
wherein A, X, Y, Z, W, and n are as described below.
The compounds of the invention and their pharmaceutically acceptable salts and the prodrugs of the compounds, are useful in the treatment of epilepsy, faintness attacks, hypokinesia, cranial disorders, neurodegenerative disorders, depression, anxiety, panic, pain, neuropathological disorders, gastrointestinal disorders such as irritable bowel syndrome (IBS), and inflammation, especially arthritis.
The invention is also a pharmaceutical composition of a compound of Formula I or II.
The invention also includes novel intermediates useful in the preparation of the final products.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the invention are those of Formula I and II:
or a pharmaceutically acceptable salt thereof wherein:
In Formula I, A is O, S, or NR wherein R is hydrogen, straight or branched alkyl of from 1 to 6 carbon atoms, cycloalkyl of from 3 to 8 carbon atoms, phenyl or benzyl;
In Formula II, A is N;
X, Y, Z and W are each independently hydrogen, straight or branched alkyl of from 1 to 6 carbon atoms;
cycloalkyl of from 3 to 8 carbon atoms, alkoxy, phenyl, benzyl, or halogen; and
n is an integer of from 1 to 4.
Preferred compounds are those of Formula I and II wherein Formula I and II are:
Other preferred compounds are those of Formula I wherein A is oxygen.
Other preferred compounds are those of Formula I wherein A is sulfur.
Other preferred compounds are those of Formula I wherein A is NR.
When A is N, preferred compounds can also be those of Formula II.
More preferred compounds are selected from:
3-Aminomethyl-4-thiophen-2-yl-butyric acid;
3-Aminomethyl-4-thiophen-3-yl-butyric acid;
3-Aminomethyl-4-furan-2-yl-butyric acid;
3-Aminomethyl-4-furan-3-yl-butyric acid;
3-Aminomethyl-4-pyrrole-2-yl-butyric acid;
3-Aminomethyl-4-pyrrole-3-yl-butyric acid; and
3-Aminomethyl-4-pyrrole-1-yl-butyric acid;
The term lower alkyl is a straight or branched group of from 1 to 6 carbons including but not limited to methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, pentyl, except as where otherwise stated.
The benzyl and phenyl groups may be unsubstituted or substituted by from 1 to 3 substituents selected from hydroxy, carboxy, carboalkoxy, halogen, CF 3 , nitro, alkyl, and alkoxy. Preferred are alkyl.
Cycloalkyl is cyclic carbon group of from 3 to 8 atoms.
Alkoxy is a straight or branched group of from 1 to 4 carbons attached to the remainder of the molecule by an oxygen.
Halogen is chlorine, fluorine, bromine, or iodine.
The prodrugs of the compounds include, but are not limited to esters, amides, and carbamates.
Since amino acids are amphoteric, pharmacologically compatible salts of appropriate inorganic or organic acids, for example, hydrochloric, sulphuric, phosphoric, acetic, oxalic, lactic, citric, malic, salicylic, malonic, maleic, succinic, methanesulfonic acid, and ascorbic. Starting from corresponding hydroxides or carbonates, salts with alkali metals or alkaline earth metals, for example, sodium, potassium, magnesium, or calcium are formed. Salts with quaternary ammonium ions can also be prepared with, for example, the tetramethyl-ammonium ion. The carboxyl group of the amino acids can be esterified by known means.
Certain of the compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
Certain of the compounds of the present invention possess one or more chiral centers and each center may exist in the R(D) or S(L) configuration. The present invention includes all enantiomeric and epimeric forms as well as the appropriate mixtures thereof.
Methods and Materials
Animals
Male Sprague-Dawley rats (180-250 g) were obtained from Bantin and Kingman, (Hull, U.K.). Animals were housed in groups of 6 to 10 under a 12 hour light/dark cycle (lights on at 7 hours, 0 minutes) with food and water ad libitum.
Carrageenan-Induced Thermal Hyperalgesia in the Rat
Thermal hyperalgesia was assessed using the rat plantar test (Ugo Basile, Italy) following a modified method of Hargreaves, et al., 1988. Rats were habituated to the apparatus which consisted of three individual perspex boxes on an elevated glass table. A mobile radiant heat source located under the table was focused onto the desired paw and paw withdrawal latencies (PWL) recorded. PWL were taken 3 times for both hind paws of each animal, the mean of which represented baselines for right and left hind paws. At least 5 minutes were allowed between each PWL for an animal. The apparatus was calibrated to give a PWL of approximately 10 seconds. There was an automatic cutoff point of 20 seconds to prevent tissue damage. After baseline PWLs were determined, animals received an intraplantar injection of carrageenan (100 μL of 20 mg/mL) into the right hind paw. PWLs were reassessed following the same protocol as above 2-hour post-carrageenan (this time point represented the start of peak hyperalgesia) to ascertain that hyperalgesia had developed. Test compounds were administered orally (in a volume of 1 ml kg) at 2.5 hours after carrageenan. PWLs were reassessed at various times after drug administration.
A Model of Anticonvulsant Efficacy and Protocol for DBA2 Test: Prevention of Audiogenic Seizures in DBA/2 Mice
Methods
All procedures were carried out in compliance with the NIH Guide for the Care and Use of Laboratory Animals under a protocol approved by the Parke-Davis Animal Use Committee. Male DBA/2 mice, 3 to 4 weeks old, were obtained from Jackson Laboratories, Bar Harbour, Me. Immediately before anticonvulsant testing, mice were placed upon a wire mesh, 4 inches square suspended from a steel rod. The square was slowly inverted through 180 degrees and mice observed for 30 seconds. Any mouse falling from the wire mesh was scored as ataxic.
Mice were placed into an enclosed acrylic plastic chamber (21 cm height, approximately 30 cm diameter) with a high-frequency speaker (4 cm diameter) in the center of the top lid. An audio signal generator (Protek model B-810) was used to produce a continuous sinusoidal tone that was swept linearly in frequency between 8 kHz and 16 kHz once each 10 msec. The average sound pressure level (SPL) during stimulation was approximately 100 dB at the floor of the chamber. Mice were placed within the chamber and allowed to acclimatize for 1 minute. DBA/2 mice in the vehicle-treated group responded to the sound stimulus (applied until tonic extension occurred, or for a maximum of 60 seconds) with a characteristic seizure sequence consisting of wild running followed by clonic seizures, and later by tonic extension, and finally by respiratory arrest and death in 80% or more of the mice. In vehicle-treated mice, the entire sequence of seizures to respiratory arrest lasts approximately 15 to 20 seconds.
The incidence of all the seizure phases in the drug-treated and vehicle-treated mice was recorded, and the occurrence of tonic seizures were used for calculating anticonvulsant ED 50 values by probit analysis. Mice were used only once for testing at each dose point. Groups of DBA/2 mice (n=5-10 per dose) were tested for sound-induced seizure responses 2 hours (previously determined time of peak effect) after given drug orally. All drugs in the present study were dissolved in distilled water and given by oral gavage in a volume of 10 ml/kg of body weight compounds that are insoluble will be suspended in 1% carboxymethocellulose. Doses are expressed as weight of the active drug moiety.
Results
The dose-dependent suppression of sound-induced tonic seizures in DBA/2 mice was tested, and the corresponding ED 50 values are shown in Table 1.
The present results show that the compounds of the invention given orally cause dose-related anticonvulsant effects in a sound susceptible strain (DBA/2) of mice, confirming previous data showing anticonvulsant activity in other models of experimental epilepsy. The effective dosages of drugs in this model are lower than those in the maximal electroshock test, confirming that DBA/2 mice are a sensitive model for detecting anticonvulsant actions.
TABLE 1
DBA2 Mouse
Pain Model
Model
α 2 δ Assay
% MPE
% Protect
Structure
IC 50 (μM)
1 h
2 h
Time
0.421
61.6
24.9
0 (1 h) 20 (2 h)
0.831
N/A
40 (1 h) 60 (2 h)
2.67
31.9
18.1
20 (1 h) 40 (2 h)
The radioligand binding assay using [ 3 H]gabapentin and the α 2 δ subunit derived from porcine brain tissue was used (“The Novel Anti-convulsant Drug, Gabapentin, Binds to the α 2 δ Subunit of a Calcium Channel”, Gee N. et al., J. Biological Chemistry , in press).
The compounds of the invention show good binding affinity to the α 2 δ subunit. Gabapentin (Neurontin®) is about 0.10 to 0.12 μM in this assay. Since the compounds of the instant invention also bind to the subunit, they are expected to exhibit pharmacologic properties comparable to gabapentin. For example, as agents for convulsions, anxiety, and pain.
The compounds of the invention are related to Neurontin®, a marketed drug effective in the treatment of epilepsy. Neurontin® is 1-(aminomethyl)-cyclohexaneacetic acid of structural formula:
The compounds of the invention are also expected to be useful in the treatment of epilepsy.
The present invention also relates to therapeutic use of the compounds of the mimetic as agents for neurodegenerative disorders.
Such neurodegenerative disorders are, for example, Alzheimer's disease, Huntington's disease, Parkinson's disease, and Amyotrophic Lateral Sclerosis.
The present invention also covers treating neurodegenerative disorders termed acute brain injury. These include but are not limited to: stroke, head trauma, and asphyxia.
Stroke refers to a cerebral vascular disease and may also be referred to as a cerebral vascular incident (CVA) and includes acute thromboembolic stroke. Stroke includes both focal and global ischemia. Also, included are transient cerebral ischemic attacks and other cerebral vascular problems accompanied by cerebral ischemia such as in a patient undergoing carotid endarterectomy specifically or other cerebrovascular or vascular surgical procedures in general, or diagnostic vascular procedures including cerebral angiography and the like.
Other incidents are head trauma, spinal cord trauma, or injury from general anoxia, hypoxia, hypoglycemia, hypotension as well as similar injuries seen during procedures from embole, hyperfusion, and hypoxia.
The instant invention would be useful in a range of incidents, for example, during cardiac bypass surgery, in incidents of intracranial hemorrhage, in perinatal asphyxia, in cardiac arrest, and status epilepticus.
A skilled physician will be able to determine the appropriate situation in which subjects are susceptible to or at risk of, for example, stroke as well as suffering from stroke for administration by methods of the present invention.
The compounds of the invention are also expected to be useful in the treatment of depression. Depression can be the result of organic disease, secondary to stress associated with personal loss, or idiopathic in origin. There is a strong tendency for familial occurrence of some forms of depression suggesting a mechanistic cause for at least some forms of depression. The diagnosis of depression is made primarily by quantification of alterations in patients' mood. These evaluations of mood are generally performed by a physician or quantified by a neuropsychologist using validated rating scales, such as the Hamilton Depression Rating Scale or the Brief Psychiatric Rating Scale. Numerous other scales have been developed to quantify and measure the degree of mood alterations in patients with depression, such as insomnia, difficulty with concentration, lack of energy, feelings of worthlessness, and guilt. The standards for diagnosis of depression as well as all psychiatric diagnoses are collected in the Diagnostic and Statistical Manual of Mental Disorders (Fourth Edition) referred to as the DSM-IV-R manual published by the American Psychiatric Association, 1994.
GABA is an inhibitory neurotransmitter with the central nervous system. Within the general context of inhibition, it seems that GABA-mimetics will decrease or inhibit cerebral function and will therefore slow function and decrease mood leading to depression.
The compounds of the instant invention may produce an anticonvulsant effect through the increase of newly created GABA at the synaptic junction. If gabapentin does indeed increase GABA levels or the effectiveness of GABA at the synaptic junction, then it could be classified as a GABA-mimetic and might decrease or inhibit cerebral function and might, therefore, slow function and decrease mood leading to depression.
The fact that a GABA agonist or GABA-mimetic might work just the opposite way by increasing mood and thus, be an antidepressant, is a new concept, different from the prevailing opinion of GABA activity heretofore.
The compounds of the instant invention are also expected to be useful in the treatment of anxiety and of panic as demonstrated by means of standard pharmacological procedures.
Carrageenin-Induced Hyperalgesia, Another Method
Nociceptive pressure thresholds were measured in the rat paw pressure test using an analgesymeter (Randall-Sellitto Method: Randall L. O., Sellitto J. J., A method for measurement of analgesic activity on inflamed tissue. Arch. Int. Pharmacodyn., 1957;4:409-419). Male Sprague-Dawley rats (70-90 g) were trained on this apparatus before the test day. Pressure was gradually applied to the hind paw of each rat and nociceptive thresholds were determined as the pressure (g) required to elicit paw withdrawal. A cutoff point of 250 g was used to prevent any tissue damage to the paw. On the test day, two to three baseline measurements were taken before animals were administered 100 μL of 2% carrageenin by intraplantar injection into the right hind paw. Nociceptive thresholds were taken again 3 hours after carrageenin to establish that animals were exhibiting hyperalgesia. Animals were dosed with either gabapentin (3-300 mg/kg, s.c.), morphine (3 mg/kg, s.c.), or saline at 3.5 hours after carrageenin and nociceptive thresholds were examined at 4, 4.5, and 5 hours post-carrageenin.
Semicarbazide-Induced Tonic Seizures
Tonic seizures in mice are induced by subcutaneous administration of semicarbazide (750 mg/kg). The latency to the tonic extension of forepaws is noted. Any mice not convulsing within 2.0 hours after semicarbazide are considered protected and given a maximum latency score of 120 minutes.
Animals
Male Hooded Lister rats (200-250 g) are obtained from Interfauna (Huntingdon, UK) and male TO mice (20-25 g) are obtained from Bantin and Kingman (Hull, UK). Both rodent species are housed in groups of six. Ten Common Marmosets (Callithrix Jacchus) weighing between 280 and 360 g, bred at Manchester University Medical School (Manchester, UK) are housed in pairs. All animals are housed under a 12-hour light/dark cycle (lights on at 07.00 hour) and with food and water ad libitum.
Drug Administration
Drugs are administered either intraperitoneally (IP) or subcutaneously (SC) 40 minutes before the test in a volume of 1 ml/kg for rats and marmosets and 10 ml/kg for mice.
Mouse Light/Dark Box
The apparatus is an open-topped box, 45 cm long, 27 cm wide, and 27 cm high, divided into a small (⅖) and a large (⅗) area by a partition that extended 20 cm above the walls (Costall B., et al., Exploration of mice in a black and white box: validation as a model of anxiety. Pharmacol. Biochem. Behav., 1989;32:777-785).
There is a 7.5×7.5 cm opening in the center of the partition at floor level. The small compartment is painted black and the large compartment white. The white compartment is illuminated by a 60-W tungsten bulb. The laboratory is illuminated by red light. Each mouse is tested by placing it in the center of the white area and allowing it to explore the novel environment for 5 minutes. The time spent in the illuminated side is measured (Kilfoil T., et al., Effects of anxiolytic and anxiogenic drugs on exploratory activity in a simple model of anxiety in mice. Neuropharmacol., 1989;28:901-905).
Rat Elevated X-Maze
A standard elevated X-maze (Handley S. L., et al., Effects of alpha-adrenoceptor agonists and antagonists in a maze-exploration model of ‘fear’-motivated behavior. Naunyn - Schiedeberg's Arch. Pharmacol., 1984;327: 1-5) was automated as previously described (Field, et al., Automation of the rat elevated X-maze test of anxiety. Br. J. Pharmacol., 1991;102(Suppl):304P). The animals are placed on the center of the X-maze facing one of the open arms. For determining anxiolytic effects the entries and time spent on the end half sections of the open arms is measured during the 5-minute test period (Costall, et al., Use of the elevated plus maze to assess anxiolytic potential in the rat. Br. J. Pharmacol., 1989;96(Suppl):312P).
Marmoset Human Threat Test
The total number of body postures exhibited by the animal towards the threat stimulus (a human standing approximately 0.5 m away from the marmoset cage and staring into the eyes of the marmoset) is recorded during the 2-minute test period. The body postures scored are slit stares, tail postures, scent marking of the cage/perches, piloerection, retreats, and arching of the back. Each animal is exposed to the threat stimulus twice on the test day before and after drug treatment. The difference between the two scores is analyzed using one-way analysis of variance followed by Dunnett's t-test. All drug treatments are carried out SC at least 2 hours after the first (control) threat. The pretreatment time for each compound is 40 minutes.
Rat Conflict Test
Rats are trained to press levers for food reward in operant chambers. The schedule consists of alternations of four 4-minute unpunished periods on variable interval of 30 seconds signaled by chamber lights on and three 3-minute punished periods on fixed ratio 5 (by footshock concomitant to food delivery) signaled by chamber lights off. The degree of footshock is adjusted for each rat to obtain approximately 80% to 90% suppression of responding in comparison with unpunished responding. Rats receive saline vehicle on training days.
The compounds of the instant invention are also expected to be useful in the treatment of pain and phobic disorders ( Am. J. Pain Manag., 1995;5:7-9).
The compounds of the instant invention are also expected to be useful in treating the symptoms of manic, acute or chronic, single upside, or recurring. They are also expected to be useful in treating and/or preventing bipolar disorder (U.S. Pat. No. 5,510,381).
Models of Irritable Bowel Syndrome
TNBS-Induced Chronic Visceral Allodynia in Rats
Injections of trinitrobenzene sulfonic (TNBS) into the colon have been found to induce chronic colitis. In human, digestive disorders are often associated with visceral pain. In these pathologies, the visceral pain threshold is decreased indicating a visceral hypersensitivity. Consequently, this study was designed to evaluate the effect of injection of TNBS into the colon on visceral pain threshold in a experimental model of colonic distension.
Materials and Methods
Animals and Surgery
Male Sprague-Dawley rats (Janvier, Le Genest-St-Ilse, France) weighing 340-400 g are used. The animals are housed 3 per cage in a regulated environment (20±1° C., 50±5% humidity, with light 8:00 am to 8:00 pm). Under anesthesia (ketamine 80 mg/kg i.p; acepromazin 12 mg/kg ip), the injection of TNBS (50 mg/kg) or saline (1.5 mL/kg) is performed into the proximal colon (1 cm from the cecum). After the surgery, animals are individually housed in polypropylene cages and kept in a regulated environment (20±1° C., 50±5% humidity, with light 8:00 AM to 8:00 PM) during 7 days.
Experimental Procedure
At Day 7 after TNBS administration, a balloon (5-6 cm length) is inserted by anus and kept in position (tip of balloon 5 cm from the anus) by taping the catheter to the base of the tail. The balloon is progressively inflated by step of 5 mm Hg, from 0 to 75 mm Hg, each step of inflation lasting 30 seconds. Each cycle of colonic distension is controlled by a standard barostat (ABS, St-Dié, France). The threshold corresponds to the pressure which produced the first abdominal contraction and the cycle of distension is then discontinued. The colonic threshold (pressure expressed in mm Hg) is determined after performance of four cycles of distension on the same animal.
Determination of the Activity of the Compound
Data is analyzed by comparing test compound-treated group with TNBS-treated group and control group. Mean and sem are calculated for each group. The antiallodynic activity of the compound is calculated as follows:
Activity (%)=(group C −group T )/(group A −group T )
Group C: mean of the colonic threshold in the control group
Group T: mean of the colonic threshold in the TNBS-treated group
Group A: mean of the colonic threshold in the test compound-treated group
Statistical Analysis
Statistical significance between each group was determined by using a one-way ANOVA followed by Student's unpaired t-test. Differences were considered statistically significant at p<0.05.
Compounds
TNBS is dissolved in EtOH 30% and injected under a volume of 0.5 mL/rat. TNBS is purchased from Fluka.
Oral administration of the test compound or its vehicle is performed 1 hour before the colonic distension cycle.
The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. Thus, the compounds of the present invention can be administered by injection, that is, intravenously, intramuscularly, intracutaneously, subcutaneously, intraduodenally, or intraperitoneally. Also, the compounds of the present invention can be administered by inhalation, for example, intranasally. Additionally, the compounds of the present invention can be administered transdermally. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of Formula I or II or a corresponding pharmaceutically acceptable salt of a compound of Formula I or II.
For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted, and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents as desired.
Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
The pharmaceutical preparation is preferably in unit dosage form. In such form the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active component in a unit dose preparation may be varied or adjusted from 0.1 mg to 1 g according to the particular application and the potency of the active component. In medical use the drug may be administered three times daily as, for example, capsules of 100 or 300 mg. The composition can, if desired, also contain other compatible therapeutic agents.
In therapeutic use, the compounds utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 0.01 mg to about 100 mg/kg daily. A daily dose range of about 0.01 mg to about 100 mg/kg is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
General Synthetic Routes
The ester 1 can be prepared by heating to reflux of the corresponding acid in a solvent such as ethanol and the like in the presence of a catalytic amount of mineral acid such as hydrochloric acid. It can also be prepared from the acid with an appropriate chloroformate in the presence of DMAP and a base such as triethylamine. Alternatively, the ester can also be prepared from the corresponding aldehyde via a “Wittig-like” reaction followed by hydrogenation of the double bond by catalytic hydrogenation according to methods described within the literature.
Diester of structure 2 can be prepared from the ester 1 by alkylation with t-butyl bromoacetate in the presence of a base, such as lithium diisopropylamide, in a solvent such as THF. The diester 2 can be selectively converted to the monoester 3 by saponification with an aqueous base, preferably lithium hydroxide. The acid 3 can be reduced to the alcohol 4 according to published literature procedures. The alcohol 4 can be converted to the azide 5 via a 2-step procedure involving first conversion of the alcohol into its tosylate or mesylate and then followed by treatment with excess sodium azide. The azide 5 can be converted to the GABA analog by another 2-step reaction sequence. Reduction of the azide group to an amine-and then deprotection of the t-butyl ester to the acid 8 produced the desired GABA analog. Alternatively, the t-butyl ester can be deprotected first before the reduction of the azide. The sequence of reaction also gave the required amino acids.
The GABA analogs of the current invention can be prepared enantioselectively by substituting the racemic acid 3 with the corresponding chiral acid. The chiral acid 3 was prepared as shown in Method B where the acid 9 is coupled with any of the Evans' chiral oxazolidinones to give compound 10. Compound 10 was alkylated with t-butyl bromoacetate in the presence of a base, such as lithium diisopropylamide, in a solvent such as THF to give the chiral ester 11. The ester 11 was saponified to the chiral acid 3 by lithium hydroxide and hydrogen peroxide treatment. The chiral acid 3 was converted to the chiral GABA analogs using the same reaction sequence as shown in Method A.
Method C can be used to prepare some of the GABA analogs of generic structure II in the current invention. The key intermediate 15 can be prepared from compound 12 via a 3-step Michael addition, Boc deprotection and reduction sequence. The amino lactam 15 can be reacted with an appropriately substituted carbonyl compound in the presence of an acid, preferably acetic acid to give the pyrrole derivative 16. Reprotection of the lactam 16 as its Boc analog followed by lithium hydroxide saponification will give the acid 18. The Boc protecting group can be removed by acid treatment to give the desired GABA analog 19.
The acid 22 can be prepared by treating the amino acid 20 with an approximately substituted carbonyl compound 21 in the presence of an acid, preferably acetic acid. The ester 23 can be prepared by heating to reflux of the corresponding acid in a solvent such as ethanol and the like in the presence of a catalytic amount of mineral acid such as hydrochloric acid. It can also be prepared from the acid with an appropriate chloroformate in the presence of DMAP and a base such as triethylamine according to methods described within the literature. Diester of structure 24 can be prepared from the ester 23 by alkylation with t-butyl bromoacetate in the presence of a base, such as lithium diisopropylamide, in a solvent such as THF. The diester 24 can be selectively converted to the monoester 25 by saponification with an aqueous base, preferably lithium hydroxide. The acid 25 can be reduced to the alcohol 26 according to published literature procedures. The alcohol 26 can be converted to the azide 27 via a 2-step procedure involving first conversion of the alcohol into its tosylate or mesylate and then followed by treatment with excess sodium azide. The azide 27 can be converted to the GABA analog by another 2-step reaction sequence. Reduction of the azide group to an amine and then deprotection of the t-butyl ester to the acid 29 produced the desired GABA analog.
The GABA analogs of generic structure II in the current invention can be prepared enantioselectively by substituting the racemic acid 25 with the corresponding chiral acid. The chiral acid 3 was prepared as shown in Method E where the acid 22 is coupled with any of the Evans' chiral oxazolidinones to give compound 30. Compound 30 was alkylated with t-butyl bromoacetate in the presence of a base, such as lithium diisopropylamide, in a solvent such as THF to give the chiral ester 31. The ester 31 was saponified to the chiral acid 25 by lithium hydroxide and hydrogen peroxide treatment. The chiral acid 25 was converted to the chiral GABA analogs using the same reaction sequence as shown in Method D.
The following examples are illustrative of methods of preparation for the final products and intermediates of the invention, they are not intended to limit the scope.
EXAMPLE 1
3-Thiophen-2-yl-propionic Acid
3-(2-Thienyl)acrylic acid (5.00 g, 32.43 mmol) was combined with 20% Pd/C (0.20 g) and methanol (150 mL) and stirred under a hydrogen atmosphere (1 atm) for 5 hours. Fresh catalyst (0.10 g) was added, and the reaction stirred another 6.5 hours under a hydrogen atmosphere (1 atm). The catalyst was filtered and washed with EtOAc (3×40 mL). The filtrate was concentrated to give the title compound 1 as a brown oil that crystallized upon standing (5.27 g, 100%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.10 (d, 1H, J=5.13 Hz), 6.89 (m, 1H), 6.80 (d, 1H, J=2.20 Hz), 3.14 (t, 2H, J=7.57 Hz), 2.71 (t, 2H, J=7.57 Hz). MS (APCI) m/z 155 (M − −1).
EXAMPLE 2
3-Thiophen-2-yl-propionic Acid Methyl Ester
Compound 1 (5.00 g, 32.01 mmol) was dissolved in anhydrous CH 2 Cl 2 (100 mL) and cooled in an ice bath while stirring under N 2 . Triethyl amine (4.95 mL, 35.53 mmol) was added, and the reaction stirred for 5 minutes. Methyl chloroformate (2.48 mL, 32.05 mmol) was added, the reaction stirred for 5 minutes, and DMAP (0.38 g, 3.11 mmol) added. The reaction was stirred at 0° C. for 30 minutes, and then diluted with CH 2 Cl 2 (200 mL). The organics were washed with saturated NaHCO 3 (100 mL), 0.1 M HCl (100 mL), brine (100 mL), and dried over MgSO 4 . The crude material was chromatographed on SiO 2 eluting with 7% EtOAc/hexanes to give the title compound 2 (3.976 g, 73%) as a colorless oil).
1 H NMR (400 MHz, CDCl 3 ) δ 7.10 (dd, 1H, J=4.64, 0.98 Hz), 6.88 (t, 1H, J=4.27 Hz), 6.78 (dd, 1H, J=2.20, 0.98 Hz), 3.66 (s, 3H), 3.13 (t, 2H, J=7.57 Hz), 2.66 (t, 2H, J=7.57 Hz). MS (APCI) m/z 171 (M + +1).
EXAMPLE 3
2-Thiophen-2-ylmethyl-succinic Acid Dimethyl Ester
Diisopropyl amine (2.1 mL, 15.0 mmol) was dissolved in anhydrous THF (35 mL) and cooled to −78° C. nBuLi (8.81 mL, 1.6 M, 14.1 mmol) was added, and the reaction stirred for 30 minutes at −78° C. Compound 2 (2.00 g, 11.75 mmol) was diluted up in THF (5 mL) and added dropwise to the LDA solution. After addition, the reaction was stirred for 30 minutes at −78° C. t-Butyl bromoacetate (2.60 mL, 17.6 mmol) was dissolved in THF (25 mL) and cooled to −78° C. The LDA solution was added via cannula to the t-butylbromo acetate solution, and the reaction stirred at −78° C. for 90 minutes. The reaction was quenched with saturate NaH 2 PO 4 . The layers were separated, and the aqueous layer extracted with EtOAc (3×20 mL). The combined organics were dried over MgSO 4 , filtered and concentrated. The crude oil was chromatographed on SiO 2 eluting with 7% EtOAc/hexanes to give the title compound 3 (1.811 g, 54%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.11 (d, 1H, J=5.13 Hz), 6.88 (m, 1H), 6.76 (d, 1H, J=2.93 Hz), 3.66 (s, 3H), 3.18 (m, 1H), 3.06-2.99 (m, 2H), 2.56 (dd, 1J=16.60, 8.55 Hz), 2.37 (dd, 1H, J=16.60, 4.64 Hz), 1.39 (s, 9H). MS (APCI) m/z 211 (M + −73, OtBu).
EXAMPLE 4
2-Thiophen-2-ylmethyl-succinic Acid 4-tert-butyl Ester
Compound 3 (1.80 g, 6.33 mmol) was dissolved in THF (20 mL) and cooled in an ice bath. LiOH (9.49 mL, 1N, 9.49 mmol) was added, followed by iPrOH (3 mL). The reaction was stirred at room temperature for 18 hours. The solvent was rotovapped off, and the residue diluted with water (50 mL). The water was extracted with ether (2×20 mL), acidified with saturated NaH 2 PO 4 , and extracted with EtOAc (3×50 mL). The combined organics were dried over MgSO 4 , filtered, and concentrated to give the title compound 4 (1.611 g, 94%) as an oil that crystallized upon standing.
1 H NMR (400 MHz, CDCl 3 ) δ 7.12 (d, 1H, J=4.88 Hz), 6.89 (dd, 1H, J=4.88, 3.42 Hz), 6.80 (d, 1H, J=2.69 Hz), 3.24 (m, 1H), 3.09-3.02 (m, 2H), 2.56 (dd, 1H, J=16.60, 8.55 Hz), 2.40 (dd, 1H, J=16.60, 4.64 Hz), 1.39 (s, 9H). MS (APCI) m/z 269 (M − −1). Analysis calculated for C 13 H 18 O 4 S: C, 57.76; H, 6.78; S, 11.74. Found: C, 57.85; H, 6.78; S, 11.74.
EXAMPLE 5
3-Hydroxymethyl-4-thiophen-2-yl-butyric Acid Tert-Butyl Ester
Compound 4 (1.576 g, 5.83 mmol) was dissolved in anhydrous THF (60 mL) and cooled in an ice bath. Borane dimethyl sulfide complex (2.91 mL, 29.1 mmol) was added dropwise, and the reaction stirred at 0° C. for 15 minutes, then at room temperature for 18 hours. The reaction was cooled again in an ice bath and quenched with methanol (25 mL) added dropwise. The solvent was then concentrated and the crude oil chromatographed on silica eluting with 25% EtOAc/hexanes to give the title compound 5 (1.05 g, 70%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.11 (d, 1H, J=5.1 Hz), 6.89 (dd, 1H, J=5.0, 3.5 Hz), 6.78 (d, 1H, J=2.69 Hz), 3.62 (m, 1H), 3.53 (m, 1H), 2.90-2.83 (m, 2H), 2.29 (s, 3H), 1.90 (t, 1H, J=5.61 Hz), 1.42 (s, 9H). MS (APCI) m/z 183 (M + −73, -OtBu).
EXAMPLE 6
4-Thiophen-2-yl-3-(toluene-4-sulfonyloxymethyl)-butyric Acid Tert-Butyl Ester
Compound 5 (1.032 g, 4.03 mmol) was dissolved in anhydrous pyridine (8 mL) and cooled to 0° C. Tosyl chloride (1.075 g, 5.64 mmol) was added, and the reaction stirred at 0° C. for 1 hour. The reaction was then placed in a freezer overnight. The reaction was then diluted with EtOAc (75 mL). The solids were filtered and washed with EtOAc (30 mL). The filtrate was then washed with water (30 mL), 1N HCl (30 mL), and then brine (2×30 mL). The organics were dried over MgSO 4 , filtered, and concentrated to give an oil. This was chromatographed on silica eluting with 15% EtOAc/hexanes to give the title compound 6 (1.486 g, 90%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.73 (d, 2H, J=8.3 Hz), 7.29 (d, 2H, J=8.1 Hz), 7.08 (m, 1H), 6.83 (dd, 1H, J=5.0, 3.41 Hz), 6.65 (d, 1H, J=2.44 Hz), 3.98 (dd, 1H, J=9.64, 4.74 Hz), 3.92 (dd, 1H, J=9.52, 4.64 Hz), 2.83 (m, 2H), 2.41 (s, 3H), 2.37 (m, 1H), 2.24 (m, 2H), 1.37 (s, 9H). MS (APCI) m/z 337 (M + −73, -OtBu).
EXAMPLE 7
3-Azidomethyl-4-thiophen-2-yl-butyric Acid Tert-Butyl Ester
Compound 6 (1.486 g, 3.62 mmol), NaN 3 (0.54 g, 8.32 mmol), and DMSO (18 mL) were combined and heated to 60° C. for 17 hours. Water (50 mL) was added to the reaction and extracted with hexanes (4×30 mL). The combined organics were dried over MgSO 4 , filtered, and concentrated to give the title compound 7 (0.965 g, 95%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.12 (dd, 1H, J=5.13, 1.22 Hz), 6.90 (dd, 1H, J=5.00, 3.54 Hz), 6.78 (m, 1H), 3.34 (dd, 1H, J=12.2, 5.1 Hz), 3.29 (dd, 1H, J=12.3, 5.2 Hz), 2.91-2.83 (m, 2H), 2.35-2.30 (m, 1H), 2.29-2.23 (m, 2H), 1.42 (s, 9H).
EXAMPLE 8
3-Azidomethyl-4-thiophen-2-yl-butyric Acid
Compound 7 (0.950 g, 3.38 mmol) was dissolved in formic acid (8 mL, 88%) and heated to 30° C. for 2 hours. The reaction was cooled and the formic acid removed. The residue was diluted with water and extracted with hexanes/ether, followed by ether (3×40 mL). The combined organics were dried over MgSO 4 , filtered and concentrated to give the title compound 8 (0.738 g, 97%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.13 (dd, 1H, J=5.1, 0.98 Hz), 6.91 (dd, 1H, J=5.0, 3.54 Hz), 6.79 (d, 1H, J=3.4 Hz), 3.40 (dd, 1H, J=12.3, 5.0 Hz), 3.34 (dd, 1H, J=12.2, 5.4 Hz), 2.92 (dd, 1H, J=14.8, 6.9 Hz), 2.88 (dd, 1H, J=14.8, 6.2 Hz), 2.47-2.33 (m, 3H). MS (APCI) m/z 224 (M − −1).
EXAMPLE 9
3-Aminomethyl-4-thiophen-2-yl-butyric Acid
A solution of compound 8 (0.70 g, 3.11 mmol) in THF (50 mL) was shaken on a Parr apparatus under a H 2 atmosphere (50 psi) for 17 hours. The catalyst was filtered and washed with boiling THF (60 mL) followed by boiling THF/water (40 mL/30 mL). The filtrate was concentrated and the water saturated with NaCl extracted with EtOAc. The water layer rotovapped off and the solids washed with MeOH. The MeOH was evaporated to give a solid which was purified on ion exchange resin (Dowex 50WX8-100 strongly acidic resin) eluting first with water, then with 5% NH 4 OH. The title compound 9 (0.360 g, 58%) was isolated as a solid.
MP=168-170° C. MS (APCI) m/z 200 (M + +1), 198 (M − −1). Analysis calculated for C 9 H 13 NO 2 S: C, 54.25; H, 6.58; N, 7.03; S, 16.09. Found: C, 53.88; H, 6.64; N, 6.86; S, 16.24.
EXAMPLE 10
3-Thiophen-3-yl-acrylic Acid Methyl Ester
To a suspension of sodium hydride (3.65 g, 91.22 mmol) in anhydrous THF (250 mL) was added trimethylphosphono acetate (10.16 mL, 62.77 mmol) in THF (50 mL) dropwise. The thick reaction mixture was then stirred for 1 hour. 3 thiophene carboxaldehyde (5.00 mL, 57.01 mmol) was dissolved in THF (50 mL) and added dropwise, and the reaction stirred at room temp for 18 hours. The reaction was quenched with half saturated NH 4 Cl (120 mL). The layers were separated and the aqueous layer extracted with EtOAc (2×100 mL). The combined organics were washed with brine (100 mL), dried over MgSO 4 , filtered and concentrated. The crude material was chromatographed on silica eluting with hexanes, then 15% EtOAc/heavens to give the title compound 10 as an oil that crystallizes upon standing (9.05 g, 94%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.64 (d, 1H, J=15.7 Hz), 7.46 (d, 1H, J=1.47 Hz), 7.30 (dd, 1H, J=5.13, 2.69 Hz), 7.26 (d, 1H, J=5.13 Hz), 6.22 (d, 1H, J=16.1 Hz), 3.76 (s, 3H). MS (APCI) m/z 169 (M + +1). Analysis calculated for C 8 H 8 O 2 S: C, 57.12; H, 4.79; S, 19.06. Found: C, 57.20; H, 4.77; S, 19.10.
EXAMPLE 11
3-Thiophen-3-yl-propionic Acid Methyl Ester
Compound 10 (5.00 g, 29.72 mmol) was combined with 20% Pd/C (0.20 g) and MeOH (150 mL) and stirred under a H 2 balloon for 5 hours. Fresh catalyst (0.15 g) was added, and the reaction stirred for 4 hours under an H 2 balloon. The catalyst was filtered, washed with EtOAc, and the filtrated concentrated. The crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 11 (4.50 g, 89%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.22 (m, 1H), 6.94 (m, 1H), 6.90 (m, 1H), 3.64 (s, 3H), 2.94 (t, 2H, J=7.7 Hz), 2.60 (t, 2H, J=7.7 Hz). MS (APCI) m/z 139 (M + −31, -OMe).
EXAMPLE 12
2-Thiophen-3-ylmethyl-succinic Acid 4-tert-butyl Ester 1-methyl Ester
Diisopropyl amine (2.11 mL, 15.0 mmol) was dissolved in anhydrous THF (30 mL) and cooled to −78° C. nBuLi (8.81 mL, 1.6M, 14.1 mmol) was added, and the reaction stirred for 30 minutes at −78° C. Compound 11 (2.00 g, 11.75 mmol) was diluted up in THF (5 mL) and added dropwise to the LDA solution. After addition, the reaction was stirred for 30 minutes at −78° C. t-Butyl bromoacetate (2.60 mL, 17.6 mmol) was dissolved in THF (30 mL) and cooled to −78° C. The LDA solution was added via cannula to the t-butylbromo acetate solution, and the reaction stirred at −78° C. for 90 minutes. The reaction was quenched with saturated NaH 2 PO 4 and warmed to room temperature. The layers were separated, and the aqueous layer extracted with EtOAc (3×20 mL). The combined organics were dried over MgSO 4 , filtered and concentrated. The crude oil was chromatographed on SiO 2 eluting with 7% EtOAc/hexanes to give the title compound 12 (1.46 g, 44%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.22 (m, 1H), 6.94 (m, 1H), 6.87 (d, 1H, J=5.1 Hz), 3.63 (s, 3H), 3.03-2.95 (m, 2H), 2.80 (m, 1H), 2.54 (dd, 1H, J=16.4, 8.8 Hz), 2.30 (dd, 1H, J=16.5, 5.0 Hz), 1.38 (s, 9H). MS (APCI) m/z 252 (M + −32, —MeOH), 211 (M + −73, -OtBu).
EXAMPLE 13
2-Thiophen-3-ylmethyl-succinic Acid 4-tert-butyl Ester
Compound 12 (1.45 g, 5.10 mmol)) was dissolved in THF (20 mL) and cooled in an ice bath. LiOH (7.65 mL, 1N, 7.65 mmol) was added, followed by iPrOH (3 mL). The reaction was stirred at room temperature for 24 hours. Additional LiOH (2.5 mL, 1N) was added, and the reaction stirred for 72 hours. The solvent was removed and the residue diluted with water (25 mL). The water was extracted with ether (2×25 mL), acidified with saturated NaH 2 PO 4 , and extracted with EtOAc (3×50 mL). The combined organics were dried over MgSO 4 , filtered, and rotovapped to give the title compound 13 (1.142 g, 83%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.24 (dd, 1H, J=5.2, 2.3 Hz), 6.97 (m, 1H), 6.90 (dd, 1H, J=4.89, 1.22 Hz), 3.14-3.02 (m, 3H), 2.88-2.80 (m, 1H), 2.53 (dd, 1H, J=16.7, 8.7 Hz), 2.33 (dd, 1H, J=16.70, 4.8 Hz), 1.39 (s, 9H).
EXAMPLE 14
3-Hydroxymethyl-4-thiophen-3-yl-butyric Acid Tert-Butyl Ester
Compound 13 (1.125 g, 4.16 mmol) was dissolved in anhydrous THF (40 mL) and cooled in an ice bath. Borane dimethyl sulfide complex (2.08 mL, 20.8 mmol) was added dropwise, and the reaction stirred at 0° C. for 15 minutes, then at room temperature for 4 hours. The reaction was cooled again in an ice bath and quenched with methanol (25 mL) added dropwise. The solvent was then rotovapped off, and the crude oil chromatographed on silica eluting with 25% EtOAc/hexanes to give the title compound 14 (0.867 g, 81%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.22 (m, 1H), 6.94 (m, 1H), 6.91 (dd, 1H, J=4.89, 1.22 Hz), 3.59 (dd, 1H, J=10.99, 4.40 Hz), 3.47 (dd, 1H, J=10.99, 5.86 Hz), 2.69 (dd, 1H, J=14.3, 6.7 Hz), 2.62 (dd, 1H, J=14.1, 6.4 Hz), 2.29-2.24 (m, 3H), 1.85 (br, 1H), 1.42 (s, 9H). MS (APCI) m/z 183 (M + −73, -OtBu).
EXAMPLE 15
4-Thiophen-3-yl-3-(toluene-4-sulfonyloxymethyl)-butyric Acid Tert-Butyl Ester
Compound 14 (0.859 g, 3.35 mmol) was dissolved in anhydrous pyridine (6.5 mL) and cooled to 0° C. Tosyl chloride (0.894 g, 4.69 mmol) was added, and the reaction stirred at 0° C. for 1 hour. The reaction was then placed in a freezer overnight. The reaction was then diluted with EtOAc (100 mL). The solids were filtered and washed with EtOAc (30 mL). The filtrate was then washed with water (40 mL), 1N HCl (30 mL), and then brine (2×30 mL). The organics were dried over MgSO 4 , filtered, and concentrated to give an oil. This was chromatographed on silica eluting with 15% EtOAc/hexanes to give the title compound 15 (1.227 g, 89%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.76 (d, 2H, J=8.42 Hz), 7.34 (d, 2H, J=8.6 Hz) 7.21 (m, 1H), 6.83 (d, 2H, J=4.2 Hz), 3.96 (dd, 1H, J=9.52, 4.76 Hz), 3.89 (dd, 1H, J=9.52, 4.58 Hz), 2.69 (d, 2H, J=6.96 Hz), 2.45 (s, 3H), 2.40 (m, 1H), 2.25 (m, 2H), 1.37 (s, 9H). MS (APCI) m/z 337 (M + −73, -OtBu).
EXAMPLE 16
3-Azidomethyl-4-thiophen-3-yl-butyric Acid Tert-Butyl Ester
Compound 15 (1.206 g, 2.94 mmol), NaN 3 (0.43 g, 6.76 mmol), and DMSO (14 mL) were combined and heated to 60° C. for 17 hours. Water (75 mL) was added to the reaction and extracted with hexanes (4×75 mL). The combined organics were dried over MgSO 4 , filtered, and rotovapped to give an oil. The oil was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 16 (0.730 g, 88%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.23 (dd, 1H, J=4.83, 2.93 Hz), 6.94 (d, 1H, J=2.93 Hz), 6.89 (dd, 1H, J=4.83, 1.22 Hz), 3.28 (dd, 1H, J=12.1, 5.3 Hz), 3.22 (dd, 1H, J=12.1, 5.5 Hz), 2.65 (m, 2H), 2.34-2.83 (m, 1H), 2.22 (m, 2H), 1.42 (s, 9H). MS (APCI) m/z 254 (M + −28, —N 2 ).
EXAMPLE 17
3-Azidomethyl-4-thiophen-3-yl-butyric Acid
Compound 16 (0.730 g, 2.59 mmol) was dissolved in CH 2 Cl 2 (10 mL) and cooled in an ice bath. TFA (2.00 mL, 25.9 mmol) was added dropwise, and the reaction stirred at room temperature for 18 hours. The solvent was rotovapped, water (50 mL) and NaCl added, and the aqueous layer extracted with hexanes (4×50 mL). The extracts were combined, dried over MgSO 4 , filtered and rotovapped to give the title compound 17 (0.432 g, 79%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.21 (dd, 1H, J=4.88, 2.93 Hz), 6.92 (d, 1H, J=2.93 Hz), 6.85 (dd, 1H, J=4.88, 1.22 Hz), 3.37 (dd, 1H, J=12.2, 4.88 Hz), 3.23 (dd, 1H, J=12.2, 5.37 Hz), 2.71-2.61 (m, 2H), 2.40-2.27 (m, 3H).
EXAMPLE 18
3-Aminomethyl-4-thiophen-3-yl-butyric Acid
Compound 17 (0.42 g, 1.86 mmol), 10% Pd/C (0.50 g) and THF (30 mL) were combined and purged with H 2 . The reaction was stirred under a H 2 balloon for 5 hours. The catalyst was filtered, and washed with boiling MeOH (150 mL). The filtrate was rotovapped to give an off-white solid. The solid was dissolved in EtOH, and passed through celite. The filtrate was rotovapped to give the title compound 18 (0.271 g, 73%) as a tan solid. MP=158-159° C.
Analysis calculated for C 9 H 13 NO 2 S 0.52H 2 O: C, 51.81; H, 6.78; N, 6.71; S, 15.37. Found: C, 51.45; H, 6.77; N, 6.47; S, 14.99.
EXAMPLE 20
2-Furan-2-ylmethyl-succinic Acid 4-methyl Ester
Compound 19 (1.216 g, 4.53 mmol) was dissolved in THF (18 mL) and cooled in an ice bath. LiOH (9.06 mL, 1N, 9.06 mmol) was added, followed by iPrOH (3 mL). The reaction was stirred at room temperature for 18 hours. The solvent was rotovapped off, and the residue diluted with water (25 mL). The water was extracted with ether (2×25 mL), acidified with 1N HCl, and extracted with EtOAc (3×50 mL). The combined organics were dried over MgSO 4 , filtered, and rotovapped to give the title compound 20 (1.076 g, 94%) as an oil that crystallized upon standing.
1 H NMR (400 MHz, CDCl 3 ) δ 7.28 (m, 1H), 6.24 (d, 1H, J=1.95 Hz), 6.04 (d, 1H, J=3.17 Hz), 3.15-3.02 (m, 2H), 2.86 (dd, 1H, J=14.89, 8.06 Hz), 2.54 (dd, 1H, J=16.85, 8.80 Hz), 2.39 (dd, 1H, J=16.85, 4.88 Hz), 1.39 (s, 9H).
EXAMPLE 21
4-Furan-2-yl-3-hydroxymethyl-butyric Acid Methyl Ester
Compound 20 (0.836 g, 3.29 mmol) was dissolved in anhydrous THF (30 mL) and cooled in an ice bath. Borane dimethyl sulfide complex (1.64 mL, 16.4 mmol) was added dropwise, and the reaction stirred at 0° C. for 15 minutes, then at room temperature for 2 hours. The reaction was cooled again in an ice bath and quenched with methanol (20 mL) added dropwise. The solvent was then rotovapped off, and the crude oil chromatographed on silica eluting with 25% EtOAc/hexanes to give the title compound 21 (0.424 g, 55%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.29 (dd, 1H, J=1.71, 0.73 Hz), 6.25 (dd, 1H, J=3.17, 1.95 Hz), 6.01 (dd, 1H, J=3.17, 0.73 Hz), 3.62-3.56 (m, 1H), 3.53-3.47 (m, 1H), 2.70 (dd, 1H, J=15.14, 6.84 Hz), 2.64 (dd, 1H, J=15.02, 6.47 Hz), 2.36-2.31 (m, 1H), 2.27-2.25 (m, 2H), 1.95 (t, 1H, J=6.10 Hz), 1.41 (s, 9H
EXAMPLE 22
4-Furan-2-yl-3-(toluene-4-sulfonyloxymethyl)-butyric Acid Tert-Butyl Ester
Compound 21 (0.371 g, 1.54 mmol) was dissolved in anhydrous pyridine (5 mL) and cooled to 0° C. Tosyl chloride (0.587 g, 3.08 mmol) was added, and the reaction stirred at 0° C. for 18 hours. The reaction was then diluted with EtOAc (75 mL). The solids were filtered and washed with EtOAc (30 mL). The filtrate was then washed with 1N HCl (50 mL), water (2×50 mL), and then brine (50 mL). The organics were dried over MgSO 4 , filtered, and rotovapped to give an oil. This was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 22 (0.41 g, 67%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.73 (d, 2H, J=8.06 Hz), 7.29 (d, 2H, J=8.06 Hz), 7.20 (m, 1H), 6.19 (m, 1H), 5.91 (m, 1H), 3.99-3.96 (m, 1H), 3.92-3.88 (m, 1H) 2.66-2.64 (m, 2H), 2.45 (m, 1H), 2.41 (s, 3H), 2.27-2.17 (m, 2H), 1.36 (s, 9H).
EXAMPLE 23
3-Azidomethyl-4-furan-2-yl-butyric Acid Tert-Butyl Ester
Compound 22 (0.85 g, 2.13 mmol), NaN 3 (0.375 g, 5.77 mmol), and DMSO (12 mL) were combined and heated to 60° C. for 16 hours. Water (50 mL) and hexanes were added to the reaction and the layers separated. The aqueous layer was extracted with hexanes (4×50 mL). The combined organics were dried over MgSO 4 , filtered, and concentrated. The crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 23 (0.4.82 g, 85%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.29 (br, 1H), 6.25 (d, 1H, J=1.71), 6.02 (d, 1H, J=2.44 Hz), 3.31-3.27 (m, 2H), 2.69 (d, 2H, J=6.59 Hz), 2.39 (quintet, 1H, J=6.35 Hz), 2.23 (m, 2H), 1.42 (s, 9H).
EXAMPLE 24
3-Aminomethyl-4-furan-2-yl-butyric Acid Tert-Butyl Ester
Compound 23 (0.482 g, 1.82 mmol) in EtOAc (50 mL) was shaken on a Parr apparatus under a H 2 atmosphere (50 psi) for 4 hours. The catalyst was filtered and washed with EtOAc. The filtrate was concentrated and the crude material chromatographed on silica eluting with MeOH to give the title compound 24 (0.335 g, 77%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.27 (dd, 1H, J=1.71, 0.73 Hz), 6.24 (dd, 1H, J=3.17, 1.95 Hz), 6.00 (dd, 1H, J=3.17, 0.73 Hz), 2.71-2.56 (m, 4H), 2.25-2.14 (m, 3H), 1.41 (s, 9H), 1.37 (br, 2H).
EXAMPLE 25
3-Aminomethyl-4-furan-2-yl-butyric Acid
Compound 24 (0.318 g, 1.329 mmol) was dissolved in CH 2 Cl 2 (6 mL) and cooled in an ice bath. TFA (0.51 mL, 6.645 mmol) was added dropwise, and the reaction stirred at room temperature for 24 hours. The solvent was rotovapped, water (50 mL) and NaCl added, and the aqueous layer extracted with hexanes (4×50 mL). The extracts were combined, dried over MgSO 4 , filtered and rotovapped. The crude material was passed through an ion exchange resin (Dowex 50WX8-100 strongly acidic resin) eluting first with water, then with 5% NH 4 OH to give the title compound the title compound 25 as an oil. The material was used as is in the next step.
EXAMPLE 26
3-Aminomethyl-4-furan-2-yl-butyric Acid Oxalic Acid Salt
Compound 25 (0.299 g, 1.632 mmol) was dissolved in EtOH (5 mL). Oxalic acid (0.206 g, 1.632 mmol) was dissolved in EtOH (1 mL) and added to 25. The mixture was stirred at room temperature for 1 hour. The solvent was rotovapped, and the residue dissolved in minimal water and added dropwise to acetone (150 mL). The solids were filtered off, and the filtrate concentrated to give a solid. The solids were filtered and washed with some acetone to give the title compound 26 (0.248 g, 56%) as the oxalate salt.
MP=128-133° C. Analysis calculated for C 9 H 13 NO 3 .1.3 C 2 H 2 O 4 : C, 46.40; H, 5.24; N, 4.67. Found: C, 46.30; H, 5.19; N, 4.35.
EXAMPLE 27
3-Furan-2-yl-acrylic Acid Ethyl Ester
To a suspension of sodium hydride (9.96 g, 249.1 mmol) in anhydrous THF (500 mL) at 0° C. was added triethylphosphono acetate (45.3 mL, 228.4 mmol) in THF (80 mL) dropwise. The reaction mixture was then stirred for 30 minutes. 2-Furaldehyde (17.2 mL, 207.6 mmol) was dissolved in THF (33 mL) and added dropwise to the reaction at 0° C. The reaction was stirred at room temp for 3 hours, and then quenched with saturated NH 4 Cl (160 mL). The layers were separated and the aqueous layer extracted with EtOAc (2×100 mL). The combined organics were washed with brine (100 mL), dried over MgSO 4 , filtered and concentrated. The crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 27 as an oil (30.4 g, 90%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.45 (m, 1H), 7.40 (d, 1H, J=15.9 Hz), 6.57 (d, 1H, J=3.42 Hz), 6.43 (m, 1H), 6.28 (d, 1H, J=15.9 Hz), 4.21 (q, 2H, J=7.2 Hz), 1.29 (t, 3H, J=7.2 Hz). MS (APCI) m/z 167 (M + +1).
EXAMPLE 28
3-Furan-2-yl-propionic Acid Ethyl Ester
A solution of compound 27 (30.60 g, 184.15 mmol) and Wilkinson's catalyst (0.5 g) in THF (250 mL) was shaken on a Parr apparatus under a H 2 atmosphere (50 psi) for 18 hours at 45° C. The solvent was concentrated and the crude material chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 28 as an oil (30.00 g, 97%).
1 H NMR (400 MHz, CDCl 3 ) δ 7.30 (dd, 1H, J=1.83, 0.73 Hz), 6.27 (dd, 1H, J=1.83, 3.1 Hz), 6.01 (dd, 1H, J=3.11, 0.92 Hz), 4.14 (q, 2H, J=7.14 Hz), 2.97 (dd, 2H, J=7.32, 7.87 Hz), 2.64 (dd, 2H, J=8.79, 7.87 Hz), 1.25 (t, 3H, J=7.14 Hz).
(APCI) m/z 169 (M + +1).
EXAMPLE 29
3-Furan-2-yl-propionic Acid
Compound 28 (15.033 g, 89.38 mmol) was dissolved in THF (250 mL) and cooled in an ice bath. LiOH (132.8 mL, 1N, 132.8 mmol) was added, followed by iPrOH (50 mL). The reaction was stirred at room temperature for 18 hours. The solvent was rotovapped off, and the residue diluted with water (100 mL). The water was extracted with ether (2×75 mL), and then acidified with 1N HCl. The aqueous layer was extracted with EtOAc (4×100 mL). The organics were combined, dried over MgSO 4 , filtered and rotovapped to give the title compound 29 (12.873 g, ˜100%) as a white solid.
1 H NMR (400 MHz, CDCl 3 ) δ 7.29 (2, 1H, J=1.22 Hz), 6.22 (dd, 1H, J=3.17, 1.95 Hz), 6.02 (dd, 1H, J=3.17, 0.73 Hz), 2.96 (t, 2H, J=7.57 Hz), 2.70 (t, 2H, J=7.57 Hz).
EXAMPLE 30
[4R-(4α,5α)]3-(3-Furan-2-yl-propionyl)-4-methyl-5-phenyl-oxazolidin-2-one
Compound 29 (11.04 g, 78.82 mmol) was dissolved in THF (190 mL) and cooled in an ice bath. Triethyl amine (41.2 mL, 295.6 mmol) was added, followed by the trimethylacetyl chloride (14.6 mL, 118.23 mmol). The reaction was stirred at 0° C. for 90 minutes, and the LiCl (3.765 g, 86.70 mmol), (4R,5S)-(+)-4-methyl-5-phenyl-2-oxazolidinone (14.24 g, 80.4 mmol), and THF (70 mL) were added. The reaction was stirred at room temperature overnight. The solids were filtered, washed with EtOAc, and the filtrate and washings rotovapped to give a brown colored suspension. The solids were filtered, washed with EtOAc, and the filtrated rotovapped. The crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 30 (15.57 g, 66%) as an off-white solid.
1 H NMR (400 MHz, CDCl 3 ) δ 7.42-7.33 (m, 3H), 7.29-7.24 (m, 3H), 6.26 (m, 1H), 6.04 (d, 1H, J=3.17), 5.65 (d, 1H, J=7.33 Hz), 4.74 (q, 1H, J=6.8 Hz), 3.35-3.21 (m, 2H), 3.01 (t, 2H, J=7.4 Hz), 0.87 (d, 3H, J=6.59 Hz).
MS (APCI) m/z 300 (M + +1). Analysis calculated for C 17 H 17 NO 4 : C, 68.22; H, 5.72; N, 4.68. Found: C, 68.32; H, 5.71; N, 4.59. [α] D =+36.6° (c=1 in CHCl 3 ).
EXAMPLE 31
(S)-3-Furan-2-ylmethyl-4-([4S-(4α,5α)]4-methyl-2-oxo-5-phenyl-oxazolidin-3-yl)-4-oxo-butyric Acid Tert-Butyl Ester
Diisopropyl amine (1.37 mL, 9.77 mmol) was dissolved in anhydrous THF (20 mL) and cooled to 0° C. nBuLi (5.64 mL, 1.6 M, 9.02 mmol) was added, and the mixture stirred for 30 minutes at 0° C., and then cooled to −78° C. Compound 30 (2.50 g, 8.35 mmol) was diluted up in TBF (5 mL) and added dropwise to the LDA solution. After addition, the reaction was stirred for 30 minutes at −78° C. t-Butyl bromoacetate was passed through a neutral Al 2 O 3 plug, was dissolved (1.67 mL, 11.28 mmol) in THF (20 mL) and cooled to −78° C. The LDA solution was added via cannula to the t-butylbromo acetate solution, and the reaction stirred at −78° C. for 30 minutes, then allowed to warm to room temperature. The reaction was quenched with saturated NaH 2 PO 4 . The layers were separated, and the aqueous layer extracted with EtOAc (3×25 mL). The combined organics were dried over MgSO 4 , filtered and rotovapped. The crude material was chromatographed on SiO 2 eluting with 10% EtOAc/hexanes to give the title compound 31 (2.60 g, 75%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.41-7.24 (m, 6H), 6.27 (d, 1H, J=1.95 Hz), 6.09 (d, 1H, J=3.17 Hz), 5.52 (d, 1H, J=7.08 Hz), 4.67 (quin, 1H, J=6.7 Hz), 4.54 4.50 (m, 1H), 2.97 (dd, 1H, J=14.8, 7.0 Hz), 2.88-2.77 (m, 2H), 2.42 (dd, 1H, J=16.7, 4.5 Hz), 1.37 (s, 9H), 0.87 (d, 3H, J=6.37 Hz). [α] D −5.5° (c=1 in CHCl 3 ).
EXAMPLE 32
(S)-2-Furan-2-ylmethyl-succinic Acid 4-tert-butyl Ester
Compound 31 (5.457 g, 13.20 mmol) was dissolved in THF (63 mL)/H 2 O (16 mL) and cooled in an ice bath. The H 2 O 2 (2.33 mL, 35%, 26.40 mmol) and LiOH (1N, 26.40 mL) were premixed, and then added dropwise to the THF/H 2 O. The reaction was stirred at 0° C. for 4 hours and then quenched with NaHSO 3 (15 g). The reaction was stirred at room temperature overnight. The THF was rotovapped off, water added (100 mL) to the residue, and the water acidified to PH=3 with 3N HCl. The aqueous layer was extracted with EtOAc (4×75 mL), and the combined organics dried over MgSO 4 , filtered, and rotovapped to give an oil. The oil was dissolved in EtOAc (10 mL), and heptane (250 mL) added to precipitate the oxazolidinone. The solution was stirred for 1 hour, and the solids filtered off. The organic filtrate was washed with water (100 mL, 60° C.). The organic layer was dried over MgSO 4 , filtered, and rotovapped to give the title compound 32 (2.603 g, 78%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.29 (d, 1H, J=0.98 Hz), 6.26 (m, 1H), 6.05 (d, 1H, J=2.93 Hz) 3.14-3.04 (m, 2H), 2.87 (dd, 1H, J=15.0, 7.94 Hz), 2.57 (dd, 1H, J=16.8, 8.55 Hz), 2.40 (dd, 1H, J=16.8, 4.88 Hz), 1.41 (s, 9H).
EXAMPLE 33
(S)-4-Furan-2-yl-3-hydroxymethyl-butyric Acid Tert-Butyl Ester
Compound 32 (2.603 g, 10.24 mmol) was dissolved in anhydrous THF (100 mL) and cooled in an ice bath. Borane dimethyl sulfide complex (3.1 mL, 31 mmol) was added dropwise, and the reaction stirred at 0° C. for 15 minutes, then at room temperature for 2 hours. The reaction was cooled again in an ice bath and quenched with methanol (20 mL) added dropwise, and then stirred at room temperature for 1 hour. The solvent was then rotovapped off, and the crude oil chromatographed on silica eluting with EtOAc/hexanes gradient (10% EtOAc for 10 minutes, gradient to 25% EtOAc at 25 minutes) to give the title compound 33 (1.852 g 75%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.29 (d, 1H, J=0.49 Hz), 6.26 (d, 1H, J=1.95 Hz), 6.03 (d, 1H, J=3.17 Hz), 3.60 (quin, 1H, J=5.37 Hz), 3.52 (quin, 1H, J=5.74 Hz), 2.72 (dd, 1H, J=15.1, 6.84 Hz), 2.66 (dd, 1H, J=15.3, 6.71 Hz), 2.38-2.32 (m, 1H), 2.28-2.26 (m, 2H), 1.97 (t, 1H, J=5.98 Hz), 1.43 (s, 9H) MS (APCI) m/z 241 (M + +1). [α] D +2.3° (c=1 in CHCl 3 ).
EXAMPLE 34
(S)-4-Furan-2-yl-3-(toluene-4-sulfonyloxymethyl)-butyric Acid Tert-Butyl Ester
Compound 33 (1.822 g, 7.58 mmol) was dissolved in anhydrous CH 2 Cl 2 (27 mL) and cooled to 0° C. DMAP (catalytic) was added followed by tosyl chloride (1.73 g, 9.10 mmol). Triethylamine (2.32 mL, 16.68 mmol) was added dropwise, and the reaction stirred at 0° C. for 18 hours. The reaction was then diluted with EtOAc (75 mL). The solvent was rotovapped, and the residue suspended in EtOAc. The solids were filtered and washed with EtOAc (30 mL). The organics were dried over MgSO 4 , filtered, and rotovapped to give an oil. This was chromatographed on silica eluting with 5% EtOAc/hexanes gradient to 20% EtOAc/hexanes to give the title compound 34 (2.85 g, 95%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.75 (d, 2H, J=8.06 Hz), 7.32 (d, 2H, J=8.06 Hz), 7.22 (s, 1H), 6.20 (d, 1H, J=1.71 Hz), 5.92 (d, 1H, J=2.93 Hz)), 3.99 (dd, 1H, J=9.64, 5.01 Hz), 3.91 (dd, 1H, J=9.64, 5.01 Hz), 2.71-2.61 (m, 2H), 2.47 (m, 1H), 2.43 (s, 3H), 2.25 (dd, 1H, J=16.5, 7.2 Hz), 2.19 (dd, 1H, J=16.4, 6.8 Hz), 1.38 (s, 9H).
EXAMPLE 35
(S)-3-Azidomethyl-4-furan-2-yl-butyric Acid Methyl Ester
Compound 34 (2.840 g, 7.20 mmol), NaN 3 (1.287 g, 19.80 mmol), and DMSO (13 mL) were combined and heated to 60° C. for 6 hours. EtOAc (100 mL) was added and the solids filtered. The filtrate was rotovapped, and the crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 35 (1.75 g, 92%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.30 (br s, 1H), 6.27 (br s, 1H), 6.04 (d, 1H, J=2.69 Hz), 3.34 (dd, 1H, J=12.2, 5.62 Hz), 3.27 (dd, 1H, J=12.1, 5.74 Hz), 2.69 (d, 2H, J=6.59 Hz), 2.40 (quintet, 1H, J=6.47 Hz), 2.25 (d, 2H, J=7.1 Hz), 1.43 (s, 9H). MS (APCI) m/z 238 (M + −28, —N 2 ).
EXAMPLE 36
(S)-3-Aminomethyl-4-furan-2-yl-butyric Acid Tert-Butyl Ester
Compound 35 (1.74 g, 6.56 mmol) in EtOAc (50 mL) was shaken on a Parr apparatus under a H 2 atmosphere (50 psi) for 2 hours. The catalyst was filtered and washed with EtOAc. The filtrate was rotovapped, and the crude material chromatographed on silica eluting with EtOAc (10 minutes), then gradient to MeOH (100% at 25 minutes) to give the title compound 36 (1.325 g, 84%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.28 (br s, 1H), 6.26 (d, 1H, J=1.71 Hz), 6.01 (d, 1H, J=2.69 Hz), 2.68-2.61 (m, 4H), 2.23-2.16 (m, 3H), 1.42 (s, 9H), 1.15 (br, 2H). MS (APCI) m/z 240 (M + +1).
EXAMPLE 37
(S)-3-Aminomethyl-4-furan-2-yl-butyric Acid
Compound 36 (1.325 g, 5.54 mmol) was dissolved in CH 2 Cl 2 /water (60 mL/2 mL)) and cooled in an ice bath. TFA (10.6 mL, 138 mmol) was added dropwise, and the reaction warmed to room temperature. The reaction was stirred for 2 hours more. The solvent was rotovapped, and the crude material passed through an ion exchange resin (Dowex 50WX8-100 strongly acidic resin) eluting first with water, then with 5% NH 4 OH to give the title compound 37 (0.53 g, 52%) as a solid.
MP=151-153° C. Analysis calculated for C 9 H 13 NO 3 : C, 59.00; H, 7.15; N, 7.65. Found: C, 58.65; H, 7.17; N, 7.37. [α] D +6.40 (c=1 in H 2 O).
EXAMPLE 38
[4S-((4α,5α)]3-(3-Furan-2-yl-propionyl)-4-methyl-5-phenyl-oxazolidin-2-one
Compound 29 (11.66 g, 83.19 mmol) was dissolved in THF (190 mL) and cooled in an ice bath. Triethyl amine (43.5 mL, 312.1 mmol) was added, followed by the trimethylacetyl chloride (15.4 mL, 125.0 mmol). The reaction was stirred at 0° C. for 2 hours, and the LiCl (3.879 g, 91.5 mmol), (4S,5R)-(−)-4-methyl-5-phenyl-2-oxazolidinone (15.02 g, 84.76 mmol), and THF (70 mL) were added. The reaction was stirred at room temperature overnight. The solids were filtered, washed with EtOAc, and the filtrate and washings rotovapped to give a brown colored suspension. The solids were filtered, washed with EtOAc, and the filtrated rotovapped. The crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 38 (19.967 g, 80%) as an off-white solid.
1 H NMR (400 MHz, CDCl 3 ) δ 7.42-7.33 (m, 3H), 7.29-7.24 (m, 3H), 6.26 (m, 1H), 6.04 (d, 1H, J=3.17), 5.65 (d, 1H, J=7.33 Hz), 4.74 (q, 1H, J=6.8 Hz), 3.35-3.21 (m, 2H), 3.01 (t, 2H, J=7.4 Hz), 0.87 (d, 3H, J=6.59 Hz). MS (APCI) m/z 300 (M + +1).
Analysis calculated for C 17 H 17 NO 4 : C, 68.22; H, 5.72; N, 4.68. Found: C, 68.34; H, 5.81; N, 4.63. [α] D =−39.5° (c=1 in CHCl 3 ).
EXAMPLE 39
(R)-3-Furan-2-ylmethyl-4-([4S-(4α,5α)]4-methyl-2-oxo-5-phenyl-oxazolidin-3-yl)-4-oxo-butyric Acid Tert-Butyl Ester
Diisopropyl amine (3.04 mL, 21.69 mmol) was dissolved in anhydrous THF (40 mL) and cooled to 0° C. nBuLi (12.53 mL, 1.6 M, 20.05 mmol) was added, and the mixture stirred for 30 minutes at 0° C., and then cooled to −78° C. Compound 38 (5.00 g, 16.70 mmol) was diluted up in THF (10 mL) and added dropwise to the LDA solution. After addition, the reaction was stirred for 30 minutes at −78° C. t-Butyl bromoacetate was passed through a neutral Al 2 O 3 plug, was dissolved (3.21 mL, 21.74 mmol) in THF (40 mL) and cooled to −78° C. The LDA solution was added via cannula to the t-butylbromo acetate solution, and the reaction stirred at −78° C. for 30 minutes, then allowed to warm to room temperature. The reaction was quenched with saturated NaH 2 PO 4 . The layers were separated, and the aqueous layer extracted with EtOAc (3×75 mL). The combined organics were dried over MgSO 4 , filtered and rotovapped. The crude material was chromatographed on SiO 2 eluting with 5% EtOAc/hexanes (5 minutes), then gradient to 15% EtOAc/hexanes (at 20 minutes) to give the title compound 39 (4.528 g, 67%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.41-7.24 (m, 6H), 6.27 (br s, 1H), 6.09 (br s, 1H), 5.53 (d, 1H, J=7.32 Hz), 4.67 (quin, 1H, J=6.71 Hz), 4.54-4.50 (m, 1H), 2.98 (dd, 1H, J=15.0, 6.71 Hz), 2.88-2.77 (m, 2H), 2.42 (dd, 1H, J=16.6, 4.64 Hz), 1.38 (s, 9H), 0.87 (d, 3H, J=6.59 Hz). [α] D +8.2° (c=1 in CHCl 3 ).
EXAMPLE 40
(R)-2-Furan-2-ylmethyl-succinic Acid 4-tert-butyl Ester
Compound 39 (4.452 g, 10.77 mmol) was dissolved in THF (52 mL)/H 2 O (13 mL) and cooled in an ice bath. The H 2 O 2 (1.90 mL, 35%, 21.54 mmol) and LiOH (1N, 21.54 mL) were premixed, and then added dropwise to the THF/H 2 O. The reaction was stirred at 0° C. for 4 hours and then quenched with NaHSO 3 (13 g). The reaction was stirred at room temperature overnight. The THF was rotovapped off, water added (100 mL) to the residue, and the water acidified to pH=3 with 3N HCl. The aqueous layer was extracted with EtOAc (4×75 mL), and the combined organics dried over MgSO 4 , filtered, and rotovapped to give an oil containing 40 and the chiral auxiliary. The crude material was used as is without further purification in the next step.
EXAMPLE 41
(R)-4-Furan-2-yl-3-hydroxymethyl-butyric Acid Tert-Butyl Ester
The crude material from example 40 was dissolved in anhydrous THF (100 mL) and cooled in an ice bath. Borane dimethyl sulfide complex (3.2 mL, 32 mmol) was added dropwise, and the reaction stirred at 0° C. for 15 minutes, then at room temperature for 2 hours. The reaction was cooled again in an ice bath and quenched with methanol (15 mL) added dropwise, and then stirred at room temperature for 1 hour. The solvent was then rotovapped off, and the crude oil chromatographed on silica eluting with EtOAc/hexanes gradient (7% EtOAc for 5 minutes, gradient to 15% EtOAc at 20 minutes) to give the title compound 41 (1.865 g 75% from example 39) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.29 (dd, 1H, J=1.83, 0.85 Hz), 6.26 (dd, 1H, J=3.05, 1.83 Hz), 6.02 (dd, 1H, J=3.05, 0.61 Hz), 3.60 (quin, 1H, J=5.37 Hz), 3.52 (quin, 1H, J=5.68 Hz), 2.72 (dd, 1H, J=15.0, 6.71 Hz), 2.66 (dd, 1H, J=15.1, 6.35 Hz), 2.38-2.32 (m, 1H), 2.28-2.26 (m, 2H), 1.94 (t, 1H, J=5.98 Hz), 1.43 (s, 9H).
MS (APCI) m/z 241 (M + +1). [α] D −2.1° (c=1 in CHCl 3 ).
EXAMPLE 42
(R)-4-Furan-2-yl-3-(toluene-4-sulfonyloxymethyl)-butyric Acid Tert-Butyl Ester
Compound 41 (1.831 g, 7.62 mmol) was dissolved in anhydrous CH 2 Cl 2 (27 mL) and cooled to 0° C. DMAP (catalytic) was added followed by tosyl chloride (1.74 g, 9.14 mmol). Triethylamine (2.32 mL, 16.76 mmol) was added dropwise, and the reaction stirred at 0° C. for 28 hours. The reaction was then diluted with EtOAc (75 mL). The solvent was rotovapped, and the residue suspended in EtOAc. The solids were filtered and washed with EtOAc (30 mL). The organics were washed with 1N HCl (25 mL), saturated NaHCO 3 (30 mL), brine (30 mL), dried over MgSO 4 , filtered, and rotovapped to give an oil. This was chromatographed on silica eluting with EtOAc/hexanes gradient (5% for 5 minutes to 10% at 10 minutes to 20% at 25 minutes) to give the title compound 42 (2.81 g, 94%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.75 (d, 2H, J=8.06 Hz), 7.31 (d, 2H, J=7.81 Hz), 7.22 (br s, 1H), 6.20 (br s, 1H), 5.92 (d, 1H, J=2.44 Hz), 3.99 (dd, 1H, J=9.64, 5.01 Hz), 3.91 (dd, 1H, J=9.52, 4.88 Hz), 2.71-2.61 (m, 2H), 2.47 (m, 1H), 2.42 (s, 3H), 2.25 (dd, 1H, J=16.5, 7.2 Hz), 2.19 (dd, 1H, J=16.4, 6.8 Hz), 1.38 (s, 9H).
EXAMPLE 43
(R)-3-Azidomethyl-4-furan-2-yl-butyric Acid Tert-Butyl Ester
Compound 42 (2.70 g, 6.845 mmol), NaN 3 (1.224 g, 18.82 mmol), and DMSO (12 mL) were combined and heated to 60° C. for 6 hours. EtOAc (100 mL) was added and the solids filtered. The filtrate was rotovapped, and the crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give the title compound 43 (1.505 g, 83%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.30 (br s, 1H), 6.27 (br s, 1H), 6.04 (d, 1H, J=2.69 Hz), 3.33 (dd, 1H, J=12.3, 5.49 Hz), 3.27 (dd, 1H, J=12.2, 5.86 Hz), 2.69 (d, 2H, J=6.59 Hz), 2.40 (quintet, 1H, J=6.35 Hz), 2.25 (d, 2H, J=6.8 Hz), 1.43 (s, 9H). MS (APCI) m/z 238 (M + −28, —N 2 ).
EXAMPLE 44
(R)-3-Aminomethyl-4-furan-2-yl-butyric Acid Tert-Butyl Ester
Compound 43 (1.50 g, 5.65 mmol) in EtOAc (50 mL) was shaken on a Parr apparatus under a H 2 atmosphere (50 psi) for 2.5 hours. The catalyst was filtered and washed with EtOAc. The filtrate was rotovapped, and the crude material chromatographed on silica eluting with EtOAc (10 minutes), then gradient to MeOH (100% at 25 minutes) to give the title compound 44 (1.133 g, 84%) as an oil.
1 H NMR (400 MHz, CDCl 3 ) δ 7.28 (d, 1H, J=0.98 Hz), 6.25 (d, 1H, J=1.95 Hz), 6.01 (d, 1H, J=2.93 Hz), 2.69-2.61 (m, 4H), 2.23-2.18 (m, 3H), 1.42 (s, 9H), 1.15 (br, 2H). MS (APCI) m/z 240 (M + +1).
EXAMPLE 45
(R)-3-Aminomethyl-4-furan-2-yl-butyric Acid
Compound 44 (1.117 g, 4.67 mmol) was dissolved in CH 2 Cl 2 /water (52 mL/1.73 mL) and cooled in an ice bath. TFA (9.0 mL, 1116.8 mmol) was added dropwise, and the reaction warmed to room temperature. The reaction was stirred for 2 hours more. The solvent was rotovapped, and the crude material passed through an ion exchange resin (Dowex 50WX8-100 strongly acidic resin) eluting first with water, then with 5% NH 4 OH to give the title compound 45 (0.603 g, 71%) as a solid.
MP=151-153° C. Analysis calculated for C 9 H 13 NO 3 : C, 59.00; H, 7.15; N, 7.65. Found: C, 58.85; H, 7.13; N, 7.47. [α] D −6.0° (c=1 in H 2 O). | The invention is a novel series of compounds which are useful in the treatment of epilepsy, faintness attacks, neurodegenerative disorders, depression, anxiety, panic, pain, neuropathological disorders, gastrointestinal disorders such as irritable bowel syndrome (IBS), and inflammation, especially arthritis. A pharmaceutical composition containing a compound of the invention as well as methods of preparing the compounds and novel intermediates useful in the preparation of the final compounds are included. | 2 |
PRIORITY TO RELATED APPLICATION(S)
[0001] This application claims the benefit of European Patent Application No. 06119758.8, filed Aug. 30, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Schizophrenia is a progressive and devastating neurological disease characterized by episodic positive symptoms such as delusions, hallucinations, thought disorders and psychosis and persistent negative symptoms such as flattened affect, impaired attention and social withdrawal, and cognitive impairments (Lewis D A and Lieberman J A, Neuron, 2000, 28:325-33). For decades research has focused on the “dopaminergic hyperactivity” hypothesis which has led to therapeutic interventions involving blockade of the dopaminergic system (Vandenberg R J and Aubrey K R., Exp. Opin. Ther. Targets, 2001, 5 (4): 507-518; Nakazato A and Okuyama S, et al., 2000 , Exp. Opin. Ther. Patents, 10 (1): 75-98). This pharmacological approach poorly address negative and cognitive symptoms which are the best predictors of functional outcome (Sharma T., Br. J. Psychiatry, 1999, 174 (suppl. 28): 44-51).
[0003] A complementary model of schizophrenia was proposed in the mid-1960' based upon the psychotomimetic action caused by the blockade of the glutamate system by compounds like phencyclidine (PCP) and related agents (ketamine) which are non-competitive NMDA receptor antagonists. Interestingly in healthy volunteers, PCP-induced psychotomimetic action incorporates positive and negative symptoms as well as cognitive dysfunction, thus closely resembling schizophrenia in patients (Javitt D C et al., 1999 , Biol. Psychiatry, 45: 668-679 and refs. herein). Furthermore transgenic mice expressing reduced levels of the NMDAR1 subunit displays behavioral abnormalities similar to those observed in pharmacologically induced models of schizophrenia, supporting a model in which reduced NMDA receptor activity results in schizophrenia-like behavior (Mohn A R et al., 1999 , Cell, 98: 427-236).
[0004] Glutamate neurotransmission, in particular NMDA receptor activity, plays a critical role in synaptic plasticity, learning and memory, such as the NMDA receptors appears to serve as a graded switch for gating the threshold of synaptic plasticity and memory formation (Hebb D O, 1949 , The organization of behavior , Wiley, NY; Bliss T V and Collingridge G L, 1993 , Nature, 361: 31-39). Transgenic mice overexpressing the NMDA NR2B subunit exhibit enhanced synaptic plasticity and superior ability in learning and memory (Tang J P et al., 1999 , Nature: 401-63-69).
[0005] Thus, if a glutamate deficit is implicate in the pathophysiology of schizophrenia, enhancing glutamate transmission, in particular via NMDA receptor activation, would be predicted to produce both anti-psychotic and cognitive enhancing effects.
[0006] The amino acid glycine is known to have at least two important functions in the CNS. It acts as an inhibitory amino acid, binding to strychnine sensitive glycine receptors, and it also influences excitatory activity, acting as an essential co-agonist with glutamate for N-methyl-D-aspartate (NMDA) receptor function. While glutamate is released in an activity-dependent manner from synaptic terminals, glycine is apparently present at a more constant level and seems to modulate/control the receptor for its response to glutamate.
[0007] One of the most effective ways to control synaptic concentrations of neurotransmitter is to influence their re-uptake at the synapses. Neurotransmitter transporters by removing neurotransmitters from the extracellular space, can control their extracellular lifetime and thereby modulate the magnitude of the synaptic transmission (Gainetdinov R R et al, 2002, Trends in Pharm. Sci., 23 (8): 367-373).
[0008] Glycine transporters, which form part of the sodium and chloride family of neurotransmitter transporters, play an important role in the termination of post-synaptic glycinergic actions and maintenance of low extracellular glycine concentration by re-uptake of glycine into presynaptic nerve terminals and surrounding fine glial processes.
[0009] Two distinct glycine transporter genes have been cloned (GlyT-1 and GlyT-2) from mammalian brain, which give rise to two transporters with ˜50% amino acid sequence homology. GlyT-1 presents four isoforms arising from alternative splicing and alternative promoter usage (1a, 1b, 1c and 1d). Only two of these isoforms have been found in rodent brain (GlyT-1a and GlyT-1b). GlyT-2 also presents some degree of heterogeneity. Two GlyT-2 isoforms (2a and 2b) have been identified in rodent brains. GlyT-1 is known to be located in CNS and in peripheral tissues, whereas GlyT-2 is specific to the CNS. GlyT-1 has a predominantly glial distribution and is found not only in areas corresponding to strychnine sensitive glycine receptors but also outside these areas, where it has been postulated to be involved in modulation of NMDA receptor function (Lopez-Corcuera B et al., 2001 , Mol. Mem. Biol., 18: 13-20). Thus, one strategy to enhance NMDA receptor activity is to elevate the glycine concentration in the local microenvironment of synaptic NMDA receptors by inhibition of GlyT-1 transporter (Bergereon R. Et al., 1998 , Proc. Natl. Acad. Sci. USA, 95: 15730-15734; Chen L et al., 2003 , J. Neurophysiol., 89 (2): 691-703).
[0010] Glycine transporters inhibitors are suitable for the treatment of neurological and neuropsychiatric disorders. The majority of diseases states implicated are psychoses, schizophrenia (Armer R E and Miller D J, 2001 , Exp. Opin. Ther. Patents, 11 (4): 563-572), psychotic mood disorders such as severe major depressive disorder, mood disorders associated with psychotic disorders such as acute mania or depression associated with bipolar disorders and mood disorders associated with schizophrenia, (Pralong E T et al., 2002 , Prog. Neurobiol., 67: 173-202), autistic disorders (Carlsson M L, 1998 , J. Neural Transm. 105: 525-535), cognitive disorders such as dementias, including age related dementia and senile dementia of the Alzheimer type, memory disorders in a mammal, including a human, attention deficit disorders and pain (Armer R E and Miller D J, 2001 , Exp. Opin. Ther. Patents, 11 (4): 563-572).
[0011] Thus, increasing activation of NMDA receptors via GlyT-1 inhibition may lead to agents that treat psychosis, schizophrenia, dementia and other diseases in which cognitive processes are impaired, such as attention deficit disorders or Alzheimer's disease.
SUMMARY OF THE INVENTION
[0012] The present invention provides compounds of formula I
wherein
R 1 is lower alkyl, aryl or heteroaryl, wherein aryl and heteroaryl are optionally substituted by halogen, lower alkyl, lower alkoxy, lower alkyl substituted by halogen, lower alkoxy substituted by halogen, cyano, amino, di-lower alkyl amino or morpholinyl; R 2 is lower alkyl, —(CH 2 ) n -aryl, —(CH 2 ) n -heteroaryl or —(CH 2 ) n -cycloalkyl, wherein the aryl or heteroaryl groups are optionally substituted by one or more substituents selected from the group consisting of halogen, lower alkyl, cyano, or lower alkoxy; R 3 is hydrogen or lower alkyl; R 4 is aryl or heteroaryl, wherein aryl and heteroaryl are optionally substituted by one or more substituents selected from the group consisting of halogen, lower alkyl substituted by halogen, lower alkoxy substituted by halogen, lower alkyl; X is a bond or —OCH 2 —; n is 0, 1 or 2;
or pharmaceutically acceptable acid addition salts thereof, with the exception of
4-methoxy-N-[2-oxo-2-(phenylamino)ethyl]-N-phenyl-benzamide, 4-chloro-N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-chloro-N-[2-[5-chloro-2-methoxyphenyl)amino]-2-oxoethyl]-N-benzamide, 4-methyl-N-(2-oxo-2-[(2,4,6-trichlorophenyl)amino]ethyl]-N-benzamide, N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-methyl-N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-chloro-N-(2-oxo-2-[(2,4,6-trichlorophenyl)amino]ethyl]-N-benzamide and N-[2-[(2,4-dimethoxyphenyl)amino]-2-oxoethyl]-N-[(2-fluorophenyl)methyl]-benzeneacetamide.
[0027] The excepted compounds have been described in Organic and Bio - Organic Chemistry (1972), (7), 909-13 in a cyclisation process of α-acylamino-acids.
[0028] Furthermore, the invention includes all racemic mixtures, all their corresponding enantiomers and/or optical isomers.
[0029] The present invention also provides pharmaceutical compositions containing a compound of formula I or a pharmaceutical salt thereof. The invention also provides methods for the preparation of the compounds and compositions of the invention.
[0030] Compounds of general formula I are good inhibitors of the glycine transporter 1 (GlyT-1) and have a good selectivity to glycine transporter 2 (GlyT-2) inhibitors. The invention provides methods for the treatment of diseases related to activation of NMDA receptors via GlyT-1 inhibition, such as psychoses, dysfunction in memory and learning, schizophrenia, dementia and other diseases in which cognitive processes are impaired, such as attention deficit disorders or Alzheimer's disease. The preferred indications of the present invention are schizophrenia, cognitive impairment and Alzheimer's disease.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The following definitions of the general terms used in the present description apply irrespective of whether the terms in question appear alone or in combination. It must be noted that, as used in the specification and the appended claims, the singular forms “a”, “an,” and “the” include plural forms unless the context clearly dictates otherwise.
[0032] As used herein, the term “lower alkyl” denotes a saturated straight- or branched-chain hydrocarbon group containing from 1 to 7 carbon atoms, for example, methyl, ethyl, propyl, isopropyl, n-butyl, i-butyl, 2-butyl, t-butyl and the like. Preferred alkyl groups are groups with 1-4 carbon atoms.
[0033] The term “cycloalkyl” denotes a saturated or partially saturated carbocyclic ring containing from 3 to 7 carbon atoms, for example cyclopropyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptyl or cycloheptenyl.
[0034] The term “halogen” denotes chlorine, iodine, fluorine and bromine.
[0035] The term “aryl” denotes a monovalent cyclic aromatic hydrocarbon radical having 6 to 12 ring atoms and consisting of one or more fused rings in which at least one ring is aromatic in nature, for example phenyl or naphthyl.
[0036] The term “heteroaryl” denotes a cyclic aromatic hydrocarbon radical, containing one, two or three heteroatoms selected from the group consisting of oxygen, sulphur or nitrogen wherein at least one ring is aromatic in nature, for example pyridyl, quinoxalinyl, dihydrobenzofuranyl, thiophenyl, benzothiophenyl, isoxazolyl, pyrazinyl, pyrimidinyl, pyridazinyl, triazinyl, thiazolyl, pyrrolyl, imidazolyl, pyrazolyl, oxazolyl and isothiazolyl.
[0037] The term “lower alkyl substituted by halogen” denotes a lower alkyl group as defined above, wherein at least one hydrogen atom is replaced by a halogen atom, for example the following groups: CF 3 , CHF 2 , CH 2 F, CH 2 CF 3 , CH 2 CHF 2 , CH 2 CH 2 F, CH 2 CH 2 CF 3 , CH 2 CH 2 CH 2 CF 3 , CH 2 CH 2 Cl, CH 2 CF 2 CF 3 , CH 2 CF 2 CHF 2 , CF 2 CHFCF 3 , C(CH 3 ) 2 CF 3 , CH(CH 3 )CF 3 or CH(CH 2 F)CH 2 F.
[0038] The term “lower alkoxy” denotes a alkyl group wherein the lower alkyl residue is as defined above and which is attached via an oxygen atom.
[0039] The term “lower alkoxy substituted by halogen” denotes an alkoxy group, wherein at least one hydrogen atom is replaced by halogen as defined above.
[0040] “Pharmaceutically acceptable,” such as pharmaceutically acceptable carrier, excipient, etc., means pharmacologically acceptable and substantially non-toxic to the subject to which the particular compound is administered.
[0041] The term “pharmaceutically acceptable acid addition salts” embraces salts with inorganic and organic acids, such as hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, citric acid, formic acid, fumaric acid, maleic acid, acetic acid, succinic acid, tartaric acid, methane-sulfonic acid, p-toluenesulfonic acid and the like.
[0042] “Therapeutically effective amount” means an amount that is effective to prevent, alleviate or ameliorate symptoms of disease or prolong the survival of the subject being treated.
[0043] The present invention provides compounds of formula I
wherein
R 1 is lower alkyl, aryl or heteroaryl, wherein aryl and heteroaryl are optionally substituted by halogen, lower alkyl, lower alkoxy, lower alkyl substituted by halogen, lower alkoxy substituted by halogen, cyano, amino, di-lower alkyl amino or morpholinyl; R 2 is lower alkyl, —(CH 2 ) n -aryl, —(CH 2 ) n -heteroaryl or —(CH 2 ) n -cycloalkyl, wherein the aryl or heteroaryl groups are optionally substituted by one or more substituents selected from the group consisting of halogen, lower alkyl, cyano, or lower alkoxy; R 3 is hydrogen or lower alkyl; R 4 is aryl or heteroaryl, wherein aryl and heteroaryl are optionally substituted by one or more substituents selected from the group consisting of halogen, lower alkyl substituted by halogen, lower alkoxy substituted by halogen, lower alkyl; X is a bond or —OCH 2 —; n is 0, 1 or 2;
or pharmaceutically acceptable acid addition salts thereof, with the exception of
4-methoxy-N-[2-oxo-2-(phenylamino)ethyl]-N-phenyl-benzamide, 4-chloro-N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-chloro-N-[2-[5-chloro-2-methoxyphenyl)amino]-2-oxoethyl]-N-benzamide, 4-methyl-N-(2-oxo-2-[(2,4,6-trichlorophenyl)amino]ethyl]-N-benzamide, N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-methyl-N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-chloro-N-(2-oxo-2-[(2,4,6-trichlorophenyl)amino]ethyl]-N-benzamide and N-[2-[(2,4-dimethoxyphenyl)amino]-2-oxoethyl]-N-[(2-fluorophenyl)methyl]-benzeneacetamide.
[0058] Preferred compounds of formula I are those, wherein X is a bond.
[0059] Preferred compounds of formula I of the present invention are further those, wherein R 1 and R 4 are both monosubstituted aryl, preferably halogen substituted phenyl, for example the following compounds:
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2,6-difluoro-benzyl)-benzamide, 4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2,3-difluoro-benzyl)-benzamide, 4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2-fluoro-benzyl)-benzamide, 4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-thiophen-2-ylmethyl-benzamide, 4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2-methoxy-benzyl)-benzamide, 4-Chloro-N-(3-chloro-benzyl)-N-[(3-chloro-phenylcarbamoyl)-methyl]-benzamide and 4-Chloro-N-(2-chloro-benzyl)-N-[(3-chloro-phenylcarbamoyl)-methyl]-benzamide.
[0067] Further preferred compounds are those, wherein R 1 and R 4 are both monosubstituted aryl, for R 1 preferably methoxy substituted phenyl and for R 4 preferably halogen substituted phenyl, for example the following compounds:
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-(2,6-difluoro-benzyl)-4-methoxy-benzamide and N-(3-Chloro-benzyl)-N-[(3-chloro-phenylcarbamoyl)-methyl]-4-methoxy-benzamide.
[0070] Preferred compounds of formula I of the present invention are further those, wherein R 1 is heteroaryl, preferably benzothiophenyl, for example the following compounds:
Benzo[b]thiophene-2-carboxylic acid (2-chloro-benzyl)-[(3-trifluoromethyl-phenylcarbamoyl)-methyl]-amide, Benzo[b]thiophene-2-carboxylic acid (2-chloro-benzyl)-[(3-fluoro-phenylcarbamoyl)-methyl]-amide, Benzo[b]thiophene-2-carboxylic acid (3,5-difluoro-benzyl)-[(3-fluoro-phenylcarbamoyl)-methyl]-amide, Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-fluoro-phenylcarbamoyl)-methyl]-(2,6-difluoro-benzyl)-amide, Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-fluoro-phenylcarbamoyl)-methyl]-(2,3-difluoro-benzyl)-amide and Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-fluoro-phenylcarbamoyl)-methyl]-(3,5-difluoro-benzyl)-amide.
[0077] Preferred compounds of formula I of the present invention are further those, wherein R 1 and R 4 are monosubstituted aryl, preferably halogen substituted phenyl for R 1 and CF 3 substituted phenyl for R 4 , for example the following compound:
N-(2-Chloro-benzyl)-4-fluoro-N-[(3-trifluoromethyl-phenylcarbamoyl)-methyl]-benzamide.
[0079] The present compounds of formula I and their pharmaceutically acceptable salts can be prepared by methods known in the art, for example, by processes described below, which processes comprise
[0080] a) reacting a compound of formula
with a compound of formula
R 2 —NH 2 II
and with a compound of formula
in the presence of N-ethyldiisopropylamine
to produce a compound of formula
wherein the substituents are as defined above, or
[0081] b) reacting a compound of formula
with a compound of formula
in presence of triethylamine
to produce a compound of formula
wherein the substituents are as defined above or
[0082] c) reacting a compound of formula
NHR 3 R 4 IX
with a compound of formula
in the presence of N-ethyldiisopropylamine and HATU [O-(7-Azabenzotriazole-1-yl)-N, N,N′N′-tetramethyluronium hexafluorophosphate],
to produce a compound of formula
wherein the substituents are as defined above, or
[0083] d) reacting a compound of formula
with a compound of formula
in the presence of triethylamine,
to produce a compound of formula
wherein the substituents are as defined above
and
[0084] if desired, converting the compounds obtained into pharmaceutically acceptable acid addition salts.
[0085] The acid addition salts of the basic compounds of formula I can be converted to the corresponding free bases by treatment with at least a stoichiometric equivalent of a suitable base such as sodium or potassium hydroxide, potassium carbonate, sodium bicarbonate, ammonia, and the like.
[0086] The compounds of formula I can be prepared in accordance with process variant a) to d), with the following schemes and with working examples 1-128.
[0087] The starting material is commercially available or can be prepared in accordance with known methods.
[0000] Procedure A
[0088] This procedure is used to prepare Example 34 (N-phenyl-N-(p-tolylcarbamoyl-methyl)-6-trifluoromethyl-nicotinamide).
[0089] To a compound of formula III, for example 2-bromo-N-(4-methyl-phenyl)-acetamide, in THF is added a compound of formula II, for example aniline and N-ethyldiisopropylamine, and a compound of formula IV, for example 6-trifluoromethyl-nicotynoyl chloride, and the reaction mixture is stirred over night at reflux. Then the reaction is concentrated in vacuo, and the reaction mixture is purified in conventional manner.
[0000] Procedure B
[0090] This procedure is used to prepare Example 30: N-[(3,4-dichloro-phenylcarbamoyl)-methyl]-N-phenyl-3-trifluoromethyl benzamide.
Step 1: Compound of Formula V
[0091] To a compound of formula III, for example 2-bromo-N-(3,4-dichloro-phenyl)-acetamide, in THF is added a compound of formula II, for example aniline and N-ethyldiisopropylamine, and the reaction mixture is stirred over night at reflux. The precipitated salt is then filtered off, and the filtrate was then concentrated in vacuo. The residue was then purified in conventional manner.
[0000] Step 2: Compound of Formula I
[0092] To a compound of formula V, for example N-(3,4-dichloro-phenyl)-2-phenylamino-acetamide, in THF is added triethylamine and a compound of formula IV, for example 3-trifluoromethylbenzoyl chloride, and the reaction mixture is stirred at room temperature for about 30 minutes. Water is then added to the mixture until precipitation occurred, and the mixture is stirred for 5 minutes. Then the precipitate is isolated by filtration and washed.
[0000] Procedure C
[0093] This procedure is used to prepare Example 30: 4-chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2-fluoro-benzyl)benzamide.
Step 1: Compound of Formula VII
[0094] To a compound of formula VI, for example (2,6-dichloro-benzylamino)-acetic acid ethyl ester, in suspension THF is added triethylamine and a compound of formula IV, for example 4-methoxybenzoyl chloride, and the reaction mixture is stirred at room temperature for 10 min. Water is then added to the reaction mixture, and the aqueous phase is extracted with diethylacetate. The combined organic phases are then dried, concentrated in vacuo and purified.
[0000] Step 2: Compound of Formula VIII
[0095] To a compound of formula VII, for example N-(3,4-dichloro-phenyl)-2-phenylamino-acetamide, in ethanol is added NaOH, and the reaction mixture is stirred at room temperature for about 3 hours. The reaction mixture is then neutralized by addition of HCl, and the ethanol is eliminated by evaporation. Water and ethyl acetate is then added to the residue. The organic phase is separated, and the aqueous phase is extracted with ethylacetate. The combined organic phase is then washed again with water, dried and concentrated in vacuo.
[0000] Step 3: Compound of Formula I
[0096] To a solution of a compound of formula IX, for example 3-chloroaniline, in DMF is added N-ethyldiiopropylamine, a compound of formula VIII, for example [(2,6-dichloro-benzyl)-(4-methoxy-benzoyl)-amino]-acetic acid, and HATU; and the reaction mixture is stirred at room temperature over night. Then water is added until precipitation occurs, and the precipitate is isolated by filtration and washed with a mixture of water and ethanol to yield the title compound.
[0000] Procedure D
[0097] This procedure was used to prepare Example 1: 4-chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2,6-difluoro-benzyl)-benzamide.
[0098] To a compound of formula III-1, for example N-1-(3-chlorophenyl)-2-chloroacetamide, in DMF is added a compound of formula II, for example 2,6-difluorobenzylamine and triethylamine, and a compound of formula IV, such as 4-chlorobenzoyl chloride. The reaction mixture is stirred at room temperature for about 15 min and then purified.
[0000] Procedure E
[0099] This procedure was used to prepare Example 97: N-[(3,4-dichloro-phenylcarbamoyl)-methyl]-N-isobutyl-4-methoxy-benzamide.
Step 1: Hydrobromide of a Compound of Formula V-1
[0100] To a solution of a compound of formula III, for example 2-bromo-N-(3,4-dichloro-phenyl)-acetamide, in dichloromethane at 0° C. is slowly added isobutylamine in dichloromethane. The reaction mixture is allowed to warm up to room temperature and then stirred for another 24 hours. Then the salt is filtered off and the filtrate is concentrated in vacuo. The residue is then purified.
[0000] Step 2: Compound of Formula I-1.
[0101] To a solution of a compound of formula V-1, such as N-(3,4-dichloro-phenyl)-2-isobutylamino-acetamide hydrobromide, in THF are slowly added a solution of triethylamine in THF and a solution of a compound of formula IV, for example 4-methoxybenzoyl chloride, in THF, and the reaction mixture is stirred at room temperature for about 24 hours. Then water is added to the reaction mixture, and the precipitate is isolated by filtration and then purified.
[0102] The compounds of formula I and their pharmaceutically usable addition salts possess valuable pharmacological properties. Specifically, the compounds of the present invention are good inhibitors of the glycine transporter I (GlyT-1).
[0103] The compounds were investigated in accordance with the test given hereinafter.
Solutions and Materials
[0104] DMEM complete medium: Nutrient mixture F-12 (Gibco Life-technologies), fetal bovine serum (FBS) 5%, (Gibco life technologies), Penicillin/Streptomycin 1% (Gibco life technologies), Hygromycin 0.6 mg/ml (Gibco life technologies), Glutamine 1 mM Gibco life technologies)
[0105] Uptake buffer (UB): 150 mM NaCl, 10 mM Hepes-Tris, pH 7.4, 1 mM CaCl 2 , 2.5 mM KCl, 2.5 mM MgSO 4 , 10 mM (+) D-glucose.
[0000] Flp-in™-CHO (Invitrogen Cat n° R758-07) cells stably transfected with mGlyT1b cDNA.
[0000] Glycine Uptake Inhibition Assay (mGlyT-1b)
[0106] On day 1 mammalian cells, (Flp-in™-CHO), transfected with mGlyT-1b cDNA, were plated at the density of 40,000 cells/well in complete F-12 medium, without hygromycin in 96-well culture plates. On day 2, the medium was aspirated and the cells were washed twice with uptake buffer (UB). The cells were then incubated for 20 min at 22° C. with either (i) no potential competitor, (ii) 10 mM non-radioactive glycine, (iii) a concentration of a potential inhibitor. A range of concentrations of the potential inhibitor was used to generate data for calculating the concentration of inhibitor resulting in 50% of the effect (e.g. IC 50 , the concentration of the competitor inhibiting glycine uptake of 50%). A solution was then immediately added containing [ 3 H]-glycine 60 nM (11-16 Ci/mmol) and 25 μM non-radioactive glycine. The plates were incubated with gentle shaking and the reaction was stopped by aspiration of the mixture and washing (three times) with ice-cold UB. The cells were lysed with scintillation liquid, shaken 3 hours and the radioactivity in the cells was counted using a scintillation counter.
[0107] The compounds described in examples 1-128 have an IC 50 data <1.0 μM. The IC 50 data (<0.4 μM) for representative compounds 1-128 is be provided in table 2.
[0108] The present invention also provides pharmaceutical compositions containing compounds of the invention, for example compounds of formula I and their pharmaceutically suitable acid addition salts, and a pharmaceutically acceptable carrier. Such pharmaceutical compositions can be in the form of tablets, coated tablets, dragées, hard and soft gelatin capsules, solutions, emulsions or suspensions. The pharmaceutical compositions also can be in the form of suppositories or injectable solutions.
[0109] The pharmaceutical compounds of the invention, in addition to one or more compounds of the invention, contain a pharmaceutically acceptable carrier. Suitable pharmaceutically acceptable carriers include pharmaceutically inert, inorganic and organic carriers. Lactose, corn starch or derivatives thereof, talc, stearic acids or its salts and the like can be used, for example, as such carriers for tablets, coated tablets, dragées and hard gelatine capsules. Suitable carriers for soft gelatine capsules are, for example, vegetable oils, waxes, fats, semi-solid and liquid polyols and the like. Depending on the nature of the active substance no carriers are however usually required in the case of soft gelatine capsules. Suitable carriers for the production of solutions and syrups are, for example, water, polyols, glycerol, vegetable oil and the like. Suitable carriers for suppositories are, for example, natural or hardened oils, waxes, fats, semi-liquid or liquid polyols and the like.
[0110] The pharmaceutical compositions can, moreover, contain preservatives, solubilizers, stabilizers, wetting agents, emulsifiers, sweeteners, colorants, flavorants, salts for varying the osmotic pressure, buffers, masking agents or antioxidants. They can also contain still other therapeutically valuable substances.
[0111] The invention also provides a method for preparing compositions of the invention which comprises bringing one or more compounds of formula I and/or pharmaceutically acceptable acid addition salts and, if desired, one or more other therapeutically valuable substances into a galenical administration form together with one or more therapeutically inert carriers.
[0112] The most preferred indications in accordance with the present invention are those, which include disorders of the central nervous system, for example the treatment or prevention of schizophrenia, cognitive impairment and Alzheimer's disease. The invention provides a method for the treatment of schizophrenia, which comprises administering to an individual a therapeutically effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof. The invention also provides a method for the treatment of Alzheimer's disease, which comprises administering to an individual a therapeutically effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof. The invention further comprises a method for improving cognition, which comprises administering to an individual a therapeutically effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof.
[0113] The dosage at which compounds of the invention can be administered can vary within wide limits and will, of course, have to be adjusted to the individual requirements in each particular case. In the case of oral administration the dosage for adults can vary from about 0.01 mg to about 1000 mg per day of a compound of general formula I or of the corresponding amount of a pharmaceutically acceptable salt thereof. The daily dosage can be administered as single dose or in divided doses and, in addition, the upper limit can also be exceeded when this is found to be indicated.
Tablet Formulation (Wet Granulation) mg/tablet Item Ingredients 5 mg 25 mg 100 mg 500 mg 1. Compound of formula I 5 25 100 500 2. Lactose Anhydrous DTG 125 105 30 150 3. Sta-Rx 1500 6 6 6 30 4. Microcrystalline Cellulose 30 30 30 150 5. Magnesium Stearate 1 1 1 1 Total 167 167 167 831 Manufacturing Procedure 1. Mix items 1, 2, 3 and 4 and granulate with purified water. 2. Dry the granules at 50° C. 3. Pass the granules through suitable milling equipment. 4. Add item 5 and mix for three minutes; compress on a suitable press. Capsule Formulation mg/capsule Item Ingredients 5 mg 25 mg 100 mg 500 mg 1. Compound of formula I 5 25 100 500 2. Hydrous Lactose 159 123 148 — 3. Corn Starch 25 35 40 70 4. Talc 10 15 10 25 5. Magnesium Stearate 1 2 2 5 Total 200 200 300 600 Manufacturing Procedure 1. Mix items 1, 2 and 3 in a suitable mixer for 30 minutes. 2. Add items 4 and 5 and mix for 3 minutes. 3. Fill into a suitable capsule.
[0114] The following examples illustrate the present invention without limiting it. All temperatures are given in degree Celsius.
[0000] Procedure A
[0115] This procedure is used to prepare Example 34
N-Phenyl-N-(p-tolylcarbamoyl-methyl)-6-trifluoromethyl-nicotinamide
[0116] To 2-bromo-N-(4-methyl-phenyl)-acetamide (100 mg) in THF (3.0 mL) was added aniline (41 mg) and N-ethyldiisopropylamine and 6-trifluoromethyl-nicotynoyl chloride (110 mg) the reaction mixture was stirred over night at reflux. Then the reaction was concentrated in vacuo and the reaction mixture was purified by column chromatography to yield the title compound as a light brown solid (127 mg, 70%).
[0000] Procedure B
[0117] This procedure was used to prepare Example 30
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-phenyl-3-trifluoromethyl benzamide
Step 1: N-(3,4-Dichloro-phenyl)-2-phenylamino-acetamide
[0118] To 2-bromo-N-(3,4-dichloro-phenyl)-acetamide (2 g) in THF (80 mL) was added aniline (41 mg) and N-ethyldiisopropylamine and the reaction mixture was stirred over night at reflux. The precipitated salt was then filtered off and the filtrate was then concentrated in vacuo. The residue was then purified by column chromatography to give the title compound as a light brown solid (1.3 g, mp=110-112° C.).
Step 2: N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-phenyl-3-trifluoromethyl benzamide
[0119] To N-(3,4-dichloro-phenyl)-2-phenylamino-acetamide (73 mg) in THF (3.1 mL) was added tiethylamine (52 μL) and 3-trifluoromethylbenzoyl chloride (62 mg) and the reaction mixture was stirred at room temperature for 30 minutes. To the mixture was then added water under precipitation occurred and the mixture was stirred for 5 minutes. Then the precipitate was isolated by filtration and washed with a mixture water-ethanol (1:1) to yield the title compound as a white solid (64 mg, mp=130-132° C.).
[0000] Procedure C
[0120] This procedure was used to prepare Example 30
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2-fluoro-benzyl)benzamide
Step 1: N-(3,4-Dichloro-phenyl)-2-phenylamino-acetamide
[0121] To (2,6-dichloro-benzylamino)-acetic acid ethyl ester (100 mg) in suspension THF (5 mL) was added triethylamine (0.08 mL) and 4-methoxybenzoyl chloride (78 mg) and the reaction mixture was stirred at room temperature for 10 min. After such time the water was added to the reaction mixture and the aqueous phase was extracted with diethylacetate. The combined organic phases were then dried over sodium sulfate, concentrated vacuo and purified by column chromatography to yield the title (128 mg). MS (m/e): 396.3 (M+H + )
Step 2: [(2,6-Dichloro-benzyl)-(4-methoxy-benzoyl)-amino]-acetic acid
[0122] To N-(3,4-dichloro-phenyl)-2-phenylamino-acetamide in ethanol (10 mL) was added 1N NaOH (0.38 μL) and the reaction mixture was stirred at room temperature for 3 hours. After such time the reaction mixture was neutralized by addition of 3N HCl and the ethanol was eliminated by evaporation. To the residue was added more water and ethyl acetate. The organic phase was separated and the aqueous phase was extracted with ethylacetate. The combined organic phase was then washed again with water, dried over sodium sulfate and concentrated in vacuo to yield the title compound (90 mg). MS (m/e): 366.0 (M−H).
Step 3: 4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2-fluoro-benzyl)benzamide
[0123] To a solution of 3-chloroaniline (20 mg) in DMF (1.5 mL) was added N-ethyldiiopropylamine (137 μL), [(2,6-Dichloro-benzyl)-(4-methoxy-benzoyl)-amino]-acetic acid (58 mg) and HATU (Across 365312) and the reaction mixture was stirred at room temperature over night. Then water was added until the precipitation occurs and the precipitate was isolated by filtration and washed with a mixture of water and ethanol (2:1) to yield the title compound (35 mg). MS (m/e): 479.2 (M+H + ).
[0000] Procedure D
[0124] This procedure was used to prepare Example 1
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-N-(2,6-difluoro-benzyl)-benzamide
[0125] To N1-(3-chlorophenyl)-2-chloroacetamide (61 mg) in DMF (1 mL) was added 2,6-difluorobenzylamine (38 mg) and triethylamine (0.1 mL) and 4-chlorobenzoyl chloride (58 mg) the reaction mixture was stirred at room temperature for 15 min and then purified by HPLC preparative to yield the title compound (55 mg). MS (m/e): 447.0 (M−H).
[0000] Procedure E
[0126] This procedure was used to prepare Example 97
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-isobutyl-4-methoxy-benzamide
Step 1: N-(3,4-Dichloro-phenyl)-2-isobutylamino-acetamide hydrobromide
[0127] To a solution of 2-bromo-N-(3,4-dichloro-phenyl)-acetamide (0.1 g) in dichloromethane (80 mL) at 0° C. was slowly added of isobutylamine (52 mg) in dichloromethane. The reaction mixture was allowed to warm up to room temperature and then stirred for another 24 hours. Then the salt was filtered off and the filtrate was concentrated in vacuo. The residue was then purified by column chromatography to yield the title compound as a white solid (0.1 g). MS (m/e): 357.1 (M+H + ).
Step 2: N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-isobutyl-4-methoxy-benzamide
[0128] To a solution of N-(3,4-dichloro-phenyl)-2-isobutylamino-acetamide hydrobromide (0.090 g) in THF were slowly added a solution of triethylamine (0.064 mg) in THF (5 mL) and a solution of 4-methoxybenzoyl chloride (47 mg) in THF (5 mL) and the reaction mixture was stirred at room temperature for 24 hours. Then water was added to the reaction mixture and the precipitate was isolated by filtration and then purified by column chromatography to yield the title compound (78 mg). MS (m/e): 409.2 (M−H, 100%).
[0129] The following starting materials for preparation of compounds of formula I have been used:
TABLE 1 Amine/ Chloro amide or Exp Procedure Aniline bromo amide Acyl chloride 1 D 2,6- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl Difluorobenzylamine 2-chloroacetamide chloride 2 D 3,4- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl Difluorobenzylamine 2-chloroacetamide chloride 3 D 3,5- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl Difluorobenzylamine 2-chloroacetamide chloride 4 D 2,3- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl Difluorobenzylamine 2-chloroacetamide chloride 5 D 2,4- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl Difluorobenzylamine 2-chloroacetamide chloride 6 D 2,5- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl Difluorobenzylamine 2-chloroacetamide chloride 7 D 4-Fluorobenzylamine N1-(3-Chlorophenyl)- 4-Chlorobenzoyl 2-chloroacetamide chloride 8 D 3-Fluorobenzylamine N1-(3-Chlorophenyl)- 4-Chlorobenzoyl 2-chloroacetamide chloride 9 D 2-Fluorobenzylamine N1-(3-Chlorophenyl)- 4-Chlorobenzoyl 2-chloroacetamide chloride 10 D Thiophen-3-yl- N1-(3-Chlorophenyl)- 4-Methoxybenzoyl methylamine 2-chloroacetamide chloride 11 D 2,6- N1-(3-Chlorophenyl)- 4-Methoxybenzoyl Difluorobenzylamine 2-chloroacetamide chloride 12 D 3,5- N1-(3-Chlorophenyl)- 4-Methoxybenzoyl Dichlorobenzylamine 2-chloroacetamide chloride 13 D 2,6- N1-(3-Chlorophenyl)- 4-Methoxybenzoyl Dichlorobenzylamine 2-chloroacetamide chloride 14 D 3-Chlorobenzylamine N1-(3-Chlorophenyl)- 4-Methoxybenzoyl 2-chloroacetamide chloride 15 D Benzylamine N1-(3-Chlorophenyl)- 4-Fluorobenzoyl chloride 2-chloroacetamide 16 D benzylamine N1-(3-Chlorophenyl)- 4-Chlorobenzoyl 2-chloroacetamide chloride 17 D Thiophen-2-yl- N1-(3-Chlorophenyl)- 4-Chlorobenzoyl methylamine 2-chloroacetamide chloride 18 D Thiophen-2-yl- N1-(3-Chlorophenyl)- 4-Methoxybenzoyl methylamine 2-chloroacetamide chloride 19 C (2,6-Dichloro- 3-Chloro aniline 4-Methoxybenzoyl benzylamino)-acetic chloride acid ethyl ester 20 D 3-Fluoroaniline 2-Bromo-N-(3,4- 4-Methoxybenzoyl dichloro-phenyl)- chloride acetamide 21 D 2-Fluoroaniline 2-Bromo-N-(3,4- 4-Methoxybenzoyl dichloro-phenyl)- chloride acetamide 22 B Aniline 2-Bromo-N-(3,4- 4-Methoxybenzoyl dichloro-phenyl)- chloride acetamide 23 C Phenylamino-acetic 3-Chloro-2- 4-Methoxybenzoyl acid ethyl ester Fluoroaniline chloride 24 C Phenylamino-acetic 5-Amino-2,2-difluoro- 4-Methoxybenzoyl acid ethyl ester 1,3-benzodioxole chloride 25 C Phenylamino-acetic 3- 4-Methoxybenzoyl acid ethyl ester (Trifluoromethoxy)aniline chloride 26 C Phenylamino-acetic m-Toluidine 4-Methoxybenzoyl acid ethyl ester chloride 27 C Phenylamino-acetic 3- 4-Methoxybenzoyl acid ethyl ester Aminobenzotrifluoride chloride 28 C Phenylamino-acetic 3-Chloroaniline 4-Methoxybenzoyl acid ethyl ester chloride 29 C Phenylamino-acetic 3-methoxybenzonitrile 4-Methoxybenzoyl acid ethyl ester chloride 30 B Aniline 2-Bromo-N-(3,4- 3-trifluoromethylbenzoyl dichloro-phenyl)- chloride acetamide 31 B Aniline 2-Bromo-N-(3,4- 3-cyanobenzoyl chloride dichloro-phenyl)- acetamide 32 B Aniline 2-Bromo-N-(3,4- 2-Methoxybenzoyl dichloro-phenyl)- chloride acetamide 33 B Aniline 2-Bromo-N-(3,4- 3-Methylbenzoyl dichloro-phenyl)- chloride acetamide 34 A Aniline 2-Bromo-N-(4-methyl- 6-trifluoromethyl- phenyl)-acetamide nicotynoyl chloride 35 B Aniline 2-Bromo-N-(3,4- 3-Chlorobenzoyl dichloro-phenyl)- chloride acetamide 36 A Aniline 2-Bromo-N-(4-fluoro- 6-trifluoromethyl- phenyl)-acetamide nicotynoyl chloride 37 B Aniline 2-Bromo-N-(3,4- 6-Trifluoromethyl- dichloro-phenyl)- nicotinoyl chloride acetamide 38 B Aniline 2-Bromo-N-(3,4- 4-cyanobenzoyl chloride dichloro-phenyl)- acetamide 39 B Aniline 2-Bromo-N-(3,4- 2-Fluorobenzoyl chloride dichloro-phenyl)- acetamide 40 B Aniline 2-Bromo-N-(3,4- 3-fluorobenzoyl chloride dichloro-phenyl)- acetamide 41 B Aniline 2-Bromo-N-(3,4- 4-methoxybenzoyl dichloro-phenyl)- chloride acetamide 42 B Aniline 2-Bromo-N-(3,4- 4-fluorobenzoyl chloride dichloro-phenyl)- acetamide 43 D 2-Chloro-benzylamine 2-Chloro-N-(3- 3-Methylbenzoyl trifluoromethyl- chloride phenyl)-acetamide 44 D 2-Chloro-benzylamine 2-Chloro-N-(3- 6-trifluoromethyl- trifluoromethyl- nicotynoyl chloride phenyl)-acetamide 45 D 3,5-difluoro- 2-Chloro-N-(3- 3-Chlorobenzoyl benzylamine trifluoromethyl- chloride phenyl)-acetamide 46 D 3,5-difluoro- 2-Chloro-N-(3- 6-trifluoromethyl- benzylamine trifluoromethyl- nicotynoyl chloride phenyl)-acetamide 47 D 3,5-difluoro- 2-Chloro-N-(3- 6-Trifluoromethyl- benzylamine trifluoromethyl- nicotinoyl chloride phenyl)-acetamide 48 D 3,5-difluoro- 2-Chloro-N-(3- 4-cyanobenzoyl chloride benzylamine trifluoromethyl- phenyl)-acetamide 49 D 3,5-difluoro- 2-Chloro-N-(3- 2-Fluorobenzoyl chloride benzylamine trifluoromethyl- phenyl)-acetamide 50 D 3,5-difluoro- 2-Chloro-N-(3- 4-cyanobenzoyl chloride benzylamine trifluoromethyl- phenyl)-acetamide 51 D 2-Chloro-benzylamine 2-Chloro-N-(3- Benzo[b]thiophene-2- trifluoromethyl- carbonyl chloride phenyl)-acetamide 52 D 2-Chloro-benzylamine 2-Chloro-N-(3- 3-fluorobenzoyl chloride trifluoromethyl- phenyl)-acetamide 53 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4-Chlorobenzoyl trifluoromethyl- chloride phenyl)-acetamide 54 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4- trifluoromethyl- trifluoromethoxybenzoyl phenyl)-acetamide chloride 55 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4-Fluorobenzoyl chloride trifluoromethyl- phenyl)-acetamide 56 D 3,5-difluoro- 2-Chloro-N-(3- 6-trifluoromethyl benzyl benzylamine trifluoromethyl- chloride phenyl)-acetamide 57 D 2-Chloro-benzylamine 2-Chloro-N-(3-fluoro- Benzo[b]thiophene-2- phenyl)-acetamide carbonyl chloride 58 D 2-Chloro-benzylamine 2-Chloro-N-(3-fluoro- 3-fluorobenzoyl chloride phenyl)-acetamide 59 D 2-Chloro-benzylamine 2-Chloro-N-(3-fluoro- 3-Methylbenzoyl phenyl)-acetamide chloride 60 D 2-Chloro-benzylamine 2-Chloro-N-(3-fluoro- 4- phenyl)-acetamide trifluoromethoxybenzoyl chloride 61 D 2-Chloro-benzylamine 2-Chloro-N-(3-fluoro- 4-Fluorobenzoyl chloride phenyl)-acetamide 62 D 2-Chloro-benzylamine 2-Chloro-N-(3-fluoro- 4-cyanobenzoyl chloride phenyl)-acetamide 63 D 3,5-difluoro- 2-Chloro-N-(3-fluoro- Benzo[b]thiophene-2- benzylamine phenyl)-acetamide carbonyl chloride 64 D 3,5-difluoro- 2-Chloro-N-(3-fluoro- 3-Methylbenzoyl benzylamine phenyl)-acetamide chloride 65 D 3,5-difluoro- 2-Chloro-N-(3-fluoro- 4- benzylamine phenyl)-acetamide trifluoromethoxybenzoyl chloride 66 D 3,4-difluoro- 2-Chloro-N-(3-fluoro- Benzo[b]thiophene-2- benzylamine phenyl)-acetamide carbonyl chloride 67 D 3,4-difluoro- 2-Chloro-N-(3-fluoro- 3-Methylbenzoyl benzylamine phenyl)-acetamide chloride 68 D 3,4-difluoro- 2-Chloro-N-(3-fluoro- 4- benzylamine phenyl)-acetamide trifluoromethoxybenzoyl chloride 69 D 2,6-difluoro- 2-Chloro-N-(3- Benzo[b]thiophene-2- benzylamine Chloro,4-fluoro- carbonyl chloride phenyl)-acetamide 70 D 2,6-difluoro- 2-Chloro-N-(3- 3-Methylbenzoyl benzylamine Chloro,4-fluoro- chloride phenyl)-acetamide 71 D 2,6-difluoro- 2-Chloro-N-(3- 4- benzylamine Chloro,4-fluoro- trifluoromethoxybenzoyl phenyl)-acetamide chloride 72 D 2-Chloro-benzylamine 2-Chloro-N-(3- Benzo[b]thiophene-2- Chloro,4-fluoro- carbonyl chloride phenyl)-acetamide 73 D 2-Chloro-benzylamine 2-Chloro-N-(3- 3-fluorobenzoyl chloride Chloro,4-fluoro- phenyl)-acetamide 74 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4-Chlrorobenzoyl Chloro,4-fluoro- chloride phenyl)-acetamide 75 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4- Chloro,4-fluoro- trifluoromethoxybenzoyl phenyl)-acetamide chloride 76 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4-Fluorobenzoyl chloride Chloro,4-fluoro- phenyl)-acetamide 77 D 2-Chloro-benzylamine 2-Chloro-N-(3- 4-cyanobenzoyl chloride Chloro,4-fluoro- phenyl)-acetamide 78 D 2,6-difluoro- 2-Chloro-N-(3- 4-Fluorobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 79 D 2-Chloro-benzylamine 2-Chloro-N-(3- 6-trifluoromethyl benzyl Chloro,4-fluoro- chloride phenyl)-acetamide 80 D 2,3-Difluoro- 2-Chloro-N-(3- Benzo[b]thiophene-2- benzylamine Chloro,4-fluoro- carbonyl chloride phenyl)-acetamide 81 D 2,3-Difluoro- 2-Chloro-N-(3- 3-fluorobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 82 D 2,3-Difluoro- 2-Chloro-N-(3- 4-Chlrorobenzoyl benzylamine Chloro,4-fluoro- chloride phenyl)-acetamide 83 D 2,3-Difluoro- 2-Chloro-N-(3- 4- benzylamine Chloro,4-fluoro- trifluoromethoxybenzoyl phenyl)-acetamide chloride 84 D 2,3-Difluoro- 2-Chloro-N-(3- 4-Fluorobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 85 D 2,3-Difluoro- 2-Chloro-N-(3- 4-cyanobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 86 D 2,3-Difluoro- 2-Chloro-N-(3- 6-trifluoromethyl benzyl benzylamine Chloro,4-fluoro- chloride phenyl)-acetamide 87 D 2,3-Difluoro- 2-Chloro-N-(3- Benzo[b]thiophene-2- benzylamine Chloro,4-fluoro- carbonyl chloride phenyl)-acetamide 88 D 2,6-difluoro- 2-Chloro-N-(3- 4-cyanobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 89 D 2,3-Difluoro- 2-Chloro-N-(3- 3-Methylbenzoyl benzylamine Chloro,4-fluoro- chloride phenyl)-acetamide 90 D 3,5-difluoro- 2-Chloro-N-(3- 4- benzylamine Chloro,4-fluoro- trifluoromethoxybenzoyl phenyl)-acetamide chloride 91 D 3,5-difluoro- 2-Chloro-N-(3- 4-Fluorobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 92 D 3,5-difluoro- 2-Chloro-N-(3- 4-cyanobenzoyl chloride benzylamine Chloro,4-fluoro- phenyl)-acetamide 93 D 3,5-difluoro- 2-Chloro-N-(3- 6-trifluoromethyl benzyl benzylamine Chloro,4-fluoro- chloride phenyl)-acetamide 94 D 3,4-Difluoro- 2-Chloro-N-(3- Benzo[b]thiophene-2- benzylamine Chloro,4-fluoro- carbonyl chloride phenyl)-acetamide 95 D 2,2-simethyl 2-Chloro-N-(3-Chloro 4-Chlrorobenzoyl propylamine phenyl)-acetamide chloride 96 D 3,3-dimethyl 2-Chloro-N-(3-Chloro 4-Chlrorobenzoyl butylamine phenyl)-acetamide chloride 97 E iso butylamine 2-Bromo-N-(3,4- 4-Methoxybenzoyl dichloro phenyl)- chloride acetamide 98 E 3-methyl butylamine 2-Bromo-N-(3,4- 4-Methoxybenzoyl dichloro phenyl)- chloride acetamide 99 B benzylamine 2-Bromo-N-(3,4- 4-Methoxybenzoyl dichloro phenyl)- chloride acetamide 100 D 3-cyano-benzylamine 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl phenyl)-acetamide chloride 101 D 3-methoxy- 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl benzylamine phenyl)-acetamide chloride 102 D 2-methoxy- 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl benzylamine phenyl)-acetamide chloride 103 D 3-methyl-benzylamine 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl phenyl)-acetamide chloride 104 D 2-methyl-benzylamine 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl phenyl)-acetamide chloride 105 D 3-Chloro-benzylamine 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl phenyl)-acetamide chloride 106 D 2-Chloro-benzylamine 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl phenyl)-acetamide chloride 107 D C-Furan-2-yl- 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl methylamine phenyl)-acetamide chloride 108 C Phenylamino-acetic 2-Bromo-N-(3,4- 4-methoxy benzoyl acid ethyl ester dichloro phenyl)- chloride acetamide 119 B 2-fluoro-benzylamine 3-Chloro aniline 6-Morpholin-4-yl- nicotinoyl chloride 120 B 2-fluoro-benzylamine 3-Chloro aniline 6-Chloro-nicotinoyl chloride 121 B 2-Fluoro-benzylamine 3-Chloro aniline 2-Chloro-isonicotinoyl chloride 122 B 2-Fluoro-benzylamine 3-Chloro aniline 2,6-Dichloro- isonicotinoyl chloride 123 A C-Cyclohexyl- 2-Chloro-N-(3-chloro- 4-chlorobenzoyl chloride methylamine phenyl)-acetamide 124 A C-Cyclohexyl- 2-Chloro-N-(3-chloro- 4-Chlorobenzoyl methylamine phenyl)-acetamide chloride 125 A C-Cyclohexyl- 2-Chloro-N-(3-chloro- 4-Fluorobenzoyl chloride methylamine phenyl)-acetamide 126 A Cyclopentylamine 2,4-Dichloro-N-(3- 4-Methoxybenzoyl chloro-phenyl)- chloride acetamide 127 A Cyclopropylamine 2,4-Dichloro-N-(3- 4-Methoxybenzoyl chloro-phenyl)- chloride acetamide 128 A Cyclohexylamine 2,4-Dichloro-N-(3- 4-Methoxybenzoyl chloro-phenyl)- chloride acetamide
[0130] The following compounds have been prepared in accordance with table 1:
TABLE 2 Procedure R 1 R 2 R 3 R 4 X IC 50 Exp D H bond 0.052 1 D H bond 0.265 2 D H bond 0.184 3 D H bond 0.074 4 D H bond 0.16 5 D H bond 0.165 6 D H bond 7 D H bond 0.128 8 D H bond 0.074 9 D H bond 0.285 10 D H bond 0.1 11 D H bond 0.243 12 D H bond 0.122 13 D H bond 0.024 14 D H bond 0.312 15 D H bond 0.156 16 D H bond 0.077 17 D H bond 0.257 18 C H bond 0.164 19 D H bond 20 D H bond 0.315 21 B H bond 22 C H bond 23 C H bond 24 C H bond 25 C H bond 26 C H bond 0.148 27 C H bond 0.267 28 C H bond 29 B H bond 30 B H bond 0.35 31 B H bond 32 B H bond 33 A H bond 34 B H bond 35 A H bond 36 B H bond 0.154 37 B H bond 38 B H bond 0.291 39 B H bond 40 B H bond 0.276 41 B H bond 42 D H bond 0.339 43 D H bond 44 D H bond 0.298 45 D H bond 46 D H bond 47 D H bond 48 D H bond 49 D H bond 50 D H bond 0.06 51 D H bond 0.153 52 D H bond 0.241 53 D H bond 0.196 54 D H bond 0.097 55 D H bond 56 D H bond 0.088 57 D H bond 58 D H bond 0.166 59 D H bond 0.107 60 D H bond 61 D H bond 0.357 62 D H bond 0.07 63 D H bond 64 D H bond 0.278 65 D H bond 0.167 66 D H bond 67 D H bond 68 D H bond 0.09 69 D H bond 70 D H bond 0.107 71 D H bond 0.205 72 D H bond 73 D H bond 0.142 74 D H bond 0.259 75 D H bond 0.159 76 D H bond 0.182 77 D H bond 0.282 78 D H bond 79 D H bond 0.066 80 D H bond 81 D H bond 0.108 82 D H bond 0.078 83 D H bond 0.178 84 D H bond 0.123 85 D H bond 86 D H bond 0.036 87 D H bond 0.199 88 D H bond 0.306 89 D H bond 0.288 90 D H bond 91 D H bond 92 D H bond 93 D H bond 94 D H bond 95 D H bond 0.359 96 E H bond 97 E H bond 98 B H bond 99 D H bond 0.192 100 D H bond 101 D H bond 0.06 102 D H bond 0.142 103 D H bond 0.209 104 D H bond 0.021 105 D H bond 0.025 106 D H bond 0.199 107 C H bond 0.182 108 C H bond 109 C H bond 0.369 110 C H bond 111 C H bond 112 B H bond 0.15 113 B H bond 0.091 114 B H bond 115 B H bond 0.191 116 B H bond 0.21 117 B H OCH 2 0.259 118 B H bond 0.355 119 B H bond 0.182 120 B H bond 121 B H bond 122 A CH 3 bond 123 A H bond 124 A H bond 125 A H bond 0.357 126 A H bond 127 A H bond 128
[0131]
TABLE 3
MS
MS
Compound name
MW
result
mode
Example
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
449.28
447.0
neg
1
N-(2,6-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
449.28
447.0
neg
2
N-(3,4-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
449.28
447.0
neg
3
N-(3,5-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
449.28
449.2
pos
4
N-(2,3-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
449.28
449.2
pos
5
N-(2,4-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
449.28
449.2
pos
6
N-(2,5-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
431.29
431.4
pos
7
N-(4-fluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
431.29
431.4
pos
8
N-(3-fluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
431.29
431.4
pos
9
N-(2-fluoro-benzyl)-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-4-
414.9
415.3
pos
10
methoxy-N-thiophen-3-ylmethyl-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-(2,6-
444.9
443.2
neg
11
difluoro-benzyl)-4-methoxy-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-(3,5-
477.8
477.1
pos
12
dichloro-benzyl)-4-methoxy-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-(2,5-
477.8
479.2
pos
13
dichloro-benzyl)-4-methoxy-benzamide
N-(3-Chloro-benzyl)-N-[(3-chloro-
443.3
443.3
pos
14
phenylcarbamoyl)-methyl]-4-methoxy-benzamide
N-Benzyl-N-[(3-chloro-phenylcarbamoyl)-methyl]-
496.8
497.1
pos
15
4-fluoro-benzamide
N-Benzyl-4-chloro-N-[(3-chloro-phenylcarbamoyl)-
413.3
413.2
pos
16
methyl]-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
419.3
419.1
pos
17
N-thiophen-2-ylmethyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-4-
449.4
449.1
pos
18
methoxy-N-thiophen-2-ylmethyl-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-(2,6-
477.8
479.2
pos
19
dichloro-benzyl)-4-methoxy-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-(3-
447.3
447.1
pos
20
fluoro-phenyl)-4-methoxy-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-(2-
447.3
447.1
pos
21
fluoro-phenyl)-4-methoxy-benzamide
Pentanoic acid [(3,4-dichloro-phenylcarbamoyl)-
379.3
379.3
pos
22
methyl]-phenyl-amide
N-[(3-Chloro-2-fluoro-phenylcarbamoyl)-methyl]-
412.8
413.4
pos
23
4-methoxy-N-phenyl-benzamide
N-[(2,2-Difluoro-benzo[1,3]dioxol-5-ylcarbamoyl)-
440.4
441.0
pos
24
methyl]-4-methoxy-N-phenyl-benzamide
4-Methoxy-N-phenyl-N-[(3-trifluoromethoxy-
444.4
445.1
pos
25
phenylcarbamoyl)-methyl]-benzamide
4-Methoxy-N-phenyl-N-(m-tolylcarbamoyl-
374.4
375.1
pos
26
methyl)-benzamide
4-Methoxy-N-phenyl-N-[(3-trifluoromethyl-
428.4
429.0
pos
27
phenylcarbamoyl)-methyl]-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-4-
394.9
395.0
pos
28
methoxy-N-phenyl-benzamide
4-Methoxy-N-[(3-methoxy-phenylcarbamoyl)-
390.4
391.3
pos
29
methyl]-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-
467.3
467.0
pos
30
phenyl-3-trifluoromethyl-benzamide
3-Cyano-N-[(3,4-dichloro-phenylcarbamoyl)-
424.3
467.0
pos
31
methyl]-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-2-
429.3
429.2
pos
32
methoxy-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-3-
413.3
413.2
pos
33
methyl-N-phenyl-benzamide
N-Phenyl-N-(p-tolylcarbamoyl-methyl)-6-
413.4
414.4
pos
34
trifluoromethyl-nicotinamide
3-Chloro-N-[(3,4-dichloro-phenylcarbamoyl)-
433.7
433.0
pos
35
methyl]-N-phenyl-benzamide
N-[(4-Fluoro-phenylcarbamoyl)-methyl]-N-phenyl-
417.4
418.0
pos
36
6-trifluoromethyl-nicotinamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-
468.3
468.1
pos
37
phenyl-6-trifluoromethyl-nicotinamide
4-Cyano-N-[(3,4-dichloro-phenylcarbamoyl)-
424.3
424.0
pos
38
methyl]-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-2-
417.3
417.3
pos
39
fluoro-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-3-
417.3
417.1
pos
40
fluoro-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-4-
429.3
429.3
pos
41
methoxy-N-phenyl-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-4-
417.3
417.1
pos
42
fluoro-N-phenyl-benzamide
N-(2-Chloro-benzyl)-4-cyano-N-[(3-
471.9
472.2
pos
43
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
N-(2-Chloro-benzyl)-3-trifluoromethyl-N-[(3-
514.9
515.2
pos
44
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
Benzo[b]thiophene-2-carboxylic acid (3,5-difluoro-
504.5
506.2
pos
45
benzyl)-[(3-trifluoromethyl-phenylcarbamoyl)-
methyl]-amide
N-(3,5-Difluoro-benzyl)-3-fluoro-N-[(3-
466.4
467.2
pos
46
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
4-Chloro-N-(3,5-difluoro-benzyl)-N-[(3-
482.8
483.4
pos
47
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
N-(3,5-Difluoro-benzyl)-4-trifluoromethoxy-N-[(3-
432.4
433.2
pos
48
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
N-(3,5-Difluoro-benzyl)-4-fluoro-N-[(3-
466.4
467.2
pos
49
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
4-Cyano-N-(3,5-difluoro-benzyl)-N-[(3-
473.4
474.2
pos
50
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
Benzo[b]thiophene-2-carboxylic acid (2-chloro-
502.9
503.1
pos
51
benzyl)-[(3-trifluoromethyl-phenylcarbamoyl)-
methyl]-amide
N-(2-Chloro-benzyl)-3-fluoro-N-[(3-
464.9
465.3
pos
52
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
4-Chloro-N-(2-chloro-benzyl)-N-[(3-
481.3
481.2
pos
53
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
#N!-(2-Chloro-benzyl)-4-trifluoromethoxy-#N!-[(3-
530.9
531.1
pos
54
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
N-(2-Chloro-benzyl)-4-fluoro-N-[(3-
464.9
465.3
pos
55
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
N-(3,5-Difluoro-benzyl)-3-trifluoromethyl-N-[(3-
516.4
517.2
pos
56
trifluoromethyl-phenylcarbamoyl)-methyl]-
benzamide
Benzo[b]thiophene-2-carboxylic acid (2-chloro-
452.9
453.0
pos
57
benzyl)-[(3-fluoro-phenylcarbamoyl)-methyl]-amide
N-(2-Chloro-benzyl)-3-fluoro-N-[(3-fluoro-
414.8
415.3
pos
58
phenylcarbamoyl)-methyl]-benzamide
4-Chloro-N-(2-chloro-benzyl)-N-[(3-fluoro-
431.3
431.1
pos
59
phenylcarbamoyl)-methyl]-benzamide
N-(2-Chloro-benzyl)-N-[(3-fluoro-
480.8
481.1
pos
60
phenylcarbamoyl)-methyl]-4-trifluoromethoxy-
benzamide
N-(2-Chloro-benzyl)-4-fluoro-N-[(3-fluoro-
414.8
415.2
pos
61
phenylcarbamoyl)-methyl]-benzamide
N-(2-Chloro-benzyl)-4-cyano-N-[(3-fluoro-
421.9
422.1
pos
62
phenylcarbamoyl)-methyl]-benzamide
Benzo[b]thiophene-2-carboxylic acid (3,5-difluoro-
454.5
455.2
pos
63
benzyl)-[(3-fluoro-phenylcarbamoyl)-methyl]-amide
4-Chloro-N-(3,5-difluoro-benzyl)-N-[(3-fluoro-
432.8
433.2
pos
64
phenylcarbamoyl)-methyl]-benzamide
N-(3,5-Difluoro-benzyl)-N-[(3-fluoro-
482.4
483.1
pos
65
phenylcarbamoyl)-methyl]-4-trifluoromethoxy-
benzamide
Benzo[b]thiophene-2-carboxylic acid (3,4-difluoro-
454.5
455.2
pos
66
benzyl)-[(3-fluoro-phenylcarbamoyl)-methyl]-amide
4-Chloro-N-(3,4-difluoro-benzyl)-N-[(3-fluoro-
432.8
433.2
pos
67
phenylcarbamoyl)-methyl]-benzamide
N-(3,4-Difluoro-benzyl)-N-[(3-fluoro-
482.4
483.4
pos
68
phenylcarbamoyl)-methyl]-4-trifluoromethoxy-
benzamide
Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-
488.9
489.1
pos
69
fluoro-phenylcarbamoyl)-methyl]-(2,6-difluoro-
benzyl)-amide
4-Chloro-N-[(3-chloro-4-fluoro-phenylcarbamoyl)-
467.3
467.1
pos
70
methyl]-N-(2,6-difluoro-benzyl)-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
518.8
517.1
pos
71
N-(2,6-difluoro-benzyl)-4-trifluoromethoxy-
benzamide
Benzo[b]thiophene-2-carboxylic acid (2-chloro-
487.4
487.2
pos
72
benzyl)-[(3-chloro-4-fluoro-phenylcarbamoyl)-
methyl]-amide
N!-(2-Chloro-benzyl)-N!-[(3-chloro-4-fluoro-
449.3
449.1
pos
73
phenylcarbamoyl)-methyl]-3-fluoro-benzamide
4-Chloro-N-(2-chloro-benzyl)-N-[(3-chloro-4-
465.7
465.2
pos
74
fluoro-phenylcarbamoyl)-methyl]-benzamide
N-(2-Chloro-benzyl)-N-[(3-chloro-4-fluoro-
515.3
512.3
pos
75
phenylcarbamoyl)-methyl]-4-trifluoromethoxy-
benzamide
N-(2-Chloro-benzyl)-N-[(3-chloro-4-fluoro-
449.3
449.1
pos
76
phenylcarbamoyl)-methyl]-4-fluoro-benzamide
N-(2-Chloro-benzyl)-N-[(3-chloro-4-fluoro-
456.3
456.3
pos
77
phenylcarbamoyl)-methyl]-4-cyano-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
450.8
451.1
pos
78
N-(2,6-difluoro-benzyl)-4-fluoro-benzamide
N-(2-Chloro-benzyl)-N-[(3-chloro-4-fluoro-
499.3
499.2
pos
79
phenylcarbamoyl)-methyl]-3-trifluoromethyl-
benzamide
Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-
488.9
489.2
pos
80
fluoro-phenylcarbamoyl)-methyl]-(2,3-difluoro-
benzyl)-amide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
450.8
451.1
pos
81
N-(2,3-difluoro-benzyl)-3-fluoro-benzamide
4-Chloro-N-[(3-chloro-4-fluoro-phenylcarbamoyl)-
467.3
467.2
pos
82
methyl]-N-(2,3-difluoro-benzyl)-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
516.8
517.1
pos
83
N-(2,3-difluoro-benzyl)-4-trifluoromethoxy-
benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
450.8
451.1
pos
84
N-(2,3-difluoro-benzyl)-4-fluoro-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
457.8
458.3
pos
85
4-cyano-N-(2,3-difluoro-benzyl)-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
500.8
501.1
pos
86
N-(2,3-difluoro-benzyl)-3-trifluoromethyl-
benzamide
Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-
488.9
499.1
pos
87
fluoro-phenylcarbamoyl)-methyl]-(3,5-difluoro-
benzyl)-amide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
457.8
458.3
pos
88
4-cyano-N-(2,6-difluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-4-fluoro-phenylcarbamoyl)-
467.3
467.4
pos
89
methyl]-N-(3,5-difluoro-benzyl)-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
516.8
517.1
pos
90
N-(3,5-difluoro-benzyl)-4-trifluoromethoxy-
benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
450.8
451.1
pos
91
N-(3,5-difluoro-benzyl)-4-fluoro-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
457.8
458.3
pos
92
4-cyano-N-(3,5-difluoro-benzyl)-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
500.8
501.1
pos
93
N-(3,5-difluoro-benzyl)-3-trifluoromethyl-
benzamide
Benzo[b]thiophene-2-carboxylic acid [(3-chloro-4-
488.9
489.1
pos
94
fluoro-phenylcarbamoyl)-methyl]-(3,4-difluoro-
benzyl)-amide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
393.3
393.1
neg
95
N-(2,2-dimethyl-propyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
407.3
408.3
neg
96
N-(3,3-dimethyl-butyl)-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-
409.3
409.2
neg
97
isobutyl-4-methoxy-benzamide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-4-
423.3
421.0
neg
98
methoxy-N-(3-methyl-butyl)-benzamide
N-Benzyl-N-[(3,4-dichloro-phenylcarbamoyl)-
443.3
441.2
neg
99
methyl]-4-methoxy-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
438.3
436.0
neg
100
N-(3-cyano-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
443.3
440.9
neg
101
N-(3-methoxy-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
443.3
440.9
neg
102
N-(2-methoxy-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
427.3
446.8
neg
103
N-(3-methyl-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
427.3
424.9
neg
104
N-(2-methyl-benzyl)-benzamide
4-Chloro-N-(3-chloro-benzyl)-N-[(3-chloro-
447.8
446.8
neg
105
phenylcarbamoyl)-methyl]-benzamide
4-Chloro-N-(2-chloro-benzyl)-N-[(3-chloro-
447.8
446.8
neg
106
phenylcarbamoyl)-methyl]-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
403.3
401.0
neg
107
N-furan-2-ylmethyl-benzamide
N-[(3-Chloro-4-fluoro-phenylcarbamoyl)-methyl]-
412.9
413.0
pos
108
4-methoxy-N-phenyl-benzamide
N-[(5-Chloro-2-methyl-phenylcarbamoyl)-methyl]-
408.9
409.2
pos
109
4-methoxy-N-phenyl-benzamide
N-[(3-Chloro-4-methyl-phenylcarbamoyl)-methyl]-
408.9
409.2
pos
110
4-methoxy-N-phenyl-benzamide
N-[(3,5-Dichloro-phenylcarbamoyl)-methyl]-4-
429.3
429.3
pos
111
methoxy-N-phenyl-benzamide
N-[(4-Bromo-3-chloro-phenylcarbamoyl)-methyl]-
473.8
472.9
pos
112
4-methoxy-N-phenyl-benzamide
Benzo[b]thiophene-2-carboxylic acid [(3,4-dichloro-
455.4
454.9
pos
113
phenylcarbamoyl)-methyl]-phenyl-amide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-N-
483.3
482.9
pos
114
phenyl-4-trifluoromethoxy-benzamide
Isoxazole-5-carboxylic acid [(3,4-dichloro-
390.2
390.0
pos
115
phenylcarbamoyl)-methyl]-phenyl-amide
N-[(3,4-Dichloro-phenylcarbamoyl)-methyl]-4-
442.3
442.0
pos
116
dimethylamino-N-phenyl-benzamide
N-(3-Chloro-phenyl)-N-[(3,4-dichloro-
463.7
462.8
pos
117
phenylcarbamoyl)-methyl]-4-methoxy-benzamide
2-(4-Chloro-phenoxy)-N-[(3,4-dichloro-
463.7
462.8
pos
118
phenylcarbamoyl)-methyl]-N-phenyl-acetamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-(2-
462.9
483.5
pos
119
fluoro-benzyl)-6-morpholin-4-yl-nicotinamide
6-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
432.3
432.2
pos
120
N-(2-fluoro-benzyl)-nicotinamide
2-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
432.3
432.1
pos
121
N-(2-fluoro-benzyl)-isonicotinamide
2,6-Dichloro-N-[(3-chloro-phenylcarbamoyl)-
466.7
468.1
pos
122
methyl]-N-(2-fluoro-benzyl)-isonicotinamide
4-Chloro-N-{[(3-chloro-phenyl)-methyl-
445.3
445.4
pos
123
carbamoyl]-methyl}-N-(3-fluoro-benzyl)-benzamide
4-Chloro-N-[(3-chloro-phenylcarbamoyl)-methyl]-
419.4
419.1
pos
124
N-cyclohexylmethyl-benzamide
N-[(3-Chloro-phenylcarbamoyl)-methyl]-N-
402.9
403.3
pos
125
cyclohexylmethyl-4-fluoro-benzamide
N-Cyclopentyl-N-[(3,4-dichloro-phenylcarbamoyl)-
421.3
420.9
pos
126
methyl]-4-methoxy-benzamide
N-Cyclopropyl-N-[(3,4-dichloro-phenylcarbamoyl)-
393.3
393.0
pos
127
methyl]-4-methoxy-benzamide
N-Cyclohexyl-N-[(3,4-dichloro-phenylcarbamoyl)-
435.3
435.1
pos
128
methyl]-4-methoxy-benzamide | The present invention relates to compounds of formula I
wherein
R 1 , R 2 ,
R 3 ,
R 4 , and
X are as defined herein or to pharmaceutically acceptable acid addition salts thereof, with the exception of 4-methoxy-N-[2-oxo-2-(phenylamino)ethyl]-N-phenyl-benzamide, 4-chloro-N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-chloro-N-[2-[5-chloro-2-methoxyphenyl)amino]-2-oxoethyl]-N-benzamide, 4-methyl-N-[2-oxo-2-[(2,4,6-trichlorophenyl)amino]ethyl]-N-benzamide, N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-methyl-N-[2-[(4-methylphenyl)amino]-2-oxoethyl]-N-phenyl-benzamide, 4-chloro-N-(2-oxo-2-[(2,4,6-trichlorophenyl)amino]ethyl]-N-benzamide and N-[2-[(2,4-dimethoxyphenyl)amino]-2-oxoethyl]-N-[(2-fluorophenyl)methyl]-benzeneacetamide. The compounds are useful in the treatment of neurological and neuropsychiatric disorders. | 2 |
FIELD OF INVENTION
This invention relates to the construction of prefabricated vacuum constructed panels within a residential, commercial or industrial structure and more specifically to a method for improving the insulating qualities within the commercial, residential or industrial structure resulting in greater retention abilities for maintaining a controlled climatic condition within a structure.
OBJECTS AND ADVANTAGES
Accordingly, several objects and advantages of my invention are as follows.
1) A construction and manufacturing method of prefabricated vacuumed constructed panels for residential, commercial or industrial structures having a much greater insulating value than present building or manufacturing processes utilizing current construction methods.
2) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures permitting the preconstruction of panels in a factory type setting thus enabling the pre-manufactured panels to be uniform in size or customized to the individuals needs.
3) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having an I beam configuration offering added strength to the structure and also serving as a load bearing surface.
4) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having the I beam configuration, wherein the right side, left side, and top cap plate are utilized as the means for the joining together of the individual panels, with the bottom toe plate edge having the means for securing the completed panels to a foundation, as well as to add strength and durability to the structure thus, giving added safeguards when severe storms are threatening or already in progress.
5) A construction and manufacturing method of prefabricated vacuum constructed panels for the residential, commercial or industrial structures utilizing steel sheet plates, (the preferred materials), offering the building greater security from the perils of every day life. The preferred construction materials will offer the exterior doors and windows the ability to be anchored steel to steel as opposed to steel to a forest product. This steel anchoring thereby affords greater security for the inhabitants of, or stored goods within the structure. Current methods offer the windows, doors and locking devices to be anchored to a forest product.
6) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having the availibility of design configuration change to meet designers, builders, owners or architects requirements.
7) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having the availibility for a vacuum to be drawn across the spectrum of the plurality of interior cavities.
8) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having uniformity in the precut window and door openings sized and placed to individual specifications.
9) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having a high insulating factor which will reduce the dependence on foreign energy sources.
10) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures having the primary exterior walls, ceilings or roof line made of materials that are impervious to distruction by termites.
11) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures wherein the raceways for the electrical boxes, electrical pipes and plumbing pipes are provided for.
12) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures where the need for a controlled environment with a constant temperature is required. This present invention can be constructed to meet those requirements.
13) A construction and manufacturing method of prefabricated vacuum constructed panels for residential, commercial or industrial structures that is, in itself, an interior vapor barrier and an exterior wind and water vapor barrier.
Further objects and advantages will become more apparent from a consideration of the drawings and ensuing descriptions thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plurality of wall panels joined to a roof line panel.
FIG. 2 shows an isolated view of the female opening, the recessed groove and gasket material contained within the left side edge.
FIG. 3 shows an isolated view of the male opening with the male protrusion contained within the left side edge.
FIG. 4 shows an isolated cross sectional view of the female opening with the recessed groove and gasket material contained within the left side edge.
FIG. 5 shows an isolated cross sectional view of the male opening and the male protrusion contained within the right side edge.
FIG. 6 shows a cross sectional view of a single completed panel having the apparatus for the introduction of the insulating material into the interior cavity.
FIG. 7 shows a cross sectional view of a single panel containing the air evacuating apparatus.
FIG. 8 shows a cut away view of a typically constructed prefabricated panel exposing the interior cavity within a single panel containing the strap dowel configuration within the interior cavity. The right side edge containing the male openings and protrusions, the left side edge containing the female openings or sealing apertures. Contained within the right side edge, left side edge, top cap edge and the bottom toe plate edge are the utility openings and hole openings.
FIG. 9 shows an isolated view of the lower portion of a typical wall panel with the vacuum valve within the front face plate, further containing the utility openings, hole openings and fasteners.
FIG. 10 shows an isolated view of the upper portion of a typical wall panel with filler cap within the front face plate having the front face plate cover in place, further containing the utility openings and hole openings.
FIG. 11 shows an isolated view of the lower portion of a typical roof line panel with the vacuum valve within the front face plate, further containing the utility openings, hole openings and fasteners.
FIG. 12 shows an isolated view of the upper portion of a typical roof line panel with filler cap within the front face plate having the front face plate cover in place, further containing the utility openings and hole openings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting and an understanding of this invention, referrences will be made to the preferred embodiment as illustrated in the drawings with specific language utilized in describing same. It is not my intention to limit the scope of this invention, since many modifications and/or alterations can be made without departing from my original intent of this invention.
The present invention provides a method for the prefabricated vacuum constructed panels having far superior insulating qualities then present methods, techniques and existing prior art teaches. The prefabricated vacuum constructed panels may come in a variety of sizes, forms and configurations, tailored to meet individual structural requirements. The present invention is well suited and readily adaptable to present day construction methods and to all exterior or interior facades. I do not wish to limit this invention to the construction of habitable buildings or storage buildings, since a variety of structures can be made from this invention.
The materials utilized in constructing this invention may vary without departing from the original intent of this invention.
When discussing the strap dowel configuration 54, the right side edge 24, with male opening 42, male protrusion 44, hole openings 34, utility openings 68, and the left side edge 26, with female opening 36, recessed groove 38, gasket material 40, hole openings 34, and utility openings 68, an implication is intended and implied, that the above mentioned components are to be included when constructing the various wall panels and roof line panels discussed within this invention regardless of shape or configuration.
The intention is implied, that, in the manufacturing of the prefabricated structural panels, the wall panels 52a and roof line panels 52d are constructed in like manner with the exception being the roof line panels 52d may contain an L type off set configuration, at an indeterminate angle, as a means to accommodate a change in direction between the roof line panel and the wall panel.
The intention is implied, that, in the manufacturing of the prefabricated structural panels, the wall panels with filler cap 52b and roof line panels with filler cap 52e are constructed in like manner with the wall panels 52a with the exception being the wall panel with filler cap 52b and roof line panel with filler cap 52e may contain a front face plate female opening 48 and a front face plate cover 50 within the upper portion of the front face plate 20. Additionally, the roof line panel with filler cap 52e may contain the L type off set configuration, at an indeterminate angle, as a means to accommodate a change in direction between the roof line panel and the wall panel.
The intention is implied, that, in the manufacturing of the prefabricated structural panels, the wall panels with vacuum valve 52c and roof line panels with vacuum valve 52f are constructed in like manner with the wall panels 52a, with the exception being the wall panel with vacuum valve 52c and roof line panel with vacuum valve 52f may contain a front face plate vacuum opening 56, a vacuum pipe 58, a porous filter 60 and a vacuum valve 62, within the lower portion of the front face plate 20. Additionally, the roof line panel with front face plate vacuum opening 56, vacuum pipe 58, porous filter 60 and vacuum valve 62 may contain the L type off set configuration, at an indeterminate angle as a means to accommodate a change in direction between the roof line panel and the wall panel,
The intention is implied, that, in the manufacturing of the prefabricated structural panels, the wall panels with a return of an indeterminate angle are constructed in like manner with wall panels 52a, the exception being the wall panels with a return may contain an L type off set configuration of an indeterminate angle as the means to accommodate a change in direction for the wall panels to form a continous loop.
The intention is implied, that, in the manufacturing of the prefabricated structural panels, as a means to accommodate a two way change in direction, both being of indeterminate angles, the roof line panels are constructed in like manner with roof line panels 52d. For example: When a roof line panel 52d meets the wall panels 52a at a corner junction of 52a. The intention is implied, that, in the manufacturing of the prefabricated structural panels, a structure having a commonly referred to configuration known within the industry as a gable. The gable, in the manufacturing of the prefabricated structural panels shall be constructed in a like manner with wall panel 52a with the exception being the gable panels may contain an elongated tapered configuration.
The intention is implied, that, in the manufacturing of the prefabricated structural panels, there are no set or exact dimensions as to length, width, thickness or configurations of the panels.
In constructing the individual panels, regardless of shape or configuration, the intention is implied, that, all individually constructed panels shall contain a right side edge 24, a left side edge 26, a top cap edge 28 and a bottom toe plate edge 30, extending outwards from, and at right angles to the front face plate 20 and back face plate 22 having a greater width, then the separated distance between the front face plate 20 and the back face plate 22.
Prior to the assembly of the individually constructed panels the following alterations are made to the right side edge 24, the left side edge 26, the top cap edge 28 and the bottom toe plate edge 30. Within the right side edge 24 a plurality of sealing apertures or female openings 36, indeterminate as to number and size are cut into the facing of the right side edge 24. Permanently joined to the plurality of female openings 36 and placed at right angles to the facing, are a plurality of recessed grooves 38. Placed into the said plurality of recessed grooves 38 is a plurality of individual gasket material 40. As with the right side edge 24, the left side edge 26 has an identical number and sized male openings 42 placed within the facing. Extending outwards and at right angles to the facing, a plurality of tubulations or male protrusions 44, are permanently joined to the male openings 42.
An indeterminate number and sized hole openings 34 are placed paralell to, but inwards from, the right hand and the left hand leading edges of the right side edge 24, the left side edge 26, the top cap edge 28 and the bottom toe plate edge 30.
An indeterminate number and size utility openings 68, are cut into the leading edges, an indeterminate distance of the right side edge 24, the left side edge 26, the top cap edge 28 and the bottom toe plate edge 30.
The gasket material 40 is formed from an indeterminate material and is fitted to the configuration of the recessed groove 38. Thus, each individual female opening 36 containing an individual recessed groove 38 will contain an individual gasket material 40.
The strap dowel configuration 54 is made in the following manner: A first plurality of straps indeterminate as to material composition, length, thickness and width is placed in a horizontal fashion an indeterminate distance apart. A second plurality of straps indeterminate as to composition, length, thickness and width is placed in a horizontal position an indeterminate distance apart and at right angles to the first plurality of horizontal straps. Thus, forming a checkerboard pattern. At each and every junction, wherein, the horizontal straps cross, a hole indeterminate in size is placed into and through the crossed straps. A dowel, indeterminate as to composition and length, but of sufficient composition and length to sustain the separation of the front face plate 20 and back face plate 22, and sufficient diameter to engulf the hole placed in the junction of the crossed straps is permanently placed into the hole opening within the crossed straps.
Referring now to the drawings and in particular to FIG. 1. This figure represents a typically preferred embodiment of the vacuum constructed panels depicting a plurality of wall panels 52a joined to a single roof line panel 52d. Said wall panel 52a and said roof line panel 52d comprise a front face plate 20 and a back face plate 22 spaced an indeteminate distance apart. A right side edge 24, a left side edge 26, and a bottom toe plate edge 30 are permanently joined to the perimeter edges of the front face plate 20 and the perimeter edges of the back face plate 22. This separation of said front face plate 20 and said back face plate 22 forms the interior cavity 32, shown in FIGS. 6, 7 and 8 within said wall panel 52a or said roof line panel 52d. A strap dowel configuration 54 shown in FIGS. 6, 7 and in detail in FIG. 8, is placed within the interior cavity 32. The top cap edge 28 is then joined to the perimeter edges of the upper most part of the front face plate 20, the back face plate 22, the right side edge 24 and left side edge 26.
A plurality of indeterminate number and sized female openings 36, containing a recessed groove 38 and gasket material 40 are placed into the facing of the left side edge 26 penetrating into the interior cavity 32, shown in FIGS. 2, 4, and 8 of the wall panel 52a, wall panel with filler cap 52b, wall panel with vacuum valve 52c or the roof line panel 52d, roof line panel with filler cap 52e and roof line panel with vacuum valve 52f. Placed into the facing of the right side edge 24, FIGS. 1, 3, 5 and 8 of the wall panel 52a, wall panel with filler cap 52b, wall panel with vacuum valve 52c or the roof line panel 52d, roof line panel with filler cap 52e and roof line panel with vacuum valve 52f is a plurality of indeterminate number and sized male openings 42 containing a male protrusion 44.
A first wall panel 52a is placed adjacent to, and joined to a first second wall panel 52a mating and merging the panels together. As the mating and merging take place, said right side edge 24, containing the plurality of male openings 42 and male protrusion 44, penetrates into the plurality of female openings 36 and the plurality of recessed grooves 38, contained within the left side edge 26, seating and sealing the plurality of male protrusions 44 into the plurality of gasket material 40.
A plurality of hole openings 34, indeterminate in size and number, are placed parallel to and inwards from an indeterminate distance from the leading edges of the right side edge 24 and the left side edge 26. A plurality of fasteners 66 are placed into the plurality of hole openings 34 within the right hand and left hand side edges of the right side edge 24 of the first wall panel 52a and the left side edge 26 of the first second wall panel 52a. As the fasteners 66 are secured, the male protrusion 44 within the male opening 42 and within the right side edge 24 of the first wall panel 52a draws further into the female opening 36 seating and sealing into the recessed groove 38 and gasket material 40 of the left side edge 26 of the first second wall panel 52a. Thus, a plurality of wall panels 52a, forming a singular, common, interior cavity 32, is formed from a plurality of joined wall panels 52a, each containing an individual interior cavity 32.
Turning now to the bottom toe plate edge 30, a plurality of fasteners 66, are inserted into and through the plurality of individual hole openings 34, within the bottom toe plate edge 30 and secured to a foundation.
Within FIGS. 1, 6, 7, 8, 9, 10, 11 and 12 a plurality of utility openings 68, indeterminate as to size, number and area of placement are cut into the right side edge 24, left side edge 26, bottom toe plate edge 30 and the top cap edge 28. Thus, creating a means to introduce the electrical conduit, plumbing pipes, etc., to the structure without violating the integrity of the singular, common, interior cavity 32 within the plurality of panels.
In joining a wall panel 52a to a roof line panel 52d, the bottom toe plate edge 30 of the roof line panel 52d, is placed on the top cap edge 28 of the wall panel 52a. The plurality of fasteners 66, are placed into and through the hole openings 34 within the bottom toe plate edge 30 of roof line panel 52d and within the top cap edge 28 of wall panel 52a and secured.
FIG. 1 further depicts the installation of a window opening 70, within a wall panel 52a, wall panel with filler cap 52b or wall panel with vacuum valve 52c. A section of the front face plate 20 and back face plate 22 is cut out and removed, thus, violating the integrity of the singular interior cavity 32. The open edges into the singular, common, interior cavity 32, are then closed and resealed by permanently joining the edge strips 74, to the right side, left side, top portion and bottom portion of said window opening 70, thus, sealing the singular, common, interior cavity 32 from the exterior ambient air.
Still further FIG. 1 depicts the installation of a door opening 72, within a wall panel 52a, wall panel with filler cap 52b or wall panel with vacuum valve 52c. A section of the front face plate 20 and back face plate 22 is removed, thus, violating the integrity of the singular, common, interior cavity 32. The open edges into the singular, common, interior cavity 32, are then closed by permanently joining the edge strips 74, to the right side, left side and top portion of said door opening 72, thus, sealing the singular, common, interior cavity 32 from the exterior ambient air.
FIG. 2 represents an isolated view of the female opening 36, the recessed groove 38, and the gasket material 40 contained within the left side edge 26.
FIG. 3 represents an isolated view of the male opening 42, and the male protrusion 44 contained within the right side edge 24.
FIG. 4 represents an isolated cross sectional view of the female opening 36, the recessed groove 38 and the gasket material 40 contained within the left side edge 26.
FIG. 5 represents an isolated cross sectional view of the male opening 42 and the male protrusion 44 contained within the right side edge 24.
FIGS. 4 and 5, were viewed collectively, show the method utilized for merging the male opening 42 containing the male protrusion 44 within the right side edge 24 of a first wall panel 52a or a first second roof line panel 52d into the left side edge 26 containing the female opening 36, the recessed groove 38 and the gasket material 40 within a first second wall panel 52a or a first second roof line panel 52d.
FIG. 6, represents a cross sectional edge view of a wall panel with filler cap 52b or a roof line panel with filler cap 52e. Within the upper portion of the front face plate 20, of a wall panel with filler cap 52b or a roof line panel with filler cap 52e a female opening 48, is cut into the front face plate 20, penetrating the interior cavity 32. The front face plate female opening 48, is further fitted with a recessed groove 38 and gasket material 40. As a means to reseal and re-estabilish the integrity of the interior cavity 32, a front face plate cover 50, containing the male protrusion 44, is placed over the front face plate female opening 48. As the front face plate cover 50, is pressed into the recessed groove 38, the male protrusion 44, enters and penetrates the recessed groove 38, seating and sealing into the gasket material 40. Thus, a method for introducing the insulating material 46, into the singular, common, interior cavity 32, has been established. A plurality of hole openings 34, are depicted within the right hand and left hand sides of the left side edge 26.
FIG. 7, represents a cross sectional edge view of a wall panel with vacuum valve 52c or a roof line panel with vacuum valve 52f. Within the lower portion of the front face plate 20, of a wall panel with vacuum valve 52c or a roof line panel with vacuum valve 52f, a front face plate vacuum opening 56 is cut into the front face plate 20, penetrating the interior cavity 32. The front face plate vacuum opening 56, is further fitted with a vacuum pipe 58. A porous filter 60, is inserted directly into the vacuum pipe 58, and is utilized as the means to retain the insulating material 46 within the singular, common, interior cavity 32. Joined to the vacuum pipe 58 is a vacuum valve 62, which is utilized as the method to join a vacuum pump, (not shown) to the vacuum valve 62.
FIG. 8, shows a sectional view of a wall panel 52a wherein the strap dowel configuration 54, is placed between the front face plate 20 and the back face plate 22, within the interior cavity 32. The strap dowel configuration 54, also provides a method for maintaining the separation of the front face plate 20, and back face plate 22.
Within the facing of the right side edge 24, the plurality of male openings 42 having a plurality of male protrusions 44 are placed, penetrating the interior cavity 32. Additionally, the right side edge 24 contains the hole opening 34. Within the left side edge 26 are the female openings 36, or sealing apertures.
Permanently placed into the top cap edge 28 and the bottom toe plate edge 30, right side edge 24 and left side edge 26 are the hole openings 34. Placed into the right side edge 24, left side edge 26, top cap edge 28 and bottom toe plate edge are utility openings 68.
FIG. 9 represents an isolated view of wall panel with vacuum valve 52c showing the lower portion of the front face plate 20 containing the front face plate vacuum opening 56, vacuum pipe 58 and the vacuum valve 62. Within the left side edge 26, is hole opening 34. Located in the bottom toe plate 30 is the utility openings 68 and the fasteners 66.
FIG. 10 represents an isolated view of the upper portion of the wall panel with filler cap 52b showing the front face plate cover 50. Within the top cap edge 28, is found the hole opening 34. Within the left side edge 28, are the utility openings 68 and hole openings 34.
FIG. 11 represents an isolated view of the roof line panel with vacuum valve 52f showing the lower portion of the front face plate 20 containing the front face plate vacuum opening 56, vacuum pipe 58 and the vacuum valve 62, (porous filter 60, not shown). Within the left side edge 26, is hole opening 34 and fasteners 66. Located in the bottom toe plate edge 30 is the utility openings 68 and the fasteners 66. In this view, the L type off set configuration is also depicted.
FIG. 12 represents an isolated view of the upper portion of the roof line panel with filler cap 52e showing the front face plate cover 50 and the top cap edge 28. Within the left side edge 28, are the utility openings 68 and hole openings 34.
While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. I do not restrict myself to the details as shown or described herein, since many modifications can be made therein without departing from the essential features of my invention.
BROADENING PARAGRAPH
For example:
The plurality of wall panels and roof line panels may contain a plurality of stud stubs, indeterminate as to length, placed inside and running in a vertical upright position within the singular, common, interior cavity as a means to further strengthen the I beam configuration for a load bearing surface.
Additionally the vacuum constructed panels may be of a singular, continous, extended wall or roof line panel containing a singular, common, interior cavity, constructed without the right side edge containing the male openings, male protrusions, or the left side edge containing the female openings, recessed grooves or gasket material.
This invention has the adaptability to a variety of other configurations to accomodate a variety of needs. With the formulation of an open ended box, containing a top, bottom, right side, left side, and a back, containing a singular, common, inter cavity within the walls, a refrigerator, freezer, oven can be easily constructed. Within the singular, common interior cavity, the strap dowel configuration is utilized as the separator and perlite as the insulator. A means for drawing a vacuum is provided by utilizing a vacuum opening, a vacuum pipe, a porous filter and vacuum valve installed within a section of the wall structure. A means for the filling of the insulating material, perlite being the preferred material, is provided with the installation of a front face plate vacuum opening, a front face plate female opening, a recessed groove and gasket material placed into a section of the wall structure. Additionally, the entrance doors to the above mentioned components can be of like construction and remain separate but hinged to the desired component. Thus, a domestic or commercial refrigerator, oven, or stove, having the means to be heated, cooled or freezing depending on what the particular needs are is also available. Further, the construction configuration can be further altered to a cylinder type form containing the above mentioned design to accomodate a hot water heater. The exception being that with a gas heater, the bottom portion will require a single plate conventional construction method without the benefit of a vacuum being drawn on the bottom plate. | The present invention relates to a method for the construction of prefabricated vacuum panels for the building of residential, commercial or industrial structures offering an extremely high insulating quality comprising; A method is disclosed whereby, a first single prefabricated constructed panel 52, containing a single interior cavity 32, can be joined and integrated to a first second prefabricated constructed panel 52, containing a single interior cavity 32, by utilizing the plurality of male protrusions 44 within the left side edge 26 of the first single contructed panel 52, penetrating and mating with the right side edge 24 of the first second panel 52 containing a plurality of female openings 36, recessed grooves 38 and gasket material 40. A method and apparatus is disclosed, wherein, an insulating material 46, can be placed within a single interior cavity 32 within a single complete panel 52 and thus, spread through the common singular interior cavity 32 contained within the plurality of completed panels 52. A further method is disclosed whereby, a vacuum can be drawn throughout the common singular interior cavity 32 within the plurality of completed panels 52. A further method and apparatus is disclosed to prevent the internal collapse of the common singular interior cavity 32 within the plurality of completed panels 52, utilizing the strap dowel 54 configuration. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to production methods and products which utilize veneer in a manner that will provide a superior, natural product, especially for window covering components, including slats and methods for construction, to enable the construction of a high quality, consistent louver product which may be trimmed to fit a custom window opening.
BACKGROUND OF THE INVENTION
[0002] Slats are utilized in a variety of window coverings, including Venetian blinds, and vertical blinds. Slats have in the past been constructed of thin metal from rolls, curved along the path of their shorter dimension to produce a break through stiffness, holding stiff unless stressed. Other slats use thicker materials, typically flat elongate members. These slats include relatively thicker structures whose stiffness is similar to that of a ruler. Modern materials have enabled the construction of slats having a wide variety of strength and size, and other attributes associated with the materials from which they were constructed.
[0003] Two opposing developing factors are causing new construction methods to be sought. The first factor is the increasing scarcity of materials, both structural and decorative. The second factor is a driving need to have an ever more custom appearance for interior finishings. In terms of materials generally, the price continues to increase. Plain ordinary unfinished wood is increasing in cost and becoming more scarce. High quality wood for producing a high quality wood finish is even more expensive. Synthetic materials which are carbon based continue to rise in price.
[0004] Another aspect of the use of materials in window coverings involves elimination of material volume while allowing the same look as could be achieved in using whole natural materials. Veneers and veneer techniques have long been employed in furniture and furniture making. The veneer technique enables the use of a thin layer of a high quality material which is laminated, glued or affixed to a less expensive structural support to give the impression that the whole member is made solidly of the higher quality material.
[0005] Veneer is good for solid furniture structures as it tends to splinter and crack with nearly any movement of the supporting substrate to which it is attached. The use of veneer with less substantial support substrates can readily result in cracking, splintering and friability. Veneers used to date with window covering materials, particularly horizontal blind slats, have been limited to being used with thick slats which are so thick and rigid that bending will not substantially occur.
[0006] The use of thick slats has a number of its own associated problems. Thicker slats are more expensive because of the sheer volume of material used. For high ceilings or vertically tall windows, thicker slats create significant weight problems. Thicker slats collected at the top of the window opening create a vertically wider block and inhibit the amount of open space which the blind set can created by being vertically raised.
[0007] Heavier components create an even greater and unseen problem. The total weight on the vertical array of horizontal blinds causes greater friction on the lifting components. Greater friction causes failure in each of the components affected. This includes the lift cord, the lift cord wear member where the cord leaves the head rail, a locking mechanism which is used to selectively lock the lift cord, the lift cord contact inside the head rail, and the angular fittings at the point where the lift cords turn down through the head rail. Component parts can wear and fray and thus increase the wear and fray on the lift cords. In some cases this creates an avalanche of wear in which wear on a component causes the lift cord to go from normal condition to rapid wear and failure.
[0008] Weight related wear will in essence destroy the value of the window covering. Worn cord fitting replacement involves the removal of the window covering and a complete re-working of the internal components, as well as a re-threading of the louvers and base slat. Many of the components depend upon the apertures and other support structures which were in existence at the time of manufacture, all of which change from time to time. As a result, a failure in a window covering set will likely render it worthless. The alternative of having someone create parts which are long since obsolete and commercially not available is so expensive that it would be less expensive to simply replace the window covering set.
[0009] Replacement of this type creates additional waste. Even where the window covering is of high quality it will be less expensive to buy a new, integrated window covering set. Where a single matched window covering fails, and becomes beyond repair, all of the window coverings in a room will likely be replaced in order to maintain the aesthetic balance. The result is that the failure rate of a window covering is of the type which creates significant, related waste.
[0010] Therefore, the need to reduce the failure rate in a window covering set is acute and has significant effect. The reduction of slat weight is one of the most critical contributors to increasing the life of window covering sets, particularly horizontal blind sets, over time. Lesser slat weight translates into lesser wear for lift cords and the fittings in a horizontal blind set.
[0011] The variety available for light weight slats have been limited to thin metal having a non-aesthetic look. Further, the use of raw metal slats or painted slats subjects them to being scratched or scored, thus permanently marking them. Raw or painted metal slats lack the resilience and repair ability of wood. Resilience and mark resistance can be had via an outer lacquer coat to reduce friction and the ability to produce scratches, as well as the ability to use wood repair techniques and stains to repair any scratches and the like.
[0012] What is therefore needed is the ability to produce slats having extreme light weight and also a repairable wood finish. The needed slat should be resilient, have the ability to assume a variety of shapes and also be amenable to cutting in order to form custom widths.
SUMMARY OF THE INVENTION
[0013] The structures and process for producing the structures of the invention enable extensive and efficient use of veneer and bamboo veneer for slat manufacturing. The techniques employed advantageously accomplish two goals simultaneously, a reduced volume of slat material to reduce the load on the internals of a horizontal blind set, and the provision of a more inexpensive but higher quality long lasting slat outward appearance. One or more core materials made of woven and non-woven and preferably fibrous cloth, as well as combining with metal and other structural layers, are combined with veneers and bamboo veneer to yield a very lightweight slat with good structural characteristics.
[0014] The technique enables scrap, such as block scrap, to be formed into longer effective lengths. Such longer effective lengths can then be cutably formed into slats of various sizes. The joinder of the block scrap is by deeply extending, finite interlock length finger joints which, once the material is cutably formed into slats, remain as relatively shallow (the thickness of the slat) and finite interlock length finger joints. The joints have the added benefit that they statistically “break up” any grain differences which would otherwise create warp, and enable long lengths of slat to be employed from several shorter lengths of scrap. The utilization of multiple sets of finger joints virtually completely eliminates the tendency to warp, and provides additional strength against twist forces. Further, as an added economic benefit above and beyond the benefits already mentioned, the technique not only enables waste normally occurring in slat manufacture to be saved, but actually encourages the manufacture of a superior quality product by encouraging lower cost scrap to be used as the primary resource in the manufacturing process. In other words, longer lengths of higher priced wood can be used elsewhere in products where grain structure and uninterrupted length is necessary, and thus drive down the costs in those industries, while at the same time enabling slat construction almost exclusively from scrap.
[0015] To further utilize scrap wood and to further reduce waste, adjacent narrower widths of wood can be utilized in combination with wider lengths of wood at the finger joint to enable two or more widths of wood material to function as if they were a single width of material. When securely glued, both at the finger joint as well as along the lengths of more narrow material, the resulting slats have as much strength as slats formed from a whole length of wood material. Even where the narrow lengths of wood have a linear, thin, glued interface, superior strength bending and twist resistance is observed.
[0016] A technique for covering the constructed slat with a layer of paper, especially paper bearing a wood grained pattern, followed by use of a gluing material of, for example vinyl acetate resin, followed by providing a clear and appropriately surface finish varnish, preferably of ultraviolet resistant material can produce a slat which has an appearance exactly as if it were formed from a single length of wood material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which:
[0018] FIG. 1 illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with two layers of veneer surrounding a core layer;
[0019] FIG. 2 illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with two layers of veneer surrounding a pair of inner layers;
[0020] FIG. 3 illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with a layer of upper veneer and an underlying layer attached to it for support;
[0021] FIG. 4 is illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with two layers of veneer surrounding a set of three inner layers which may be any type of layer but preferably a center scrap veneer layer surrounded by two cloth or non-woven layers;
[0022] FIG. 5 is a plan view of the end of a bamboo embodiment of the composite slats shown in FIGS. 1-4 , but emphasizing the generally uniform lateral profile of bamboo assemblies as one possible overall layout as might be seen from the formation of a slat according to the invention utilizing bamboo strips;
[0023] FIG. 6 is an end view of a curved slat having a core layer to illustrate that the technique of the invention can be used for producing curved slats; and
[0024] FIG. 7 is an end view showing a technique in which one or any number of core layers terminate short of the full extent of the width of veneer layers to enable the veneer layers to attach to each other and form a double thickness, shapable, otherwise finely finish able curved edge termination.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The description and operation of the veneer system and method of the invention will begun to be best described with reference to FIG. 1 which illustrates an end perspective exploded view of the end of a short length of slat 21 shown in extreme detail. From the outermost perspective, the slat 21 is covered and surrounded with a layer of lacquer, typically an acrylic, typically a UV resistant and UV cured material to seal the components within. As seen in exploded view, the layer of lacquer includes an upper layer 23 , lower layer 25 , left side layer 27 and right side layer 29 . The lacquer is typically sprayed on and thus envelops the entire assembled slat 21 . The lacquer layers 23 , 25 , 27 , and 29 completely surround and envelop the slat 21 continuously and may be expected to occur at the ends, such as into the face directed toward the viewer in FIG. 1 , as is necessary to seal all layers within the slat 21 .
[0026] The lacquer layers 23 , 25 , 27 , and 29 will preferably resist ultraviolet radiation degradation, and may include a simple lacquer, a poly resin, polyester or acrylic. The lacquer layers 23 , 25 , 27 , and 29 are shown exploded and schematic, but this is a crude representation of the annular surrounding nature and the annular sealing nature which the lacquer layers 23 , 25 , 27 , and 29 provide to the more internal layers. Sealing is important as it shuts out moisture and makes the resulting slat 21 (as well as all of the slats shown in subsequent Figures) stronger and more mark resistant.
[0027] This is not to imply necessarily that the lacquer layers 23 , 25 , 27 , and 29 make a shiny or even flat finish. Where the finished surfaces 33 and 37 are roughened, the lacquer layers 23 , 25 , 27 , and 29 may preferably be thin enough to enable the roughened surface to express itself through the lacquer. As such, the selection of the viscosity of the lacquer layers 23 , 25 , 27 , and 29 can effect the outside surface characteristics. A roughened appearance can do more for light dispersal than a simply flat-color appearance, particularly a low light angle incidence.
[0028] Within the slat 21 seen in FIG. 1 is an upper veneer layer 31 having an upper finished surface 33 and a lower veneer layer 35 having a lower finished surface 37 (indicated but not seen). Since the lacquer layers 23 , 25 , 27 , and 29 are typically extremely thin and transparent, the veneer layers 31 and 35 , and their finished surfaces 33 and 37 will form the visual impression of the resulting surface color and texture of the slat 21 . A bonding core layer 39 is provided to which the veneer layers 31 and 35 are attached along their main surfaces opposite their finished surfaces 33 and 37 . A layer of glue or adhesive 41 is also shown for completeness, and only over a rear portion of the slat 21 and will not be shown further, although such layer of flue or adhesive 41 may exist between any of the layers shown for the invention.
[0029] The dimensions for the components shown in FIG. 1 will be discussed. The purpose of the invention is to provide a wood finish through the use of veneer, to produce an ultra thin slat 21 which is very light, but has a substantial appearance in terms of its color and texture. The upper and lower veneer layers 31 may have a thickness of from about 0.2 mm to about 0.6 mm with the most preferable being veneer thickness nearer the 0.2 side of the thickness scale, limited only by the need to have a minimum thickness which will (1) not become transparent enough to transmit any light from the bonding core layer 39 and (2) will not be so thin where it is desired to show and present a pattern having three dimensional variance, such as deep grain, where the deepest grain might otherwise form an opening to the bonding core layer 39 .
[0030] The bonding core layer 39 may be any of a variety of materials. A few of the materials may include a non-woven material or woven material, cloth, glass, carbon composite, wood, wood veneer, woven wood veneer, cross grain ply-veneer or ply-veneer, or metal.
[0031] The term “woven wood veneer” may refer to a woven pattern of veneer strips having a main length parallel to the grain of the wood. Having such strips woven into a crossing matrix can increase the strength of the woven pattern. There is very little overall difference between woven veneer and a woven cloth except for the size and longitudinal grain of the material. A finely subdivided very thin material approaches a structure similar to cloth. Most woven materials exist as groups of fibers rather than individually cris-crossing to make up the cloth. Many woven materials have significant lateral friction and can have various degrees of cross linking if desired. Cross linking, or cross friction, can be as a result of friction, lateral projecting interfering members, or bonding.
[0032] Ply-veneer is a thin version of ply wood. In Ply wood, alternate layers of wood are bonded or glued together with each succeeding layer having its grain situated at an angle, preferably perpendicular, to the next most adjacent layer, although angularity less than perpendicularity if possible. It will be understood that ply-veneer or woven veneer may have a variety of thicknesses. The number of layers and weaves of such material permitted will depend upon their contribution to the slat into which they will be incorporated.
[0033] Metals which can be used include thin steel, aluminum, titanium, or any other material having the ability to impart a strength to the veneer layers 31 and 35 lying on either side. The ability of the metal or indeed any material of the bonding core layer 39 to bond to the layers of veneer 31 and 35 is important. The bonding of the core layer 39 to the layers of veneer 31 and 35 can be accomplished with any type of glue or adhesive which will give good non-separating results, and may depend upon the materials chosen for the core layer 39 and layers of veneer 31 and 35 . The core layer 39 can have a thickness of from about 0.15 mm to about 0.3 mm. For metals, this number might be a simple, uniform material thickness. For a non-woven, or cloth, or ply veneer or woven veneer, or fiber based core layer 39 , this thickness might be the final thickness after heating and pressing. Heating and pressing and other curing or final bonding steps may help produce an improved tensile strength through forced thickness reduction during processing.
[0034] As a result, the potential thickness of the final slat will depend upon which materials are used, how many layers are used and how the core layer 39 is constructed. At the extreme lower dimensions, where the core layer 39 is made from a paper-thin non-woven material, it may be as low as 0.1 mm, but it is believed that 0.15 mm is necessary to impart some lower acceptable strength. For thicker slats, the core layer 39 (as well as other core-type layers shown in subsequent Figures) may even approach 1.0 mm for a thicker slat. Where the core layer approaches 1.0 mm, the resulting slat may preferably be 3.0 mm or thicker.
[0035] Further, the thickness of the veneer layers 31 and 35 may also depend upon a number of other factors, including the ability to cut and handle the veneer layers 31 and 35 , as well as the needed thickness of the veneer layers 31 and 35 for adequate color appearance. The color appearance of the combination of the core layer 39 and the veneer layers 31 and 35 will combine to affect the thickness of the veneer layers 31 and 35 necessary to produce an acceptable result. As in the Figures following FIG. 1 , the final thickness of the resulting slat 21 will depend upon the thicknesses of material used with a judicious selection of such materials to make an acceptable appearing slat 21 .
[0036] The thickness of the lacquer layers 23 , 25 , 27 , and 29 may be so thin as to be negligible. In some examples, however an effect can be produced by a thicker layer of lacquer, but this should only occur in some types of effects for certain types of window coverings, much like table tops which are over lacquered to produce a three dimensional effect. However, this type of effect is not desired where the goal is to produce the lightest slat 21 possible.
[0037] The finish of the upper finished surface 33 and lower finished surface 37 can be formed either before or after the layers of veneer 31 and 35 are bonded to the core layer 39 . In practice, and especially where the core layer 39 is to have a shape, the layers of veneer 31 and 35 can be added before or after the core layer 39 is shaped or bonded in the same step in which the core material 39 is shaped, such as in a press die or similar.
[0038] The steps for formation, in any order, are to provide layers of veneer 31 and 35 , finish their upper finished surface 33 and lower finished surface 37 , bond the layers of veneer 31 and 35 to the core layer 39 , shape the core layer 39 if necessary, and lastly to apply a surrounding layer of lacquer to form lacquer layers 23 , 25 , 27 , and 29 to seal the resulting slat 21 . Pressure, heat, and other environmental aspects may be applied, especially during the bonding step, in order to work with the glues or adhesives present.
[0039] The slat 21 opens the possibility for other combinational processing steps. Sheets of the bonding core layer 39 may be bonded to sheets of veneer, and then finished, before being cut into the slat 21 shape. Shaping of the core layer 39 can occur at any time due to the superior bond formed between the core layer 39 and the upper and lower veneer layers 31 and 35 . Shaping of a core layer 39 can be done by bending, such as over bending to use Young's modulus for a stable spring back effect, or the shape can be formed based upon heat and pressure in a die or other holding device, which will cause the core layer 39 to achieve a stable shape after such processing.
[0040] The use of a core material with fibrous tensile qualities is important in holding together the upper and lower veneer layers 31 and 35 . This is especially true where wood grain upper and lower veneer layers 31 and 35 have a grain which is longitudinal to the extent of the slat 21 and would tend to exacerbate the splintering effect of each on bending. The core layer 39 provides close attachment, along with isolation of any deleterious synergy from having grain oriented in the same direction.
[0041] Other combinational possibilities are also shown, with general spatial equivalence to previously shown layers being illustrated with the same numbering. Referring to FIG. 2 , a perspective exploded view of the end of a short length of slat 31 utilizes a pair of core layers, including an upper core layer 53 and a lower core layer 55 . The use of two core layers of either woven or non-woven material gives an opportunity for further strengthening without much expense in terms of adding to the thickness or weight. For example, where upper core layer 53 may have a fibrous structure which is predominantly oriented in one direction, the lower core layer 55 may have a fibrous structure oriented in an orthogonal direction. These directions need not necessarily be oriented along or perpendicular to the length of any resulting slat 31 . In some cases, and depending upon the glue or adhesive 41 used, the bonding of a pair of core layers 53 and 55 can produce a “composite” core which is even stronger. The remainder of the slat 21 is similar to that seen in FIG. 1 .
[0042] Referring to FIG. 3 , a perspective exploded view of the end of a short length of slat 61 material with exploded lacquer layer with an upper layer of veneer 31 and an underlying layer 63 having a lower surface 65 . As stated above, it is generally not favored to have two layers of veneer attached to each other, but it is possible. Further, the underlying layer 63 can be any of a number of other materials. Underlying layer 63 can be metal, to support the upper layer of veneer 31 , it can be a simple layer of wood with a lower surface 65 which is painted, it can be a lower sheet of veneer such as lower veneer layer 35 , it can be a wooden layer having grains which are perpendicular to the grains of the upper layer of veneer 31 , and a further variety of materials. In some window coverings and horizontal blinds it is desired to have one side of a slat such as slat 61 to have a finish different than the finish of the upper finished surface 33 . The use of an underlying layer 63 of reflective metal could produce a cooling effect by re-radiating visible light back through the window. Conversely, an underlying layer 63 which is black could help turn incident light into heat by heating of the slat 61 . When it is remembered that the upper veneer layer 31 can range in color from dark wood finish to a bright very light wood finish it can be seen that the upper surface can be light and the lower surface can be dark, and vice versa.
[0043] FIG. 3 illustrates the simplest construction and perhaps therefore the lightest. The use of an underlying layer 63 to give brightness variation can be important and useful. Slat 61 can be particularly useful where the lower surface 65 can be made to be decorative or reflective or have some other useful characteristic. An underlying layer 63 made of polished metal on its lower surface 65 , with a roughened upper surface for bonding to the underside of the upper veneer layer 31 would be one good combination.
[0044] Referring to FIG. 4 , a slat 71 is shown has having a series of three additional core layers between the upper and lower veneer layers 31 and 35 , namely core layers 73 , 75 , and 77 . Although the addition of more core layers may add somewhat to the weight, the use of additional core layers can contribute to formation of a stiff, very strong slat 71 .
[0045] Further, it may also be preferable for core layers 73 and 77 to be made from a non-woven or woven cloth or other material, with core layer 75 preferably being a non-decorative or low quality veneer. In this configuration, the core layer 75 as a veneer layer 75 would not need to have high quality as it would not be seen. This opens the possibility of using a scrap wood material having a grain which runs across the shorter dimension of the slat 71 which might be able to give additional strength without sacrificing flexibility.
[0046] Other possibilities for the core layers 73 , 75 and 77 include the use of a cloth or non-woven for all three. However, it is believed that the best combination is having core layers 73 and 77 made of a fibrous material such as cloth or woven or non-woven material, with core layer 75 being a thin, scrap quality veneer.
[0047] Referring to FIG. 5 , a plan view of the end of a bamboo embodiment of the composite slats shown in FIGS. 1-4 , but emphasizing the generally uniform lateral profile of bamboo assemblies. In a related case, U.S. patent Ser. No. 11/529,971; which is incorporated by reference herein, it was shown and described and illustrated in detail how long strips are cut from bamboo culm, boiled in water to cause the bamboo material in the strips to relax, so that they can be pressed flat. The radially arc shaped strips come to have a trapezoidal cross section and are then typically cut into a rectangular square. The exterior of the bamboo is then sanded or planed to produce a bamboo finished surface, either before or after the strips are joined to other strips, to a substrate of different material. The hallmark of bamboo veneer or bamboo boarding is the provision of strips which are close fitting and of uniform width.
[0048] FIG. 5 illustrates an end view of an assembled bamboo slat 81 made in a way in which the bamboo strips have uniform width and generally oppose each other. From the top, the ends of an upper row of bamboo strips 83 are seen. The bamboo strips 83 are attached to each other and to a first core layer 85 of woven or non woven fibrous material. A central core layer 87 can be made of the same materials as were mentioned for bonding core layer 39 , including metal, wood veneer (scrap), composite carbon, and more.
[0049] Under the central core layer 87 , a second core layer 89 of woven or non woven fibrous material is seen. Under the second core layer 89 a lower row of bamboo strips 91 are seen. The result is a slat 81 having a bamboo finish on both sides. Where the central core layer 87 is either bendable or capable of being formed as a non-flat shape, the slat 81 can be shaped accordingly.
[0050] The configuration of FIG. 5 is just one of many configurations, with some other structural configurations seen in U.S. patent Ser. No. 11/529,971. Where the thickness of the bamboo strips 83 become very thin, the perpendicular quality of their matching adjacent surfaces begins to diminish and the result can be a very thin slat 81 . Where the core layer 87 is made of thin metal, a very thin bamboo slat 81 results. Very thin bamboo can be easily formed and bent, particularly when it is wet or hot. As was described in the above patent, since the bamboo strips 83 and 91 were initially formed from arc pieces of material, it is an easy matter to alter the final formation steps where it is needed to make a thick, shaped slat. The steps of construction of the slats herein can be modified to replace any of the veneer layers with very thin layers of bamboo.
[0051] Further, the manner in which bamboo is made and used, by forming strips, is amenable to the process and layers described by making a slight modification in the order of processing. The bamboo strips 83 can be formed onto first core layer 85 in a separate operation. This can involve a sheet of bamboo strips if varying length and offset from each other which can be kept flat and continue to be processed, sanded, planed, etc. The same is true for the bamboo strips 91 to form the lower layer. Then the upper and lower layer assemblies of the bamboo strips 83 and their core layer 85 , as well as the bamboo strips 91 and their core layer 89 can be then bonded onto central core layer 87 . In some cases, any shaping may be done under any stage of processing and preferably under high pressure to insure that the widths of the bamboo strips 83 and 91 bend adequately across their width and do not produce protrusions at their interfaces. Further sanding or planing might be in order for curved slats. Again, although not shown, the lacquer layers 23 , 25 , 27 , and 29 would be applied to the completed bamboo slat 81 .
[0052] Referring to FIG. 6 , a perspective end view of a curved slat 95 formable with any of the structures and techniques shown herein, is illustrated. Some layering appearance may occur at an end 97 , especially where the end 97 is not painted or where the end 97 is cut, but the remainder of the slat 95 will appear as if it is made of a unitary material. A lift cord aperture 99 is also seen.
[0053] Referring to FIG. 7 an illustration of the advantage of using veneer is seen. A slat 101 is shown without lacquer layers 23 , 25 , 27 , and 29 , and is seen as having an upper veneer layer 103 a core layer 105 and a lower veneer layer 107 . Note that the core layer 105 stops just short of the extent of the lateral extent of the upper veneer layer 103 and the lower veneer layer 107 . Due to the fact that the core layer 105 stops short, and especially where pressure and adhesive is used, the upper veneer layer 103 naturally extends and is attached to the lower veneer layer 107 to form a very slight double veneer termination. Because these layers are bonded together, they present twice the thickness of veneer at the edge and can be easily finished to an edge which is essentially twice the thickness of the upper veneer layer 103 and the lower veneer layer 107 . Since the finishing forces are applied laterally with respect to the view of FIG. 7 , and because the core layer 105 terminates only very slightly earlier than the upper veneer layer 103 and the lower veneer layer 107 , good structural support is had and separation does not occur under normal finishing. Finishing after formation will most likely involve some blend sanding to remove the upper and lower square corner which might otherwise occur with a square sheet of veneer if such is used for the upper veneer layer 103 and the lower veneer layer 107 . The result is a smooth edge 109 where the dividing line between the upper veneer layer 103 and the lower veneer layer 107 cannot be seen.
[0054] While the present invention has been described in terms of a system and method for forming of various constructions of slats from various layers of wood veneer and thin strips of bamboo, as well as a wide variety of core materials, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many structures, including any structure or technique where joinder with enhanced contact structures for slat formation with veneer and bamboo, both for appearance and for inexpensive structural reinforcement.
[0055] Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art. | The structures and process for producing the structures of the invention enable extensive and efficient use of veneer and bamboo veneer for slat manufacturing. The techniques employed advantageously accomplish two goals simultaneously, a reduced volume of slat material to reduce the load on the internals of a horizontal blind set, and the provision of a more inexpensive but higher quality long lasting slat outward appearance. One or more core materials made of woven and non-woven and preferably fibrous cloth, as well as combining with metal and other structural layers, are combined with veneers and bamboo veneer to yield a very lightweight slat with good structural characteristics. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to mobile communication technologies, and particularly, to a method for transmitting multiple input and multiple output (MIMO) related information in a long-term evolution-advanced (LTE-A) system.
BACKGROUND OF THE INVENTION
[0002] Cellular mobile phones bring a lot of convenience for people in communicating with each other. The second generation global system for mobile communication (GSM) adopts digital communications techniques, and greatly improves the quality of voice communication in mobile communications. The 3rd generation partnership project (3GPP), as an important organization in the mobile communication field, greatly accelerates the standardization process of the third generation (3G). 3GPP has set up a series of specifications for communication systems including the wide code division multiple Access (WCDMA), the high speed downlink packet access (HSDPA), the high speed uplink packet access (HSUPA), and etc.
[0003] To cope with challenges of broadband accessing techniques and to satisfy the ever-increasing demands for new types of services, 3GPP launched standardization work of 3G long term evolution (LTE) techniques in 2004, hoping to further improve frequency efficiency, to improve performances of users on cell edges, to reduce system delay, and to provide access services with higher speed for users moving at a high speed. LTE-A is based on the LTE, having spectrum bandwidth and data rate multiple times larger than that of the LTE, and is able to provide higher speed and higher quality of services for mobile users.
[0004] The LTE-A system supports multi-user (MU)-MIMO techniques, i.e., the LTE-A system can schedule multiple users at the same time on the same frequency resources. That is, in an LTE-A system, multiple users can share frequency resources, such as resource blocks (RB) and so on. The multiple UEs sharing the same frequency resources can be called a group of coordinated transmitting UEs participating in the MU-MIMO transmission.
[0005] Besides the common reference signal (CRS) inherited from the LTE release 8 (Rel-8), the LTE-A system also introduces two types of new reference signals (RS), including channel state information reference signal (CSI-RS) and demodulation reference signal (DM-RS). The DM-RS is used as reference signals for demodulating channel estimation.
[0006] In addition, LTE-A Rel-10 defines that an LTE-A system should support downlink MIMO satisfying the following conditions:
[0007] 1) for orthogonal DM-RS which the SU-MIMO should support and when the SU-MIMO supports 1 to 8 layers (i.e., Rank) in total, when the Rank is 1 to 2, the DM-RS density is 12 resource elements (REs), and the length of orthogonal cover code (OCC) is 2; when the Rank is 3 to 4, the DM-RS is 24 REs, and the OCC length is 2; when the Rank is 5 to 8, the DM-RS density is 24 REs, and the OCC length is 4;
[0008] 2) when the MU-MIMO should support at most 4 layers, each MU-MIMO supports at most 2 layers;
[0009] 3) dynamic switching between SU-MIMO and MU-MIMO should be supported.
[0010] For the above downlink MIMO defined, current LTE-A specification does not provide a method for a base station transmitting information which is a must for performing data demodulation in a UE to the UE, thus the UE can not obtain the information necessary for the data demodulation and therefore can not perform the data demodulation. To facilitate description, information necessary for a UE to perform the data modulation is referred to as data demodulation information, among which information related to MIMO is referred to as MIMO related information. And the MIMO related information generally includes: the Rank (number of layers) of the UE, the DM-RS port (antenna port) of the UE, and DM-RS scrambling sequence index or scrambling identity (SCID) of the UE.
SUMMARY OF THE INVENTION
[0011] A method for transmitting MIMO related information is provided, through which a base station can transmit MIMO related information needed by a UE to the UE with small overhead.
[0012] The method provided by examples of the present invention for transmitting MIMO related information may include:
[0013] encoding, by a base station, MIMO related information of a user equipment (UE), transmitting a downlink control signaling which includes a result of the encoding to the UE;
[0014] receiving, by the UE, the downlink control signaling transmitted by the base station, obtaining the result of the encoding, and obtaining the MIMO related information of the UE by decoding the result of the encoding.
[0015] In the above process, the encoding by the base station MIMO related information of the UE may include: encoding, by the base station, the MIMO related information to obtain a three-bit result of the encoding.
[0016] The transmitting the downlink control signaling which includes the result of the encoding to the UE may include: adding, by the base station, a MIMO information field of three bits in the downlink control signaling for bearing the result of the encoding; and loading, by the base station, the result of the encoding into the MIMO information field of the downlink control signaling, and transmitting the downlink control signaling to the UE.
[0017] Specifically, the adding by the base station a MIMO information field of three bits to the downlink control signaling may include: removing a scrambling code identity (SCID) field in the downlink control information (DCI) format 2B in the downlink control signaling, and adding a three-bit MIMO information field, and generating a new DCI format of the downlink control signaling.
[0018] Or, the transmitting the downlink control signaling which includes the result of the encoding to the UE may include: adding, by the base station, a MIMO information field with two bits to the downlink control signaling, the MIMO information field being used together with a scrambling code identity (SCID) field to bear the result of the encoding; and loading, by the base station, the result of the encoding into the MIMO information field and the SCID field of the downlink control signaling, and transmitting the downlink control signaling to the UE.
[0019] Specifically, the adding by the base station the MIMO information field with two bits to the downlink control signaling comprises: adding the MIMO information field with a length of two bits in a downlink control information (DCI) format 2B of the downlink control signaling, and generating a new DCI format of the downlink control signaling.
[0020] When having four antenna ports, the encoding by the base station the MIMO related information may include: encoding, by the base station, the MIMO related information to obtain a result of the encoding in two bits.
[0021] The transmitting the downlink control signaling which includes the result of the encoding to the UE may include: adding, by the base station, a MIMO information field with two bits to the downlink control signaling to bear the result of the encoding; and loading, by the base station, the result of the encoding into the MIMO information field of the downlink control signaling, and transmitting the downlink control signaling to the UE.
[0022] Specifically, the adding by the base station the MIMO information field with two bits to the downlink control signaling includes: removing a scrambling code identity (SCID) field in a downlink control information (DCI) format 2B in the downlink control signaling, and adding the MIMO information field with a length of two bits, and generating a new DCI format of the downlink control signaling.
[0023] Or, the transmitting the downlink control signaling which includes the result of the encoding to the UE may include: adding, by the base station, a MIMO information field with one bit to the downlink control signaling, the MIMO information field being used together with a scrambling code identity (SCID) field to bear the result of the encoding; and loading, by the base station, the result of the encoding into the MIMO information field and the SCID field of the downlink control signaling, and transmitting the downlink control signaling to the UE.
[0024] Specifically, the adding by the base station the MIMO information field with one bit to the downlink control signaling includes: adding the MIMO information field with a length of one bit into a downlink control information (DCI) format 2B of the downlink control signaling, and generating a new DCI format of the downlink control signaling.
[0025] When dynamic switching between single-user (SU) and multi-user (MU) is supported, the base station transmits the MIMO related information to the UE via a downlink control information (DCI) format 2B of the downlink control signaling.
[0026] When the base station includes eight antenna ports, the encoding by the base station the MIMO related information includes: encoding, by the base station, the MIMO related information of the UE to obtain the result of the encoding in three bits and when the dynamic switching between the SU and the MU is not necessarily supported; the transmitting the downlink control signaling which includes the result of the encoding to the UE may include: adding, by the base station, a MIMO information field with three bits in the downlink control signaling to bear the result of the encoding; and loading, by the base station, the result of the encoding into the MIMO information field of the downlink control signaling, and transmitting the downlink control signaling to the UE. Specifically, the adding by the base station a MIMO information field with three bits to the downlink control signaling may include: removing a scrambling code identity (SCID) field in the DCI format 2B in the downlink control signaling, adding the MIMO information field with a length of three bits, and generating a new DCI format of the downlink control signaling.
[0027] When the base station includes four antenna ports, the encoding by the base station the MIMO related information includes: encoding, by the base station, the MIMO related information of the UE to obtain the result of the encoding in one bit when dynamic switching between SU and MU is not necessarily supported; the transmitting the downlink control signaling which includes the result of the encoding to the UE may include: adding, by the base station, a MIMO information field with a length of one bit into the downlink control signaling to bear the result of the encoding; loading, by the base station, the result of the encoding into the MIMO information field of the downlink control signaling, and transmitting the downlink control signaling to the UE. Specifically, the adding by the base station the MIMO information field with one bit to the downlink control signaling may include: removing a scrambling code identity (SCID) field in the DCI format 2B of the downlink control signaling, adding the MIMO information field with one bit, and generating a new DCI format of the downlink control signaling.
[0028] The method may further includes: when only one codeword of the UE is enabled, utilizing a new data indication (NDI) field corresponding to an disabled codeword for bearing the result of the encoding.
[0029] The method may further includes: when only one codeword of the UE is enabled and the Rank of the UE is larger than one, utilizing a new data indication (NDI) field corresponding to a disabled codeword to bear the result of the encoding.
[0030] The MIMO related information may include: the total number of layers (Rank) of the UE, a demodulation reference signal (DM-RS) port, and a scrambling code identity (SCID) of DM-RS. Or, the MIMO related information may further include a DM-RS density, the length of orthogonal cover code (OCC) or a transmission mode of the UE.
[0031] Examples of the present invention provide a method for transmitting MIMO related information which is applicable to an LTE-A system. Through the method, a base station may first encode MIMO related information of a UE, and loads a result of the encoding into downlink control signaling to be transmitted to the UE. By adopting the method, a base station is enabled to transmit MIMO related information required by a UE to the UE with small signaling overhead.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a flowchart illustrating a method for transmitting MIMO related information in accordance with the present invention;
[0033] FIG. 2 is a flowchart illustrating a method for transmitting MIMO related information in accordance with an example of the present invention;
[0034] FIG. 3 is a flowchart illustrating a method for transmitting MIMO related information in accordance with another example of the present invention;
[0035] FIG. 4 is a flowchart illustrating a method for transmitting MIMO related information in accordance with yet another example of the present invention;
[0036] FIG. 5 is a flowchart illustrating a method for transmitting MIMO related information in accordance with still another example of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0037] As described above, LTE-A Rel-10 recommends that an LTE-A system should support downlink MIMO satisfying the following conditions:
[0038] 1) for orthogonal DM-RS which the SU-MIMO should support and when the SU-MIMO support 1 to 8 layers (i.e. Rank) in total, when the Rank is 1 to 2, the DM-RS density is 12 Resource Elements (REs), and the OCC length is 2; when the Rank is 3 to 4, the DM-RS is 24 REs, and the OCC length is 2; when the Rank is 5 to 8, the DM-RS is 24 REs, and the OCC length is 4;
[0039] 2) when the MU-MIMO should support at most 4 layers, each MU-MIMO supports at most 2 layers;
[0040] 3) dynamic switching between SU-MIMO and MU-MIMO should be supported, i.e., supporting dynamic switching between Single User (SU) and Multiple Users (MU).
[0041] In addition, UEs in an LTE-A system may be classified into two types according to transparency of the UEs: transparent UEs and non-transparent UEs. A transparent UE refer to a UE which can only obtain information for data demodulation of the UE itself, and can not obtain whether there are other UEs on the same RB. That is, a transparent UE does not know whether the UE itself is SU-MIMO or MU-MIMO. MU-MIMO techniques based on the transparent UEs are referred to as transparent MU-MIMO techniques. A non-transparent UE refers to a UE which can obtain information of UEs on the same RB besides information for the data demodulation of the UE itself, e.g. the Rank of RB allocated to the non-transparent UE and DM-RS ports of other UEs sharing the RB. That is, the non-transparent UE can know whether the UE itself is SU-MIMO or MU-MIMO. MU-MIMO techniques based on the non-transparent UEs are referred to as non-transparent MU-MIMO techniques. At present, there is no final decision on whether to adopt the transparent MU-MIMO or the non-transparent MU-MIMO in the standardization organization. The present invention is based on transparent MU-MIMO techniques, thus is applicable to transparent MU-MIMO.
[0042] To accommodate LTE-A Rel-9, the present invention requires that when downlink MIMO is MU-MIMO, two orthogonal DM-RS ports and two scrambling sequences should be supported, the DM-RS density should be 12 REs, and the OCC length should be two.
[0043] Based on the above restrictions, the present invention provides a method for transmitting MIMO related information. As shown in FIG. 1 , the method mainly includes:
[0044] step 101 in which a base station encodes MIMO related information of a UE;
[0045] step 102 in which the base station transmits downlink control signaling including an encoding result of the MIMO related information to the UE;
[0046] step 103 in which the UE receives the downlink control signaling transmitted by the base station, obtains the encoding result; and
[0047] step 104 in which the UE decodes the encoding result to obtain the MIMO related information of the UE.
[0048] The MIMO related information of the present invention includes: the Rank (i.e. number of layers) of the UE, DM-RS port (i.e. antenna port) of the UE, scrambling identity (i.e. SCID) of the DM-RS of the UE, or further includes DM-RS density and OCC length. The MIMO related information may further include a transmission mode, e.g. Transmit diversity, of the UE when only one codeword is enabled. Those information is necessary for the UE to perform data demodulation.
[0049] The transmitting method of the present invention will be hereinafter described in detail with reference to preferred examples.
[0050] In an example, eight antenna ports are supported.
[0051] According to research, when an LTE-A system supports eight antenna ports and both of the two codewords of the UE are enabled, the UE may only be in any one of the following eight states listed in Table 1. Each state sequence in Table 1 corresponds to MIMO related information determined, such as the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE. In addition, the DM-RS density and OCC length of the UE in each state in Table 1 can be uniquely determined according to the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE.
[0000]
TABLE 1
State
UE
DM-RS
OCC
MIMO
sequence
Rank
DM-RS Port
density
length
mode
SCID
state 0
Rank 2
port {7, 8}
12
2
SU/MU
0
state 1
Rank 2
port {7, 8}
12
2
SU/MU
I
state 2
Rank 3
port {7, 8,
24
2
SU
default
9}
state 3
Rank 4
port {7, 8,
24
2
SU
default
9, 10}
state 4
Rank 5
port {7, 8,
24
4
SU
default
9, 10, 11}
state 5
Rank 6
port {7, 8,
24
4
SU
default
9, 10, 11,
12}
state 6
Rank 7
port {7, 8,
24
4
SU
default
9, 10, 11,
12, 13}
state 7
Rank 8
port {7, 8,
24
4
SU
default
9, 10, 11,
12, 13, 14}
[0052] If the LTE-A system supports eight antenna ports and only one of the two codewords of the UE is enabled, the UE may be in any one of the following four states listed in the following Table 2. Each state sequence in Table 2 also corresponds to MIMO related information determined, such as the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE. In addition, the DM-RS density and OCC length of the UE in each state in Table 2 can be uniquely determined according to the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE.
[0000]
TABLE 2
State
UE
DM-RS
DM-RS
OCC
MIMO
sequence
Rank
Port
density
length
mode
SCID
state 8
Rank 1
port {7}
12
2
SU/MU
0
state 9
Rank 1
port {7}
12
2
SU/MU
1
state 10
Rank 1
port {8}
12
2
SU/MU
0
state 11
Rank 1
port {8}
12
2
SU/MU
1
[0053] Table 1 and Table 2 list 12 states in total, and MIMO related information for each state has been determined. Whether one or two of the two codewords of the UE is enabled can be indicated by both a modulation and coding scheme (MCS) field and a redundancy version (RV) field corresponding to each codeword in the downlink control signaling. For example, when an MCS field corresponding to one codeword in the downlink control signaling is 0 and the RV field corresponding to the codeword is 1, it indicates that the codeword is disabled; otherwise, it indicates that the codeword is not enabled. Therefore, in this example, only three bits are needed for encoding the MIMO related information.
[0054] The following Table 3 illustrates a result obtained by encoding the MIMO related information using 3 bits.
[0000]
TABLE 3
Result of encoding
MIMO related
State
information
sequence
000
state 0
001
state 1
010
state 2
011
state 3
100
state 4
101
state 5
110
state 6
111
state 7
000
state 8
110
state 9
011
state 10
101
state 11
[0055] In addition, states 8-11 and states 0-3 can be distinguished from each other by utilizing the value of the MCS field and the RV field of the two codewords in the downlink control signaling. It should be noted that the above Table 3 is merely an example, any other encoding schemes may also be adopted to establish the relation which associates a state sequence with a result of encoding MIMO related information.
[0056] It should also be noted that, besides the above 12 states, one more state may also be added, which may be denoted as State 16 to indicate a transmission mode such as Transmit diversity of the UE when only one codeword is enabled. As described above, whether both or one of the two codewords of the UE is enabled can be indicated through both the MSC field and the RV field corresponding to each of the codewords in the downlink control signaling, and therefore, the encoding can still adopt three bits. For example, an item may be added to the Table 3, which indicates that the UE is in State 16 when the result of encoding is 111.
[0057] Based on the above research, this example provides a transmitting method. As shown in FIG. 2 , the method mainly includes:
[0058] step 201 in which a base station encodes MIMO related information to obtain a three-bit result of the encoding;
[0059] step 202 in which the base station adds a MIMO information field with three bits to the downlink control signaling for bearing the result of the encoding;
[0060] step 203 in which the base station loads the result of the encoding into the MIMO information field of the downlink control signaling, and transmits the downlink control signaling to the UE;
[0061] step 204 in which the UE receives the downlink control signaling and obtains the result of the encoding; and
[0062] step 205 in which the UE decodes the result of the encoding to obtain the MIMO related information of the UE.
[0063] This example further defines a format of the downlink control signaling, i.e. downlink control information (DCI) format. To distinguish from the DCI format defined in LTE-A Rel-9, the newly-defined DCI format is referred to as DCI format 2C.
[0064] In this example, the structure of the newly-defined DCI format 2C is as shown in Table 4.
[0000]
TABLE 4
Field
Length (bit)
Resource allocation header
0 or 1
Resource block assignment
TPC command of PUCCH
2
Downlink Assignment Index
2
HARQ process ID
3 or 4
TB 1 MCS
5
TB 1 NDI
1
TB 1 RV
2
TB 2 MCS
5
TB 2 NDI
1
TB 2 RV
2
MIMO information field
3
[0065] As can be seen from Table 4, the DCI format 2C provided by the example differs from existing DCI format 2 or DCI format 2A defined in LTE-A Rel-8 in that: the precoding information field of DCI format 2 or DCI format 2A is modified to a MIMO information field with other fields unchanged. The DCI format 2C of the example differs from existing DCI format 2B defined in LTE-A Rel-9 in that: the SCID field of DCI format 2B is removed and a MIMO information field with three bits is added while other fields keep unchanged.
[0066] Specifically, in this example, the base station first encodes the MIMO related information according to an encoding method, such as the one shown in Table 3, to obtain a three-bit result of encoding; loads the three-bit result into the MIMO information field of a DCI format 2C signaling, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE obtains the value of the MIMO information field, decodes the result of the encoding obtained according to the encoding method such as the one shown in Table 3, obtains the state of the UE, and thereby obtains the MIMO related information of the UE, such as the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE. And then, the DM-RS density and the OCC length are determined according to the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE.
[0067] According to this example, the base station can transmit MIMO related information to the UE simply by adding a MIMO information field with three bits to existing DCI format signaling.
[0068] In another example, eight antenna ports are supported also.
[0069] As the foregoing description, when an LTE-A system supports eight antenna ports and both of the two codewords of the UE are enabled, the UE may only be in one of the eight states listed in the above Table 1. If the LTE-A system supports eight antenna ports and only one of the two codewords of the UE is enabled, the UE may be in any one of the four states listed in the above Table 2.
[0070] Since the DCI format 2B defined in LTE-A Rel-9 includes an SCID field of one bit for bearing the DM-RS SCID, the SCID field can be utilized for bearing the MIMO related information.
[0071] Based on the above research, this example provides a transmitting method. As shown in FIG. 3 , the method mainly includes:
[0072] step 301 in which a base station encodes MIMO related information to obtain a three-bit result of the encoding;
[0073] step 302 in which the base station adds a MIMO information field with two bits to the downlink control signaling to bear the result of the encoding together with the SCID field;
[0074] step 303 in which the base station loads the result of the encoding into the MIMO information field and the SCID field of the downlink control signaling, and transmits the downlink control signaling to the UE;
[0075] step 304 in which the UE receives the downlink control signaling, and obtains the result of the encoding; and
[0076] step 305 in which the UE decodes the result of the encoding to obtain the MIMO related information of the UE.
[0077] This example further defines a format for the above downlink control signaling, which is also referred to as DCI format 2C.
[0078] In this example, the structure of the newly-defined DCI format 2C is as shown in Table 5.
[0000]
TABLE 5
Field
Length (bit)
Resource allocation header
0 or 1
Resource block assignment
TPC command of PUCCH
2
Downlink Assignment Index
2
HARQ process ID
3 or 4
SCID
1
TB 1 MCS
5
TB 1 NDI
1
TB 1 RV
2
TB 2 MCS
5
TB 2 NDI
1
TB 2 RV
2
MIMO information field
2
[0079] It can be seen from Table 5 that the DCI format 2C of the example differs from existing DCI format 2B defined in LTE-A Rel-9 in that: a MIMO information field with two bits is added while other fields keep unchanged.
[0080] Table 6 illustrates an example of utilizing the SCID field and the MIMO information field together to bear results of encoding the MIMO related information. It should be noted that the Table 6 is merely an example, and any other encoding schemes may also be adopted to establish the relation which associates a state sequence with the value of the SCID field and the MIMO information field.
[0000]
TABLE 6
MIMO
Result of encoding
SCID
information
MIMO related
State
field
field
information
sequence
0
00
000
state 0
1
00
100
state 1
0
01
001
state 2
1
01
101
state 3
0
10
010
state 4
1
10
110
state 5
0
11
011
state 6
1
11
111
state 7
0
00
000
state 8
0
10
010
state 9
1
11
111
state 10
1
01
101
state 11
[0081] As described above, besides the 12 states, State 16 may further be added to indicate a transmission mode, e.g., Transmit diversity, of the UE when only one codeword is enabled. In this case, the MIMO related information can still be encoded into three bits. For example, one entry may be added to the above Table 3, indicating that the UE is in State 16 when the result of the encoding is 001, and in this case, the SCID is set as 0 and the MIMO information field is set as 01.
[0082] In this example, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 3, to obtain a three-bit result of the encoding; loads the three-bit result of the encoding into the SCID field and the MIMO information field of DCI format 2C signaling, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE obtains the value of the MIMO information field, decodes the result of the encoding according to the encoding method such as the one shown in Table 6, obtains the state of the UE, and thereby obtains the MIMO related information of the UE, such as the Rank (i.e. number of layers) of the UE, the DM-RS port (i.e. antenna port) of the UE, the scrambling identity (i.e. SCID) of the DM-RS of the UE, and then further determines the DM-RS density and the OCC length.
[0083] According to this example, when the DCI format signaling already includes an SCID field, the base station may transmit the MIMO related information to the UE simply by adding a MIMO information field with two bits in the DCI format signaling.
[0084] In the above two examples, four or three results of encoding the MIMO information will not be used and are referred to as reserved information.
[0085] It should be noted that the method in the above two examples may also be applied to a LTE-A system supporting four antenna ports or two antenna ports, and in this case there will be more of such reserved information.
[0086] In yet another example, four antenna ports supported.
[0087] According to research, when an LTE-A system supports four antenna ports and both of the two codewords of the UE are enabled, the UE may be in any one of the following four states as listed in Table 1.
[0000]
TABLE 7
State
UE
DM-RS
OCC
MIMO
sequence
Rank
DM-RS Port
density
length
mode
SCID
state 0
Rank 2
port {7, 8}
12
2
SU/MU
0
state 1
Rank 2
port {7, 8}
12
2
SU/MU
1
state 2
Rank 3
port {7, 8,
24
2
SU
default
9}
state 3
Rank 4
port {7, 8,
24
2
SU
default
9, 10}
[0088] If the LTE-A system supports four antenna ports and only one of the two codewords of the UE is enabled, the UE may be in any one of the following four states listed in the following Table 8.
[0000]
TABLE 8
State
UE
DM-RS
DM-RS
OCC
MIMO
sequence
Rank
Port
density
length
mode
SCID
state 4
Rank 1
port {7}
12
2
SU/MU
0
state 5
Rank 1
port {7}
12
2
SU/MU
1
state 6
Rank 1
port {8}
12
2
SU/MU
0
state 7
Rank 1
port {8}
12
2
SU/MU
1
[0089] A total of eight states are listed in Table 7 and Table 8. According to the above, whether one or both of the two codewords of the UE are enabled can be indicated by both an MCS field and an RV field corresponding to each codeword in the downlink control signaling. Therefore, in this example, only two bits are needed for encoding the MIMO related information.
[0090] The following Table 9 illustrates a result obtained by encoding the MIMO related information using two bits.
[0000]
TABLE 9
Result of encoding
MIMO related
State
information
sequence
00
state 0
01
state 1
10
state 2
11
state 3
00
state 4
01
state 5
10
state 6
11
state 7
[0091] In the above table, states 4-7 and states 0-3 can be distinguished from each other by utilizing values of the MCS field and the RV field of the two codewords in the downlink control signaling. It should be noted that the above Table 9 is merely an example, and that any other encoding schemes may also be adopted to establish the relation which associates a state sequence with a result of encoding MIMO related information.
[0092] Based on the above research, this example provides a transmitting method. As shown in FIG. 4 , the method mainly includes:
[0093] step 401 in which a base station encodes MIMO related information to obtain a two-bit result of the encoding;
[0094] step 402 in which the base station adds a MIMO information field with two bits to the downlink control signaling for bearing the result of the encoding;
[0095] step 403 in which the base station loads the result of the encoding into the MIMO information field of the downlink control signaling and transmits the downlink control signaling to the UE;
[0096] step 404 in which the UE receives the downlink control signaling and obtains the result of the encoding; and
[0097] step 405 in which the UE decodes the result of the encoding to obtain the MIMO related information of the UE.
[0098] This example further defines a format for the above downlink control signaling, which is also referred to as DCI format 2C. In this example, the structure of the newly-defined DCI format 2C is as shown in Table 10.
[0000]
TABLE 10
Field
Length (bit)
Resource allocation header
0 or 1
Resource block assignment
TPC command of PUCCH
2
Downlink Assignment Index
2
HARQ process ID
3 or 4
TB 1 MCS
5
TB 1 NDI
1
TB 1 RV
2
TB 2 MCS
5
TB 2 NDI
1
TB 2 RV
2
MIMO information field
2
[0099] It can be seen from Table 10 that the DCI format 2C of this example differs from the DCI format 2C of the example described firstly in the foregoing in that the length of the MIMO information field of this example is two bits.
[0100] In this example, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 9, to obtain a two-bit result of encoding; loads the two-bit result of encoding into the SCID field and the MIMO information field of DCI format 2C signaling, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE obtains the value of the MIMO information field, decodes the result of the encoding according to the encoding method such as the one shown in Table 9, obtains the state of the UE, and then obtains the MIMO related information of the UE by utilizing both Table 7 and Table 8 together.
[0101] According to this example, the base station can transmit the MIMO related information to the UE simply by adding a MIMO information field with two bits to existing DCI format signaling.
[0102] In this example, when there is a need to add State 16 for representing a transmission mode, e.g. Transmit diversity, of the UE when only one codeword is enabled, two bits are not enough for encoding the MIMO related information, and thus three bits may be used for encoding the MIMO related information. The detailed implementation can refer to the example described firstly in the foregoing. When eight antenna ports are supported, a UE may at most have 13 states; but when four antenna ports are supported, the UE may at most have 9 states. Thus, compared with the case that eight antenna ports are supported, the case that four antenna ports are supported may have more reserved information when three bits are used for encoding the MIMO related information.
[0103] In still another example, four antenna ports are supported also.
[0104] According to the foregoing, when an LTE-A system supports four antenna ports and both of the two codewords of the UE are enabled, the UE may only be in any one of the four states listed in the above Table 7. If the LTE-A system supports four antenna ports and only one of the two codewords of the UE is enabled, the UE may be in any one of the four states listed in the above Table 8.
[0105] Because the DCI format 2B defined in LTE-A Rel-9 includes an SCID field with one bit for bearing the DM-RS SCID, the SCID field can be utilized for bearing the MIMO related information in this example.
[0106] Based on the above, this example provides a transmitting method. As shown in FIG. 5 , the method mainly includes:
[0107] step 501 in which a base station encodes MIMO related information to obtain a two-bit result of the encoding;
[0108] step 502 in which the base station adds a MEMO information field with one bit to the downlink control signaling for bearing the result of the encoding together with the SCID field;
[0109] step 503 in which the base station loads the result of the encoding into the MIMO information field and the SCID field of the downlink control signaling, and transmits the downlink control signaling to the UE;
[0110] step 504 in which the UE receives the downlink control signaling and obtains the result of the encoding;
[0111] step 505 in which the UE decodes the result of the encoding to obtain the MIMO related information of the UE.
[0112] This example further defines a format for the above downlink control signaling, which is also referred to as DCI format 2C.
[0113] In this example, the structure of the newly-defined DCI format 2C is as shown in Table 11.
[0000]
TABLE 11
Field
Length (bit)
Resource allocation header
0 or 1
Resource block assignment
TPC command of PUCCH
2
Downlink Assignment Index
2
HARQ process ID
3 or 4
SCID
1
TB 1 MCS
5
TB 1 NDI
1
TB 1 RV
2
TB 2 MCS
5
TB 2 NDI
1
TB 2 RV
2
MIMO information field
1
[0114] It can be seen from Table 11 that the DCI format 2C of this example differs from the DCI format 2C described secondly in the foregoing in that the length of the MIMO information field in this example is one bit.
[0115] Table 12 illustrates an example of utilizing a SCID field and a MIMO information field together to bear results of encoding the MIMO related information. It should be noted that the Table 12 is merely an example and any other encoding schemes may also be adopted to establish the relation which associates a state sequence with the values of the SCID field and the MIMO information field.
[0000]
TABLE 12
MIMO
result of encoding
SCID
information
MIMO related
State
field
field
information
sequence
0
0
00
state 0
1
0
10
state 1
0
1
01
state 2
1
1
11
state 3
0
0
00
state 4
1
0
10
state 5
0
1
01
state 6
1
1
11
state 7
[0116] In this example, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 12, to obtain a two-bit result of encoding; loads the two-bit result into the SCID field and the MIMO information field of DCI format 2C signaling, and transmits the DCI format 2C signaling to the UE.
[0117] After receiving the DCI format 2C signaling transmitted by the base station, the UE obtains the value of the MIMO information field, decodes the result of the encoding according to the encoding method such as the one shown in Table 12, obtains the state of the UE, and then obtains the MIMO related information of the UE by utilizing both Table 7 and Table 8 together.
[0118] According to this example, when the DCI format signaling already includes an SCID field, the base station may transmit the MIMO related information to the UE simply by adding a MIMO information field with one bit in the DCI format signaling.
[0119] In this example, when there is a need to add State 16 for representing a transmission mode, e.g. Transmit diversity, of the UE when only one codeword is enabled, two bits are not enough for encoding the MIMO related information, and therefore three bits may be used for encoding the MIMO related information. Detailed implementation can refer to the example described secondly in the foregoing. When eight antenna ports are supported, a UE may at most have 13 states; but when four antenna ports are supported, the UE may at most have 9 states. Thus, compared with the case that eight antenna ports are supported, the case that four antenna ports are supported may have more reserved information when three bits are used to encode the MIMO related information.
[0120] In yet another example:
[0121] For the MU-MIMO, the LTE-A Rel-9 at most supports four layers, and each MU-MIMO at most supports two layers; while for the SU-MIMO, it at most supports Rank 2. Therefore, when eight antenna ports are supported, when dynamic switching between SU and MU needs to be supported, i.e. when the UE is in the state 0 or 1 shown in Table 1, or in any of states 8-11 shown in Table 2, the DCI format 2B defined in LTE-A Rel-9 can be directly utilized for transmitting the MIMO related information to the UE; when dynamic switching between SU and MU need not be supported, i.e. when the UE is in any of states 2-7 shown in Table 1, the MIMO information field with three bits can be used for transmitting the MIMO related information to the UE according to the method shown in FIG. 2 . The newly-defined DCI format is similar to that shown in Table 5 except that the SCID field is not needed and is omitted. Therefore, when four antenna ports are supported, when dynamic switching between SU and MU needs to be supported, i.e. when the UE is in the state 0 or 1 shown in Table 7, or in any of states 4-7 shown in Table 8, the DCI format 2B defined in LTE-A Rel-9 can be directly utilized for transmitting the MIMO related information to the UE; when dynamic switching between SU and MU need not be supported, i.e. when the HE is in state 2 or 3 shown in Table 7, the MIMO information field with one bit can be added to the DCI format signaling for transmitting the MIMO related information to the UE. The newly-defined DCI format is similar to that shown in Table 5 except that the length of the MIMO information field is one bit and the SCID field thus is omitted.
[0122] It should be noted that in the above five examples, when only one codeword is enabled, the Rank higher than Rank 1 is applicable only to data re-transmission. Specifically, when eight antenna ports are supported, only one codeword is enabled and the Rank is higher than Rank 1, the UE may be in any one of the following four states. In order to be distinguished from the states 1-11 in the first two examples, states 12-15 are used for denoting the four states in this example. The following Table 13 shows the MIMO related information in the above four states. It should be noted that the state 13 in the following Table 13 is optional, i.e. when eight antenna ports are supported and only one codeword is enabled and the Rank is higher than Rank 1, the UE may be in one of the following three states: state 12, state 14 and state 15.
[0000]
TABLE 13
State
UE
DM-RS
OCC
re-transmitted or
MIMO
sequence
Rank
DM-RS Port
density
length
not
mode
SCID
state 12
Rank 2
port {7, 8}
12
2
Yes
SU/MU
0
state 13
Rank 2
port {7, 8}
12
2
Yes
SU/MU
1
state 14
Rank 3
port {7, 8, 9}
24
2
Yes
SU
default
state 15
Rank 4
port {7, 8, 9,
24
2
Yes
SU
default
10}
[0123] In this case, the base station may inform the UE to perform data re-transmission via a new New Data Indication (NDI) field corresponding to the enabled codeword, and inform the UE of the MIMO related information via the newly-added MIMO information field when the UE is in one of the above four or three states.
[0124] According to the above example described firstly in the foregoing, the base station may encode the MIMO related information of a UE when only one codeword is enabled and the Rank is higher than Rank 1, load the result of the encoding into the newly-added MIMO information field, and inform the UE that it is data re-transmission via the NDI field corresponding to the enabled codeword. The following Table 14 illustrates a relation which associates each of states 12-15 with the newly-added MIMO information field and the NDI field corresponding to the enabled codeword.
[0000]
TABLE 14
result of encoding
MIMO
MIMO related
information
State
NDI
information
field
sequence
not inverted
000
000
state 12
not inverted
110
110
reserved or
state 13
not inverted
011
011
state 14
not inverted
101
101
state 15
[0125] In this example, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 14, to obtain a three-bit result of encoding; loads the three-bit result into the MIMO information field of DCI format 2C signaling, sets the NDI corresponding to the enabled codeword as not-inverted, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE detects that the DCI format 2C signaling is for data re-transmission based on the NDI corresponding to the enabled codeword, obtains the value of the MIMO information field, and decodes the result of the encoding according to the encoding method such as the one shown in Table 14, and obtains the MIMO related information of the UE by utilizing Table 13.
[0126] According to the example described secondly in the forgoing, the base station may encode the MIMO related information of a UE when only one codeword is enabled and the Rank is higher than Rank 1, and load the result of the encoding into the SCID field and the newly-added MIMO information field, and inform the UE that it is data re-transmission via the NDI field corresponding to the enabled codeword. The following Table 15 illustrates a relation which associates each of states 12-15 with the newly-added MIMO information field, the SCID field and the NDI field corresponding to the enabled codeword.
[0000]
TABLE 15
result of encoding
MIMO
MIMO related
information
State
NDI
information
SCID
field
sequence
Not-inverted
000
0
00
state 12
Not-inverted
101
1
01
reserved or
state 13
Not-inverted
010
0
10
state 14
Not-inverted
111
1
11
state 15
[0127] In this situation, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 15, to obtain a three-bit result of encoding; loads the three-bit result into the SCID field and the MIMO information field of DCI format 2C signaling, sets the NDI corresponding to the enabled codeword as not-inverted, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE detects that the DCI format 2C signaling is for data re-transmission based on the NDI corresponding to the enabled codeword, obtains the values of the SCID field and the MIMO information field from the NDI, decodes the result of the encoding according to the encoding method such as the one shown in Table 15, and obtains the MIMO related information of the UE by utilizing Table 13.
[0128] In addition, from the Table 3 of the example described firstly in the foregoing and the Table 6 of the example described secondly in the foregoing, it can be seen that the first two examples, when only one codeword is enabled, the UE only has four states, or five states when state 16 exists. However, a three-bit result of encoding the MIMO relation information can indicate eight states, and therefore, four or three of the results of encoding are reserved information which is unused in first two examples respectively. Based on the above research, as an alternative of the above scheme, reserved information can be used for informing the UE of the state that only one codeword is enabled and the Rank is higher than Rank 1. For example, when there are four states as the reserved information, the reserved information may be used for informing the UE of four re-transmission states or three re-transmission states (e.g. state 12, state 14 and state 15) when only one codeword is enabled and the Rank is higher than Rank 1. When there are three states as the reserved information, the reserved information may be used for informing the UE of three re-transmission states (e.g. state 12, state 14 and state 15) when only one codeword is enabled and the Rank is higher than Rank 1. That is, when only one codeword is enabled, the four or five non-retransmission states corresponding to Rank 1 and the four or three retransmission states corresponding to the Rank higher than Rank 1 are associated for encoding, and a three-bit result of encoding MIMO related information is adopted to denote the seven or eight states without utilizing the NDI field corresponding to the enabled codeword.
[0129] Specifically, according to the example described firstly in the foregoing, the base station may encode MIMO related information of a UE (including MIMO related information of the UE when only one codeword is enabled and the Rank is higher than Rank 1), and load the result of the encoding into the newly-added MIMO information field. The following Table 16 illustrates a relation which associates each state of UE with a result of encoding MIMO related information and the newly-added MIMO related information.
[0000]
TABLE 16
Result of encoding
MIMO
MIMO related
information
State
information
field
sequence
000
000
state 0
001
001
state 1
010
010
state 2
011
011
state 3
100
100
state 4
101
101
state 5
110
110
state 6
111
111
state 7
000
000
state 8
110
110
state 9
011
011
state 10
101
101
state 11
001
001
state 12
100
100
reserved or state
13 or 16
010
010
state 14
111
111
state 15
[0130] In this situation, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 16, to obtain a three-bit result of encoding; loads the three-bit result into the MIMO information field of DCI format 2C signaling, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE obtains the value of the MIMO information field, decodes the result of the encoding according to the encoding method such as the one shown in Table 16, obtains the state of the UE, and then obtains the MIMO related information of the UE by utilizing Table 1, Table 2 and Table 13 in combination.
[0131] Specifically, corresponding to the example described secondly in the foregoing, the base station may encode MIMO related information of a UE (including MIMO related information of the UE when only one codeword is enabled and the Rank is higher than Rank 1), and load the result of the encoding into the SCID field and the newly-added MIMO information field. The following Table 17 illustrates a relation which associates each state of UE with a result of encoding MIMO related information, the SCID field and the newly-added MIMO related information.
[0000]
TABLE 17
Result of encoding
MIMO
MIMO related
information
State
information
SCID
field
sequence
000
0
00
state 0
001
0
01
state 1
010
0
10
state 2
011
0
11
state 3
100
1
00
state 4
101
1
01
state 5
110
1
10
state 6
111
1
11
state 7
000
0
00
state 8
110
1
10
state 9
011
0
11
state 10
101
1
01
state 11
001
0
01
state 12
100
1
00
reserved or state
13 or 16
010
0
10
state 14
111
1
11
state 15
[0132] In this situation, the base station first encodes the MIMO related information according to an encoding method, e.g. the one shown in Table 17, to obtain a three-bit result of encoding; loads the three-bit result into the SCID field and the MIMO information field of DCI format 2C signaling, and transmits the DCI format 2C signaling to the UE. After receiving the DCI format 2C signaling transmitted by the base station, the UE obtains the values of the SCID field and the MIMO information field, decodes the result of the encoding according to the encoding method such as the one shown in Table 17, and obtains the MIMO related information of the UE by utilizing Table 1, Table 2 and Table 13 in combination.
[0133] It should be noted that the above Table 14-Table 17 are merely exemplary manners of encoding MIMO related information. Those skilled in the art can understand that other encoding manners can also be adopted for establishing the relation which associates each state sequence with a result of encoding the MIMO related information.
[0134] In addition, it should be noted that the above method is not only applicable to situations in which eight antenna ports are supported, but also applicable to LTE-A systems which support four or two antenna ports.
[0135] Furthermore, in the above five examples, when only one codeword is enabled, the NDI field corresponding to the disabled codeword is idle and can be encoded together with the newly-added MIMO information field (or further with the SCID field), i.e. the NDI field and the MIMO information field are used together to bear the result of encoding MIMO relation information.
[0136] The foregoing is only examples of the present invention. The protection scope of the present invention, however, is not limited to the above description. Any change or substitution, easily occurring to those skilled in the art, should be covered by the protection scope of the present invention. | The present invention provides a method for transmitting MIMO related information. The method includes: encoding MIMO related information of a user equipment (UE) by a base station, and transmitting downlink control signaling including a result of the encoding; receiving by the UE the downlink control signaling transmitted by the base station, obtaining the result of the encoding, and obtaining the MIMO related information of the UE by decoding the result of the encoding. By adopting the method, the base station is enabled to transmit MIMO related information required by the UE to the UE with small signaling overhead. | 7 |
FIELD OF THE INVENTION
[0001] This invention generally relates to techniques for fluorescence labelling, and to methods, apparatus and computer program code implementing numerical algorithms for processing fluorescence signal data. The techniques we describe are particularly useful in biotechnology applications.
BACKGROUND TO THE INVENTION
[0002] A common biological problem is the measurement of the optical emission from spatially coincident fluorophores (dyes). Imaging the functional components of a living cell often involves the registration of multiple fluorescent markers. Quantifying the hybridisation of labelled nucleic acids (probes) to immobilised target molecules in a microarray (“gene chip”) can also require the simultaneous detection of multiple-component fluorescent spectra.
[0003] We have previously described, in WO 03/023376 (hereby incorporated by reference in its entirety) cryogenic detector technology, in particular employing a superconducting tunneling junction (STJ), for the detection of a fluorescent signal from, for example, a DNA (deoxyribonucleic acid) microarray. An STJ device is sensitive over a range of wavelengths (colours or energies), generally down to the single photon level, as well as exhibiting a highly linear response and high signal-to-noise ratio. The energy-resolving capability of the STJ in the optical band (embodiments of the device may be described as hyperspectral) facilitates simultaneous multi-colour detection of hybridisation to microarrays for applications such as drug discovery.
[0004] In a typical microarray experiment two samples or targets are reverse transcribed into cDNA (complementary DNA) and labelled using different fluorescent dyes. The DNA microarray comprises an array of DNA sequences which act as probes, and the targets are mixed and hybridised with these probes and then, after removal of excess unbound material by washing, the microarray is imaged, generally using a scanner which responds to the fluorescence signal at each of the array spots. The differential hybridisation of the two targets to a probe sequence is, broadly speaking, determined by the ratio of the fluorescence intensities at the spot on the microarray for the probe sequence. In this way, the relative abundance of each of the probe sequences in the two targets may be assessed. There are a number of variants of this basic technique. Currently the majority of microarrays comprise DNA (which here includes cDNA), but microarrays may also be fabricated using RNA (ribonucleic acid), proteins, antibodies, antigens and the like.
[0005] A conventional scanner typically employs a photomultiplier to record the signals from the microarray but we have described how an STJ detector device can be used to provide substantial improvements in performance (ibid; also Review of Scientific Instruments, Volume 74, Number 9, September 2003, “Detection of multiple fluorescent labels using superconducting tunnel junction detectors”, G. W. Fraser. J. S. Helsop-Harrison, T. Schwarzacher, A. D. Holland, P. Verhoeve and A. Peacock). For example one detector used in a study of biological fluorescence was a single 30×30 μm 2 STJ with 100 nm thick Ta layers and 30 nm thick Al layers on either side of the tunnel barrier. The detector was made using photolithographic techniques from a Ta/Al multilayer deposited on a polished sapphire substrate. Cooling to 300 mK in a 3 He cryostat (i.e., T˜T c /15, where T c denotes the superconducting transition temperature) kept the thermally excited quasiparticle current well below the leakage current level. The STJ had a measured resolving power (λ/Δλ) of 14.1 at 600 nm. Samples were stimulated with a Leica microscope with mercury lamp excitation. Preferential selection of colour from fluorophore samples could be made using an Omega triple filter set, which gives transmission in narrow bands centred on 450 nm (blue), 520 nm (green) and 620 nm (red). The integration times were ˜30 s.
[0006] Such Ta/Al devices (resolving power ˜10-20) are capable of simultaneously measuring at least four well-separated fluorophores. Smaller band gap, lower operating temperature, STJ devices with better resolving power—e.g. Hf with R˜80 or Mo with R˜40—are potentially even better. The modest throughput of single pixel STJs can be improved by the development of large format arrays. (See Nuclear Instruments and Methods in Physics Research A 559 (2006) 782-784, “Optical fluorescence of biological samples using STJs”, G. W. Fraser, J. S. Helsop-Harrison, T. Schwarzacher, P. Verhoeve, A. Peacock and S. J. Smith).
[0007] Typically, a scanner will include an image capture/processing system, for example based upon a digital signal processor or a suitably programmed general purpose computer, and the fluorescence signals from the imaged microarray are typically output as a colour image file in an industry standard format, such as a 16 bit GIF (graphics interchange format) or TIFF (tagged image file format) format. Different fluorophores have different emission peaks and, in general, different (shorter wavelengths) absorbtion peaks. The scanner may either excite both absorption peaks simultaneously with a single wavelength, then read both emission wavelengths simultaneously, or, the microarray may be scanned at first one absorption wavelength and then at the other(s). Often lasers are employed to excite the fluorescence. It is generally preferable to read multiple fluorescence signals (colours) simultaneously as re-scanning can damage the hybridised entities and can, in particular, cause photo bleaching. Generally, passband filtering is employed to discriminate between the excitation illumination and the fluorescent emission as well as, optionally, between the different fluorescence signals.
[0008] Background material relating to microarray data analysis can be found in “Microarray data analysis: from disarray to consolidation and consensus”; David B. Allison, Xiangqin Cui, Grier P. Page and Mahyar Sabripour, NATURE REVIEWS, GENETICS, Volume 7, January 2006, page 55-65; and “Improving false discovery rate estimation”, Bioinformatics 20(11), 2004, page 1737-1745; Material published after the earliest priority date of this application can be found in “Speed-mapping quantitative trait loci using micromays”, Chao-Qiang Lai, Jeff Leips, Wei Zou, Jessica F Roberts, Kurt R Wollenberg, Laurence D Parnell, Zhao-Bang Zeng, Jose M Ordovas & Trudy F C Mackay, NATURE METHODS, Vol. 4 No. 10, October 2007, pages 841-839; and “HoughFeature, a novel method for assessing drug effects in three-color cDNA microarray experiments”, Hongya Zhao and Hong Yan, 17 Jul. 2007, BMC Bioinformatics 2007, 8:256, doi: 10.1186/1471-2105-8-256.
[0009] Conventionally, the processing of fluorescence signals from a microarray has been based upon some implicit assumptions, in particular that there is a linear relationship between the fluorescent signals from a particular spot and the relative abundances of the labelled sample or target. The inventors have, however, recognised that this is not generally true and that coupling between two different fluorophores will introduce non-linearities. The inventors have further recognised that non-linearities can occur even in a single fluorophore system. The degrees of non-linearity will in part depend upon the fluorophores employed. We will describe techniques by which these non-linearities can be taken into account. More particularly, we will describe both techniques for improved processing of signals from entities labelled or associated with two different fluorophores, and techniques relating to the determination of an optimum degree of labelling i.e. one which produces maximum brightness.
SUMMARY OF THE INVENTION
[0010] According to a first aspect of the invention, there is therefore provided a method of determining respective first and second degree-of-labelling signals for different respective first and second fluorophores associated with a common entity, the method comprising: determining a first fluorescence signal from said first and second fluorophores under first conditions; determining a second fluorescence signal from said first and second fluorophores under second conditions different to said first conditions; and determining said first and second degree-of-labelling signals for said first and second fluorophores from said first and second fluorescence signals; and wherein said determining of said first and second degree-of-labelling signals is responsive to at least one coupling value (c 12 ; c 21 ) representing a coupling of energy between said fluorophores, or the absorption of light emitted by one fluorophore by the other fluorophore.
[0011] The skilled person will understand that in a microarray experiment signal intensities (corrected for the effects of non-linearity) are measured. The degree of labelling may be, for example, either the number of fluorophores on a particular molecule or entity or the number of fluorescent labelled molecules which bind to an entity. An example of the first case is where multiple fluorophores bind, at spatial intervals, to DNA. An example of the second case is where, say, an antibody has multiple binding sites and binds to a plurality of molecules simultaneously each carrying a single fluorophore. Embodiments of the technique can still further be used in a situation where the degree of labelling signals associated with a common entity arise from a physical mixture of different fluorophores attached to different individual molecules or entities of the same type. An example of this is where a microarray spot contains a physical mixture of the same conjugate molecule some of which have one or more fluor A moieties attached and others of which have one or more fluor B moieties attached.
[0012] Embodiments of the technique allow the degree-of-labelling signals from two different fluorophores to be separated, thus dispensing with the need for re-scanning and minimising the deleterious effects of photo bleaching. In some particularly preferred embodiments, the technique is employed with fluorescence signals from a superconducting tunnel junction detector device as described above. The techniques are particularly advantageous with this type of detector because of the relatively small number of photons which may be detected. However, more generally, embodiments of the method may be employed with any type of microarray scanning system, as well as in the context of other systems in which optical emission from spatially substantially coincident fluorophores may be observed. Thus, for example, the method may be embodied as computer programme code to implement a front end for conventional microarray scan analysis software. The degree-of-labelling signals determined for the first and second chromophores (fluorophores) may either comprise a degree-of-labelling per se, or, for example, separated signals from the two fluorophores from which respective degrees of labelling or other hybridisation information may later be derived.
[0013] In preferred embodiments of the method, at least one coupling value represents a coupling between light emitted by one of the fluorophores and absorbed by the other of the fluorophores.
[0014] In embodiments of the method the first fluorophore has an emission peak at a longer wavelength than that of the second fluorophore and the coupling value represents a coupling between light emitted by the second fluorophore and absorbed by the first fluorophore; in embodiments of the method coupling in the other direction may be substantially neglected.
[0015] The conditions under which the first and second fluorescence signals are determined generally define one or both of different illumination wavelengths and different detection wavelengths for the determination of the first and second fluorescence signals. Thus, a common illumination signal may be applied to a microarray in a single scan, using different wavelengths or wavelength bands, for example selected by filters, to determine the two fluorescence signals.
[0016] In embodiments an estimate for the one or more coupling values may be determined by performing a calibration over a range of combinations of the first and second fluorophores in different proportions. In preferred embodiments of the method the determining of the two degree-of-labelling signals also takes into account respective parameters for the two fluorophores representing a respective degree of self-quenching. Such parameters may be available or derivable from published data or may again be determined by performing a calibration, here for each fluorophore separately.
[0017] The skilled person will appreciate that the techniques we describe may be applied to a range of entities with which the first and second fluorophores are associated. For example, in a microarray experiment the two fluorophores may be associated with a common probe entity to which the separately tagged targets are attached, for example to determine a degree of relative hybridisation. Additionally or alternatively the two fluorophores may be associated with a common sample or target entity. Typically the two fluorophores will be part of a probe-target experiment, but, potentially, they may also be incorporated into the structure of a common molecule, for example as differently fluorescently tagged bases in a strand of DNA or RNA.
[0018] In some preferred embodiments the method is employed to process fluorescence data from a microarray. Generally this will comprise a microarray of DNA or RNA, although the microarray may additionally or alternatively comprise antibodies or antigens; in other applications the technique may be employed to process fluorescence data from a sandwich assay.
[0019] Thus in a further aspect there is provided a method of processing fluorescence data from a microarray, the microarray being labelled with two or more different fluorophores, the method comprising: inputting said fluorescence data, the fluorescence data representing fluorescence signals from said microarray at two or more wavelengths; determining data representing a line of parity for said fluorescence signals, said line of parity being a line along which signal intensities from fluorescence at said two or more wavelengths are expected to represent substantially equal quantities of the entities to which the fluorophores are attached; and correcting a said fluorescence signal from said microarray at one of said wavelengths using said determined line of parity.
[0020] The skilled person will appreciate that the technique may be extended to three or more fluorophores, in which case the concept of a line of parity may be extended accordingly (i.e. to a surface of equivalence, or set of such surfaces). Thus in the above method “line of parity” includes “surface of parity”. In embodiments of the method the fluorescence signal corresponds to one or more biological parameters, for example a level of gene expression or the like. In embodiments of the method is preferable that at one of the fluorescence signals used for determining the line of parity represents a control level of fluorescence (although this is not essential since one signal may be used as a control for the other even where both represent a level of a biological parameter). Where one signal is used as a control, the other generally represents a level of a biological parameter, as previously mentioned.
[0021] In embodiments the determining of the line of parity comprises determining first and second end points of the line, optionally excluding outlier data signals. One end point may correspond to fluorescence intensity signals at first and second wavelengths being substantially zero (in terms of the later equations, assuming n is approximately unity). Thus one point on the line of parity may be determined using:
[0000] S G /S R =( a G −b G )/( a R −b R )
[0000] where a and b represent characteristics of a fluorophore, the subscripts G and R representing fluorophores which fluoresce primarily at first and second respective wavelengths, for example a green fluorophore such as Cyanine 3 fluorescent dye Cy3® and a red fluorophore such as Cyanine 5 fluorescent dye Cy5®.
[0022] In preferred embodiments a second point on the line is determined using:
[0000] S G /S R =( b G +c RG )/ b R
[0000] Where c RG accounts for emission from one fluorophore which is absorbed by the other fluorophore. More particularly the c RG term takes account of quenching of a short wavelength fluorescence emitter by a longer wavelength fluorescence emitter (so the longer wavelength emitter is less perturbed by this effect than the shorter wavelength emitter). In some preferred embodiments a value for c RG may be determined from the fluorescence data, for example by a best-fit technique. The point on the line of parity determined by this method may be a maximum fluorescence end point, that is where the fluorescence intensity signals at the two or more wavelengths are substantially at a maximum.
[0023] In preferred embodiments the correcting process comprises compensating for a difference between a measurement variable (i.e. a non-control) fluorescence signal and a value of that fluorescence signal predicted from the line of parity, for example by subtracting one from the other. In some preferred embodiments the method also comprises correcting for systematic noise comprising one or both of: fixed pattern noise from the microarray, and noise resulting from division of one digital number by another. The fixed pattern noise may arise, for example, from artefacts due to deposition of the microarray and may have a cyclic repetition, for example at row or column sub-array intervals.
[0024] Thus, in a further aspect the invention provides a method of processing fluorescence data from a microarray, the method comprising: inputting said fluorescence data, the fluorescence data representing fluorescence signals from said microarray at a plurality of different spot locations: and processing said fluorescence data to determine a biological parameter associated with fluorescence from a said spot; and wherein said processing includes: compensating said fluorescence data for systematic noise comprising one or both of fixed pattern noise from said microarray and noise resulting from the division of one digital number by another.
[0025] The invention further provides processor control code, in particular on a carrier, to implement embodiments of the above described method. The carrier may comprise a disc such as a CD (compact disc)- or DVD (digital video disc)-Rom, programmed memory such a read only memory, or a data carrier such as an optical or electrical signal carrier. The processor control code may comprise source, object or executable code in any conventional programming language, for example C, or code for a hardware description language. As the skilled person will appreciate such code and/or associated data may be distributed between a plurality of coupled components in communication with one another.
[0026] The invention further provides apparatus configured to implement a method as described above. In general such apparatus comprises an input to receive fluorescence data to be processed, an output to provide the processed fluorescence data, either for further analysis or, for example, as a set of gene expression levels, and a data processor coupled to the input and the output, to working memory, and to program memory storing processor control code to implement a fluorescence data processing method.
[0027] In a related aspect, the invention provides apparatus for determining respective first and second degree-of-labelling signals for different respective first and second fluorophores associated with a common entity, the apparatus comprising: means for determining a first fluorescence signal from said first and second fluorophores under first conditions; means for determining a second fluorescence signal from said first and second fluorophores under second conditions different to said first conditions; means for determining said first and second degree-of-labelling signals for said first and second fluorophores from said first and second fluorescence signals; and wherein said means for determining said first and second degree-of-labelling signals is responsive to at least one coupling value (c 12 ; c 21 ) representing a coupling of energy between said fluorophores.
[0028] The inventors have further recognised that the above-described techniques may also be employed to determine an optimum degree-of-labelling of an entity with a fluorophore and, more particularly, by two or more fluorophores. This is advantageous because a procedure to label entities with one or more fluorescent tags generally involves multiple labelling experiments which are tedious and time consuming. The inventors have recognised that, depending upon the data available, only a single labelling experiment or, potentially no labelling experiments may be necessary.
[0029] Thus, according to a further aspect of the invention, there is provided a method of labelling an entity with a fluorophore, the method comprising inputting a first parameter dependent on a light creation efficiency of said fluorophore; inputting a second parameter dependent on a degree of self-quenching of said fluorophore; determining an estimate of an optimum degree-of-labelling of said entity by said fluorophore using said first and second parameters; and labelling said entity with said fluorophore in accordance with said estimated optimum degree-of-labelling.
[0030] In embodiments the estimated optimum degree-of-labelling comprises an estimated degree-of-labelling (number of fluorophores per entity, e.g. molecule) at which fluorescence intensity (brightness) is predicted to a maximum.
[0031] Preferably the first parameter is further dependent on one or more of a structure of the entity, a structure of the fluorophore, and a bonding between the fluorophore and the entity. In some particularly preferred embodiments, the method is employed with a plurality of fluorophores, using a third parameter dependent upon the degree of coupling between at least two of the plurality of fluorophores to determine an estimated optimum degree-of-labelling for each of the fluorophores in the presence of the other. The degree of coupling may be estimated, for example, by performing a calibration experiment using entities labelled with a range of different respective combinations of the plurality of fluorophores.
[0032] In a further aspect the invention provides an entity labelled with one or more fluorophores using the above described method. Thus in embodiments the entity has a substantially optimum degree-of-labelling by the one or more fluorophores. The optimum degree-of-labelling may be defined as a degree-of-labelling which corresponds to substantially the maximum fluorescent light yield from the labelled entity for the relevant fluorophore.
[0033] Thus in further aspects the invention provides an entity labelled with a plurality of different fluorophores, and a kit of fluorescent probes, respective numbers of said different fluorophores being such that a fluorescence signal (S(n)) from each said fluorophore is substantially maximised.
[0034] The invention still further provides a fluorophore-labelled entity having a number of labelling fluorophores determined by a product of a figure of merit (R), an example of which is described later, multiplied by a constant of proportionality determined from a measured set of peak values of fluorescence against respective figures of merit for a plurality of different other fluorophores. For example the constant of proportionality may be that shown in FIG. 7 , discussed later, +/−50%.
[0035] The invention still further provides a method of manufacturing a kit of fluorophore labelled probes, the method comprising: determining a combination of fluorophores for said kit; and manufacturing said kit using said determined combination of fluorophores; and wherein said determining of said combination of fluorophores comprises: selecting one or both of a set of fluorophores for said kit of fluorophore labelled probes and a degree of labelling of said probes by said fluorophores using a fluorescence brightness figure of merit function (R) for a candidate said fluorophore of the set.
[0036] In embodiments, the fluorescence brightness figure of merit function is dependent on a degree of overlap between emission and absorption spectra of a said candidate said fluorophore. Preferably R also comprises a function dependent on the quantum yield of a said candidate fluorophore, a maximum value of an extinction coefficient of the fluorophore. Additionally or alternatively said function comprises a function of i) a parameter dependent on a light creation efficiency of fluorophore, and ii) a parameter depending on a degree of self-quenching of the fluorophore, said selecting further being dependent on iii) a parameter dependent on a degree of coupling between the fluorophore and another fluorophore.
[0037] In embodiments the kit of fluorophore labelled probes comprises a calibration kit for a microarray or another diagnostic platform. In embodiments the number of calibration fluorophores matches the number of experimental fluorophores. In some preferred embodiments the kit of fluorophore labelled probes for use with an STJ detector.
[0038] The invention also provides a kit of fluorophore labelled probes comprising a kit of fluorophores, and wherein one or both of a set of fluorophores for said kit of fluorophore labelled probes and a degree-of-labelling of said probes by said fluorophores are selected using a fluorescence figure of merit function (R) for a candidate said fluorophore of the set, and wherein said fluorescence brightness figure of merit function is dependent on a degree of overlap between emission and absorption spectra of a said candidate said fluorophore.
[0039] In embodiments the fluorophores and/or degree-of-labelling of the fluorophores is selected to optimise subsequent signal detection and/or measurement and/or spectral deconvolution.
BRIEF DESCRIPTION OF DRAWINGS
[0040] These and other aspects of the invention will now be further described, by way of example only, with reference to the accompanying figures in which:
[0041] FIG. 1 shows a comparison of measured brightness data for Alexa (Registered Trade Mark, RTM, of Invitrogen Corp.) 488 (individual squares), Fluorescein-EX (circles) and Alexa® 546 (triangles), with calculated curves based on eq. 3b and the best-fit values for the parameters a and b given in Table 2, (GAM IgG Goat Anti-Mouse (secondary antibody conjugate) based on the G structural form of immunoglobulin for the Alexa® fluorophores, streptavidin for F-EX);
[0042] FIG. 2 shows a comparison of measured and calculated brightness data for Alexa® 350 (diamonds; streptavidin conjugate), Alexa® 555 (squares; GAR Table 1 conjugate (Goat Anti-Rabbit (secondary antibody conjugate)-, AMCA (fluorophore amino-methylcoumarin acetic acid) (crosses; streptavidin) and Cy3 (open circles; streptavidin conjugate: filled circles GAR conjugate;
[0043] FIG. 3 shows a comparison of measured and calculated brightness data for Oregon Green 514 (diamonds), Oregon Green 488 (squares), FITC (fluorophore fluorescein isothiocyanate) (circles) and Rhodamine Red-X (circles), (GAM conjugate in all cases);
[0044] FIG. 4 shows a comparison of measured (individual symbols) and calculated (full curves) brightness functions for Alexa® 647-labelled conjugates: crosses—streptavidin conjugate; squares—transferrin Transferrin (a protein) circles—concanavidin A; diamonds—GAR IgG; diagonal crosses—GAM IgG; the single theoretical curve is calculated for a=1.5, b=0.14;
[0045] FIG. 5 shows a comparison of measured (individual symbols) and calculated (full curves) brightness functions for Texas Red-X-labelled conjugates
[0046] FIG. 6 shows a comparison of measured and calculated brightness data for Alexa® 532 and Rhodamine 6G, both conjugated to GAM;
[0047] FIG. 7 shows a linear relationship between measured n peak and figure-of-merit R for GAM conjugates of Table 2; this figure allows the maximum of the brightness function S(n) to be estimated for any (GAM-conjugated) fluorophore for which a value of R can be constructed;
[0048] FIG. 8 shows apparatus implementing an embodiment of a technique according to the invention;
[0049] FIGS. 9 a to 9 c show, respectively, a microarray data scatter plot showing construction of a line of parity according to an embodiment of the invention, the plot of FIG. 9 a with fluorescence data corrected for inter-fluorophore fluorescence quenching based on fluorescence level prediction from the line of parity of FIG. 9 a , and a so-called MA plot (scatter plot with transformed axes) for the corrected data, also illustrating the imposition of a signal-to-noise (S/N) threshold; and
[0050] FIGS. 10 a to 10 d show, respectively, background noise from the HFF-PDS (Human foreskin fibroblasts, infected with the PDS strain of the parasite Toxoplasma gondii (a close relation of the organism which causes malaria)) data set folded modulo-28 illustrating artefacts due to fixed pattern noise, systematic noise arising from the division of one small digital number by another, results of a simulation illustrating how noise could be misinterpreted as gene expression, and a similar example showing real, raw microarray (from SMD data set 3932).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0051] Broadly speaking we will describe a model of the self-quenching of fluorescent emission and compare this with measurements of light yield versus degree-of-labelling for a number of fluorophores (dyes) commonly used in biology. The model is physically based on the emission and absorption of light by molecules of the same species. The model shows that the optimum degree-of-labelling corresponding to maximum light yield, is predictable from a combination of basic parameters of the fluorophore. However the maximum can also depend on the fluorophore's conjugate molecule. Extension of the model to multi-fluorophore systems is described, as is a method for determining degree-of-labelling signals in such systems, and procedures for the recovery of biological information in such systems in the presence of non-linearities.
[0052] In dye-labelled biological systems, the fluorescent signal I s is not always linearly related to the degree-of-labelling n—the number of fluorophores present per conjugate molecule. (In what follows,
[0000]
I
s
=
∫
λ
1
λ
2
i
(
λ
)
λ
[0000] formally denotes the integral of the wavelength-dependent emission function i over an output filter bandpass [λ 1 ≦λ≦λ 2 ]). The conjugate molecule is the biologically active protein or antibody to which the fluorophore is attached. The phenomenon of self quenching—the decrease in fluorescent signal observed for high labelling densities—is poorly understood [S. Hamann, J. F. Kiilgaard, T. Litman, F. J. Alavrez-Leefmans, B. R. Winther and Zeuthen, J. Fluorescence 12 (2002) 139], even though it leads in many cases to a well-defined degree of labelling (n=n peak ) for maximum brightness.
[0053] Of possible quenching mechanisms dynamic fluorescence quenching cannot be considered a universal process because it depends on collisional energy exchange with a quenching agent distinct from the fluorophore itself. Static quenching, by contrast, depends on the formation of non-emitting molecular complexes by the fluorophore and the quencher. The process of fluorescent resonant energy transfer (FRET), thirdly, requires the overlap of the donor emission spectrum and the absorption spectrum of the acceptor in a system whose two components are separated by only ˜nanometre distances.
[0054] Here, we assume that self quenching—leading to signal non-linearity—is primarily due to the absorption by the fluorophore molecules of their own emitted light. In other words, we suppose that, fundamentally, self-quenching arises from the overlap of the absorption and emission spectra in the same dye molecule in an otherwise transparent system. In what follows, we compare the predictions of our model with measurements of the brightness function S(n) reported in the literature, calculate n peak , the labelling density which corresponds to maximum signal.
[0055] Table 1 summarises the acronyms used below to denote specific fluorophores, conjugate molecules and reference standards for the estimation of quantum yield [R. F. Rubin and A. N. Fletcher, J. Luminescence 27 (1982) 445].
[0000]
TABLE 1
Acronyms of biological entities.
AMCA
Amino-methylcoumarin acetic acid (fluorophore)
CTMR
Carboxytetramethylrhodamine (reference standard)
DDAO
Dodecyldimethylamine Oxide (reference standard)
FITC
Fluorescein Isothiocyanate (fluorophore)
GAM IgG
Goat Anti-Mouse (secondary antibody conjugate)
based on the G structural form of immunoglobulin
GAR IgG
Goat Anti-Rabbit (secondary antibody conjugate)
S101
Sulforhodamine 101 (reference standard)
Calculation of Fluorescent Intensity
[0056] Consider the absorption of light from a monochromatic source of intensity I 0 (photons/cm 2 /s) and wavelength λ s in a dye-labelled biological sample whose thickness is d and whose volume is V. In a weakly absorbing system, the absorbance A due to the fluorophore may be written as either:
[0000] A=ε·d·C -(1a)
[0000] or
[0000] A=N·σ·d -(1b)
[0000] where:
ε is the extinction coefficient, in units of cm −1 Mol −1 C is the concentration, in Mol σ is the wavelength-dependent absorption cross-section, in units of cm 2 . N is the number of fluorophore molecules per unit volume
while, if dΩ is the solid angle which an ideal detector subtends at the sample and Q is the absolute quantum efficiency of the fluorophore, the signal intensity I s (detected photons/s) is:
[0000] I s =I 0 AQ[V/d][dΩ/ 4π] -(1c)
[0061] Eqs. (1a, b) express, for biologists and physicists respectively, the same underlying Beer-Lambert law. We see from eq. (1b) that it is the number of fluorophores per unit volume, N, which quantitatively determines the degree of absorption, but note from above that the parameter almost always reported in biology is n, the number of fluorophores per conjugate molecule, measured in Mol/Mol. The relationship between N and n, however, is simple and linear if M, the mass of the conjugate molecule (e.g. 52,800 Da for the protein streptavidin) is much greater than that of the fluorophore (e.g. 300-900 Da for the fluorophores below). With Min grams:
[0000] N=[n·N a ·ρ]/M -(2)
[0000] where:
N a is Avogadro's number and ρ is the effective density of the conjugate molecule
[0064] Substituting for A (from eq. 1b) and N (from eq. 2) in eq. (1c), we find, after some manipulation:
[0000] I s =I 0 nQN c σ[dΩ/ 4π]= I 0 S ( n ) N c σ[dΩ/ 4π] (3)
[0000] where N c is the number of conjugate molecules in the sample and the physical brightness function S(n)=nQ incorporates the possibility that the quantum efficiency depends on the degree of labelling, n.
[0065] This analysis suggests that the brightness function S(n) should be higher, for a given n value, the lower the mass of the conjugate molecule, since then there will be proportionately more fluorophores per unit volume, provided the density varies little between conjugates. This hypothesis is tested later.
Brightness Function
[0066] In order to estimate the form of S(n), we need to consider first the absorption of the source flux and, second, the reabsorption of the fluorescent emission by the same population of dye molecules. Applying eqs. (1b, 2), the probability of fluorescent light emission and the probability of reabsorption of that fluorescent photon within the sample are both proportional to n, the number of fluorophores per conjugate molecule. We write λ p (>λ s ) for the wavelength corresponding to the peak of the fluorophore's emission spectrum.
[0067] Thus, disregarding details of both the sample geometry and of the interaction of the fluorophore with its host molecule, the brightness function, in arbitrary units, is then found from the product of the production and reabsorption probabilities as follows:
[0000] S=[k 1 n][ 1− k 2 n] -(4a)
[0000] which is of the form:
[0000] S=an−bn 2 -(4b)
[0000] where: a=k 1 and b=ak 2 are characteristics of the fluorophore. A close identification of the former constant follows from the biological definition of brightness function:
[0000] S ( n )= n ·RQY( n ) -(5)
[0000] where RQY(n) denotes the relative quantum yield for a degree-of-labelling, n. From eq. (4b). it follows that:
[0000] Lim n→0 ( S ( n )/ n )=Lim n→0 RQY( n )= a -(6)
[0000] is Differentiating eq. (4b) we find that, if n peak is the value of n which corresponds to the maximum light yield, we have:
[0000]
n
peak
=
1
2
k
2
=
a
2
b
(
7
)
[0068] The optimum degree-of-labelling can therefore be estimated for any fluorophore for which the constants a and b (or simply k 2 ) have been determined. The same analysis gives the maximum useful labelling density, n zero , for which the signal is totally quenched:
[0000] n zero =2n peak -(8)
[0069] Thus, a defining characteristic of a fluorophore exhibiting self quenching by self-absorption is that the maximum degree of labelling is exactly twice the value corresponding to maximum light yield. Formally, this result is in conflict with the starting mathematical assumption of weak absorption and with the physical observation that, for most fluorophores, the absorption spectrum does not completely overlap the emission spectrum. The physical (above) and biological definitions of brightness function differ only by a multiplicative factor which is the absolute quantum yield of a reference standard (see below).
[0000] Comparison with Published Data
[0070] FIGS. 1 to 6 compare published S(n) data sets with calculations based on eqn. (4b). We see that, for determined values of a and b, the universal function derived from a “self-absorption” model of self quenching is well supported by measurements on a number of well-known dyes, conjugated to a variety of biomolecules [B. Randolph and A. S. Waggoner, Nucleic Acids Research 25 (1997) 2923; N. Panchuk-Voloshina and seven co-authors, J. Histochemistry and Cytochemistry 47 (1999) 1179; H. J. Gruber and seven co-authors, Bioconjugate Chem. 11 (2000) 696; J. E. Berlier and fourteen co-authors, J. Histochemistry and Cytochemistry 51 (2003) 1699; Invitrogen (formerly Molecular Probes Inc., Oregon) Online Handbook, Section 1 http://www.probes.com/handbook/sections/0001.html; C. Lefevre, H. C. Kang, R. P. Haugland, N. Malekzadeh, S. Arttamangkul and R. P. Haugland, Bioconjugate Chem. 7 (1996) 482]. The F-EX and Texas Red-X data sets ( FIGS. 1 and 5 respectively), in particular exhibit maximum light yields at half the degree of labelling corresponding to total quenching.
[0071] FIGS. 4 and 5 also indicate that maximum light yield occurs at higher n values for fluorophores conjugated to the protein streptavidin than for (much heavier) secondary antibody conjugates such as GAM (defined in Table 1). The masses of these antibodies are difficult to find in the literature, but a single heavy (H) chain of immunoglobin (Ig) with a mass of ˜50,000 Da alone weighs approximately the same as streptavidin. Thus, our prediction that the fluorescent signal should depend inversely on the mass of the conjugate molecule, appears confirmed. The other protein represented in FIG. 3 —Concanavidin A—is about twice as heavy at 104 kDa as streptavidin.
Prediction of the Self-Quenching Properties of New Fluorophores
[0072] It is useful to be able to predict the optimum degree of labelling for new fluorophores, given only basic physical data.
[0073] Returning to eq. (4), the fluorophore constant k 1 accounts for the details of the fluorescent light creation process and for the wavelength-dependent losses of fluorescent light in a given absorber geometry; it includes the subtleties of the chemical bonding between the fluorophore and its conjugate biomolecule. In terms of measurable quantities, therefore, k 1 is, as already demonstrated (eq. (6)), related to the quantum yield Q (fluorescent photons/absorbed photon), and to the maximum value of the extinction coefficient, ε max . The fluorophore constant k 2 , by contrast, should also account for the degree of overlap between the emission and absorption spectra of the fluorophore. One measure of this overlap is the value of the extinction coefficient at the wavelength of maximum emission, ε(λ p ). One may argue, therefore, that the combination of measurable quantities:
[0000] R=Qε max /ε(λ p ) -(9)
[0000] should track n peak , if the self-absorption model of self-quenching is correct.
[0074] In order to test this hypothesis, we use values of the absolute quantum yield Q, measured (ideally) for a common degree-of-labelling, n=1. Readily available efficiency values usually refer to the pairwise comparison of spectrally similar fluorophores and are measured relative to a reference standard (such as S101) for degrees-of-labelling chosen to match the absorbances of the fluorophore pair. Table 2 (below) gives the values for relative quantum yield RQY(n) and the correction factors used to arrive at the desired absolute quantum yield Q(n=1) via:
[0000]
TABLE 2
Derived model parameters for fluorophores conjugated to GAM IgG or
streptavidin (denoted G or S in the leftmost Column).
−(10)
Q
(
n
=
1
)
=
[
RQY
(
n
)
·
Q
ref
]
[
1
-
b
/
a
1
-
n
(
b
/
a
)
]
Extinction
Fluorophore/
Standard
Scale
Qrel
Qabs
Coefficent
Conjugate
a
b
a/2b
RQY(n*)
n
fluorophore
Qref
Factor
(n = 1)
(n = 1)
Ratio
R
Alexa 488 (G)[3]
0.82
0.045
9.11
0.6
5.3
Fluorescein
0.97
1.33
0.8
0.776
3.6
2.79
Alexa 532 (G)
1.75
0.255
3.43
0.59
3.7
Rhodamine
1.039
3.3
3.43
Alexa 546 (S)
0.4
0.026
7.69
1.25
4
CTMR
0.68
1.26
1.579
1.074
2.08
2.23
Alexa 594 (G)
5.0
0.53
4
S101
0.9
5
0
Oregon Green 488
0.73
0.037
9.86
0.43
5.5
Fluorescein
0.97
1.32
0.566
0.549
10
5.49
(G)
Texas Red-X (G)
0.78
0.125
3.12
0.27
3.9
S101
0.9
2.24
0.605
0.544
2.44
1.33
FITC (S)
0.54
0.035
7.71
0.23
4.4
0.97
1.31
0.30
0.29
8.33
2.43
Rhodamine Red-X
0.8
0.121
3.31
0.16
4.6
S101
0.9
2.79
0.45
0.40
2.54
1.02
(G)
Fluorescein EX
0.8
0.054
7.35
0.23
4.4
Fluorescein
0.97
1.33
0.31
0.297
8.33
2.47
(G)[3]
Alexa 568 (G)
0.37
4.2
S101
0.9
0
3.85
0
Oregon Green 514
0.63
0.018
17.5
1
1
0
1
1
1
1
5.5
5.5
(G)
Rhodamine 6G (G)
0.5
0.34
0.74
0.03
3
R6G
0.95
1
0.03
0.0285
9.23
0.26
Alexa 647 (G)
1.5
0.14
5.36
1
1
DDAO
1
1
1
2
2
[0075] Thus, we are able to construct, for eight fluorophores conjugated to GAM for which all the basic data is available, the relationship between n peak and the figure of merit R shown in FIG. 6 . Apart from one outlier, the relationship is linear, enabling us to predict values for n peak for two further fluorophores—Alexa® 568 and Alexa® 594—for which no estimate of R is available. For Alexa® 568, R=1.28, implying that the brightness function should have a maximum at ˜2 fluorophores/molecule. For Alexa® 594, R=2.39, implying a peak at n ˜4.
Extension to Two or More Fluorophores
[0076] If two fluorophores (subscripted 1 and 2) label the same conjugate molecule to degrees n 1 and n 2 respectively, and both fluorophores independently exhibit self-quenching due to self-absorption, the brightness function S will have the form:
[0000] S ( n 1 ,n 2 )= a 1 n 1 −b 1 n 1 2 +a 2 n 2 −b 2 n 2 2 −( c 12 +c 21 ) n 1 n 2 -(11a)
[0077] The term c 12 accounts for emission from fluorophore 1 being absorbed by fluorophore 2 while c 21 describes emission from fluorophore 2 being absorbed by fluorophore 1. In other words, there is likely to be mutual quenching observed in the two signal channels.
[0078] Typically, the fluorophores chosen for a dual labelling experiment have very distinct (absorption and) emission spectra. Measuring in a well-defined bandpass, one would therefore hope to see the signature of only one fluorophore of the pair, but our model indicates otherwise. In the bandpass appropriate to fluorophore number 1:
[0000] S 1 ( n 1 ,n 2 )= S ( n 1 )− c 12 n 1 n 2 <S ( n 1 ) -(11b)
[0000] and
[0000] ( I s ) 1 =I 0 S 1 ( n 1 ,n 2 ) N c σ 1 [dΩ/ 4π] -(11c)
[0000] with similar expressions for fluorophore number 2:
[0000] S 2 ( n 1 ,n 2 )= S ( n 2 )− c 21 n 1 n 2 <S ( n 2 ) -(11d)
[0000] ( I s ) 2 =I 0 S 2 ( n 1 ,n 2 ) N c σ 2 [dΩ/ 4π] -(11e)
[0079] A number of points emerge from this discussion, which have useful implications for the interpretation of (for example) DNA microarray data.
[0080] Even in the complete absence of spillover of the emission spectra between output bandpasses, dual (or, by extension, multiple) labelling experiments can be expected to exhibit inter-dependent signal intensities in the output channels because of mutual quenching. The fluorescent intensity from one fluorophore, its concentration held constant, is reduced by an increase in the concentration of a second fluorophore.
[0081] The signal intensities described in eqs. (11c) and (11e) therefore lead to underestimates of the “true” degrees of expression in a microarray experiment. Furthermore, if the fluorophores are ordered by increasing wavelength of maximum emission, then we expect that c 21 <<c 12 . In other words, the response of the red fluorophore in a dual labelling experiment should be less perturbed by the presence of the second species than that of the blue fluorophore.
[0082] The skilled person will also understand that the above considerations can be used to select two or more fluorophores for a kit of fluorophores for detector calibration. The fluorophores may, for example, be selected to optimise (maximum) the signal from each according to the above equations, optimally taking into account detector sensitivity.
[0083] These predictions can be subject to experimental test in the form of a dilution experiment, in particular with an STJ detector, use of a superconducting tunnel junction (STJ) detector permitting the registration of fluorescent spectra on a photon-by-photon basis from DNA labelled, in proportions ranging from 1:4 to 4:1, with both Alexa® 488 (emission in the 510-543 nm band of a triple band output filter) and Cy3 (emission in a longer wavelength band 607-659 nm). The counting rates in these two bands are summarised in Table 3 (below). The ratio of count rates follows the dilution ratio more or less linearly, although the dynamic range is only 6.4:1, rather than the 16:1 expected from the known amounts of fluorophore. Of more interest in the present context is the decrease (from 0.45 to 0.27 to 0.32 counts/second) in the Alexa® 488 signal as the amount of Cy3 present is increased above parity and the decrease in the Cy3 signal (from 1.85 to 0.8 to 1.39 counts/second) as the amount of Alexa® 488 increases. These results could be artefacts of subtle variations in the absolute amounts of dye present in the various samples, but the suppression of one fluorophore's signal intensity by the increased presence of a second fluorophore is also clearly embodied in eqs. (11a-e).
[0084] These results suggest that the full recovery of biological information from multiple fluorophore systems (such as microarrays) will benefit from preparatory calibration experiments of the kind summarised in Table 3, in order to account for non-linear behaviour due to self- and mutual quenching.
[0000]
TABLE 3
Alexa488/
Cy3 Ratio
4:1
2:1
1:1
1:2
1:4
Count rate in
0.88
0.27
0.45
0.27
0.32
short wavelength
band (s −1 )
Count rate in long
1.39
0.80
1.85
1.47
3.14
wavelength
band (s −1 )
Ratio
0.64
0.34
0.245
0.18
0.10
[0085] The skilled person will appreciate that the brightness function described above may be employed in a number of different methods. For example a value for c 12 (and optionally also c 21 ) may be determined by a calibration procedure in which the combined brightness function S is measured for a range of different values of n 1 and n 2 . Then a value for S(n 1 ,n 2 ) may be measured and, knowing c 12 , a value for S(n 1 ) may be determined; and similarly for S(n 2 ). Using equation 11a self-quenching may be taken into account (through b, which is related to k 2 ).
[0086] FIG. 8 shows a block diagram of a microarray scanner and analysis system 800 configured to implement an embodiment of the described method. The system includes a microarray scanner 802 employing a superconducting tunnel junction detector, coupled to an interface 804 which provides an output to a data processor 806 storing code for determining degree-of-labelling signals for an entity tagged with two different fluorophores, in accordance with equation with 9b. The output of this data processor is provided to a further data processor 808 to further analyse the fluorescence data from the microarray.
Application to Microarray Analysis
[0087] The desired result of an example two-colour microarray analysis is the identification of those genes which are significantly over- or under-expressed in a disease or experimental state relative to a normal or control state. The experimental state signal is represented by the fluorescent intensity in one colour channel (Green, represented by the fluorophore Cy3, in the example below) relative to the intensity in a second colour channel (Red, represented by Cy5). The crucial step in any microarray analysis, therefore, is to establish a line of parity—the locus of points where degrees of expression in the two channels—represented externally by the signal intensities—are equal. The above analysis suggests an unambiguous method to closely approximate the line of parity.
[0088] Let the ratio of experimental to control intensities be denoted G/R. Then:
[0000] G/R≈S G ( n )/ S R ( n )=[ a G n −( b G +c RG ) n 2 ]/[a R n−b R n 2 ] -(12)
[0089] This general expression is not particularly useful, since it is not easy to identify physical values of n in a microarray context, but one can identify two limiting cases which are useful—as n tends to unity, when:
[0000] G/R≈[a G −b G −c RG ]/[a R −b R ] -(13a)
[0000] and as n tends to infinity, when:
[0000] G/R≈[b G +c RG ]/[b R ] -(13b)
[0090] For any given fluorophore there are two wavelength-independent constants: a and b. In the above equations the subscript G denotes the green fluorophore (e.g. Cy3). The subscript R denotes the red fluorophore (e.g. Cy5). The values for a G , b G , a R and b R are determined independently from analysis of published curves of light yield versus degree-of-labelling. The remaining coupling constant (c RG ) expresses the mutual self-quenching between fluorophores and is a free parameter fixed by fitting to the data.
[0091] All the parameters in eqs. (13a, b) are known from the earlier characterisation of the individual Cy3 and Cy5 fluorophores, except c RG , which can safely be approximated by zero in the dilute case, eq. (13a), but not in the intensive case, eq. (13b). Thus, we have limiting expressions for the local line of parity, with only one free parameter to be fit to data (c RG ), and with no a priori assumptions regarding the biology of the system.
[0092] The procedure is illustrated in FIGS. 9( a,b ) using a dataset from the Stamford Microarray Database (SMD). The first 1000 genes (ex 23,000 total) from the dataset SMD 3932 are plotted in a (base 2) log-log space and the upper 900 and lower 902 “tangent” lines found from eqs. 13a, b with the values of the fluorophore parameters recorded in the inset and shown below:
[0000] a G =0.55
[0000] b G =0.044
[0000] a R =1.65
[0000] b R =0.55
[0000] c RG =0.4 (fitted)
[0000]
S
G
=K·S
R
[0000] For line 900 , k =( b G +c RG )/ b R
[0000] For line 902 , k =( a G −b G )/( a R −b R )
[0000] For line 904 , k=1
[0093] The overall line of parity is taken to be the diagonal straight line joining the bottom left (bottom of line 902 ) and top right (top of line 904 ) of the “box” containing the bulk of the data points.
[0094] FIG. 9( b ) shows the results of collapsing the data onto this line of parity, by subtracting on a point-by-point basis the difference between the measured Green signal intensity and that predicted from the Red signal intensity and a knowledge of the true line of parity. FIG. 9( b ) also shows that the best-fit to the first 1000 data points is good also for the next 1000 in the sequence (the different shaped data points represent two different 1000—point data sets).
[0095] Thus the above example uses the limiting cases of the fluorophore brightness function ratio S(n)Cy3/S(n)Cy5 to “box” the microarray data scatter plot. Joining the corners of the box gives a good approximation to the true line of parity, taking account of the non-linearity of the two fluorophore responses. Then the data is collapsed onto the nominal line of parity by calculating the difference in the y-axis between the data point and the line of parity established. FIG. 9 c shows an MA plot of the ln 2 ratio versus the control Cy5 signal, (not versus the average of Cy3 and Cy5, because if there is any gene expression averaging will make the x-axis noisier), after the transformation, with the identification of the unity signal-to-noise ratio S/N line (imposition of a unity S/N threshold). Optionally there may then be rejection of points based on systematic, for example, fixed pattern noise.
[0096] There is evidence for fixed pattern noise related to the 28×27 sub-array pattern of the microarray data for the system HFF-PDS (no. 3932). In FIG. 10 a , folding the data series modulo (in this example) 28 produces a cyclic deviation of the noise in signal channel 1 from its mean. Thus channels 8-10 and 25-28 in every cycle may be flagged as unreliable. There is also evidence at low signal levels for “preferred locations” associated with the division of one digital number by another. FIG. 10 b shows the 25 possible outcomes of dividing two integers in the range (8±2) one by the other. Further, the spread in signal levels at the low end is explicable by assuming exact parity (R=G) perturbed by Poissonian statistics in both channels. This is confirmed by the simulation shown in FIG. 10 c , although this produces what might be identified as “over” and “under” expressed genes.
[0097] FIG. 10 c provides a model template to which the real data can be transformed. FIG. 10 d shows the raw 3932 data set overlaid on this template.
[0098] An analysis therefore preferably includes a systematic error analysis and correction, in particular one or more of: removal of data points corresponding to fixed pattern noise locations, in particular Modulo x elimination of data points corresponding to fixed pattern noise locations (in the example above, x=28); an approach as described above which aims for (objective) minimisation of the match between theoretical and measured Ln(G/R) versus Ln(R) patterns (R and G comprise first and second colour, eg. Red and Green, signal data).
[0099] On closer examination it turns out that the modulo-x (e.g. 28) fixed pattern noise effect is not the most effective discriminant against “falsely expressed” genes. If the pin array has a size χ×y (27×28) or modulo χy (e.g. 756) cycle—which has been confirmed experimentally: The modulo 28 effect is observable as a small ripple, but there is also a repeating “wave” and “giant excursions” occur in the same parts of the cycle. Thus a more efficient way of reducing fixed pattern noise than simply rejecting “every 28 th event” is to reject every event with a mean noise value greater than a threshold or outside a determined range e.g. 200-550 (say) in both Channel 1 and Channel 2.
[0100] Imposing the requirement that the mean noise be less than a threshold level, say 550, reduces the number of apparently under-expressed genes above the S/N=1 level of ˜8 bits, almost to zero. Imposing the condition that the mean noise level should not fall below a threshold level, e.g. 200 has a similar effect on the over expressed genes. No doubt many other effective alternatives will occur to the skilled person. In particular application of the techniques we describe are not limited to use with STJ-type detectors.
[0101] The techniques we describe may also be applied to: correcting fluorescence images from comparative biochemistry carried out in microtitre plates, including experiments involving whole or live cells, for example for high throughput drug discovery. Also to fluorescence imaging of whole or live cells or synthetic particles with fluorophore tagged moieties attached in biological experiments involving flow cytometry. Also to tissue and whole cell imaging by fluorescence microscopy or confocal microscopy down to the level of single molecule detection, particularly for example for the identification of the very earliest stages of the development of cancers. The spatial location and movement of individual proteins in whole cells is under early development for both basic biomedical research and for drug discovery. Most whole cell experiments are currently qualitative in nature, but there will be an increasing demand for quantitative imaging, which will require understanding and correction for coupling and energy transfer between fluorophores. Similarly in an important area of future research, at present in its infancy, which involves the characterisation of the autofluorescence of biomarkers, particularly in whole cells.
[0102] It will be understood that the invention is not limited to the described embodiments and encompasses modifications apparent to those skilled in the art lying within the spirit and scope of the claims appended hereto. | Fluorescence Labelling This invention generally relates to techniques for fluorescence labelling, and to methods, apparatus and computer program code for processing fluorescence signal data. A method of determining respective first and second degree-of-labelling signals for different respective first and second fluorophores associated with a common entity, the method comprising: determining a first fluorescence signal from said first and second fluorophores under first conditions; determining a second fluorescence signal from said first and second fluorophores under second conditions different to said first conditions; and determining said first and second degree-of-labelling signals for said first and second fluorophores from said first and second fluorescence signals; and wherein said determining of said first and second degree-of-labelling signals is responsive to at least one coupling value (c 12 ; c 21 ) representing a coupling of energy between said fluorophores. | 6 |
[0001] This application is concurrently filed together with commonly owned related application entitled, A Method for Retrieving Information From an Information Repository, Serial No. ______ filed Mar. 9, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for processing information from an information repository, and in particular to a method for presenting information from the repository in a form more readable by humans.
BACKGROUND OF THE INVENTION
[0003] Use of computerized databases as information repositories has increased tremendously in the recent past. Such databases are used to store all sorts of information. In order for all the stored information to be useful, a user must be able to find desired information quickly and accurately and then that information must be displayed in a manner which is easily and completely understandable to the user. As the amount of information stored in databases has increased, the difficulty of finding and displaying desired information from among the stored information has also increased.
[0004] Finding desired information involves allowing a user to be able to enter a search criteria and have a computer system analyze the search criteria and the contents of the database to find information which satisfies the entered criteria without missing any information which satisfies the criteria and also without including any information which does not satisfy the criteria. This is not a simple problem. To solve this problem, much work has been done to derive processes to retrieve desired information from such databases.
[0005] Information stored in some databases is meant to be read by humans. Such information includes textual or graphical information related to all areas of human endeavor, such as informational articles, books, photographs, illustrations, stories, opinions etc. Other such information is numeric information related, for example, to demographics, statistics, scientific analysis, business management, etc. All of this information is of interest only to humans, and must be retrieved and displayed in human readable form. Display of information meant to be read by humans in a form readable by humans is seldom a problem. Instead, retrieval is the problem. The main problem of retrieval processes for this type of information is to properly interpret the search criteria entered by the user and to properly find only relevant information and reject irrelevant information. Much work has been done in this area. See, for example, U.S. Pat. Nos. 5,421,008, issued May 30, 1995 to Banning et al. and entitled SYSTEM FOR INTERACTIVE GRAPHICAL CONSTRUCTION OF A DATA BASE QUERY AND STORING OF THE QUERY OBJECT LINKS AS AN OBJECT; 5,701,456, issued Dec. 23, 1997 to Jacopi et al. and entitled SYSTEM AND METNOD FOR INTERACTIVELY FORMULATING DATABASE QUERIES USING GRAPHICAL REPRESENATIONS; 6,094,648 issued Jul. 25, 2000 to Aalbersberg and entitled USER INTERFACE FOR DOCUMENT RETRIEVAL; 6,345,273 issued Feb. 5, 2002 to Cochran and entitled SEARCH SYSTEM HAVING USER-INTERFACE FOR SEARCHING ONLINE INFORMATION; and 6,026,388 issued Feb. 15, 2000 to Liddy et al. and entitled USER INTERFACE AND OTHER ENHANCEMENTS FOR NATURAL LANGUAGE INFORMATION RETRIEVAL SYSTEM AND METHOD.
[0006] However, information stored in other databases is used within equipment and systems, and especially within computer-controlled equipment and systems, to store information necessary to operate the equipment. Such information is not inherently of interest to humans, but instead contains, for example, data, characteristics, and/or parameters used for controlling the operation of the equipment. Nevertheless, it is still necessary for a human to interact with the database. For example, initial data and data for controlling a new operational mode of the equipment or system must be entered into the database. In this case, data must be requested from the user in human readable/writable form, and then converted to machine usable form and stored in the database. Further, it is sometimes necessary for a user such as a technician to analyze the data already existing in the database to either change an existing operational mode or to optimize the database itself. In this case, information in the database must be retrieved, converted from machine usable form into human readable form.
[0007] There are usually relationships among data stored in a database. That is, some data is especially related to each other. For example, some portion of the data and parameters can be described as a linear relationship, such as data defining and controlling input, process and output processes. Other data can be related to each other hierarchically. Still other data can be related to a common feature or characteristic. Yet other data can be related to mapping between different data elements. Analysis of such data by a technician would generally involve seeking and recognizing such relationships.
[0008] One example of such a database system is the OPENLink system produced by Siemens Medical Systems, Inc. The OPENLink system is an application for facilitating exchange of data among different electronic data systems. One electronic data system transmits data to the OPENLink system in a predetermined data format via a specific communications medium and protocol acceptable to the transmitting system. The OPENLink system, in turn relays this data to a second electronic data system. The second electronic data system receives the data in a predetermined data format via a specific communications medium and protocol acceptable by the receiving system. The data format, communications medium and protocol of the receiving system are not necessarily the same as those of the transmitting system.
[0009] The OPENLink System includes a database containing a plurality of around 60 data tables containing the data required to control the processing necessary to receive, transform (if required) and transmit data among electronic data systems. In the OPENLink system, the database information necessary to perform one data communications task, from one electronic data system to another, is termed an interface. The database contains information related to a plurality of interfaces, and typically contains thousands of pieces of information, stored in the data tables in a format appropriate to control the functioning of the OPENLink system, but not for human analysis.
[0010] The OPENLink system includes a toolkit application which is used to solicit information from a user related to a new interface. Information entered by the user defines the data formats, communications media and/or protocols for the new interface, and any data conversion necessary. The solicited information is then converted into internal machine usable form and stored in the tables in the database. This toolkit application may also be used to edit the information related to a single interface at a time. However, there is no corresponding tool for analyzing the current contents of this database.
[0011] Because the information stored in such databases is not inherently of interest to humans, it is usually formatted and stored in the database a manner which allows the most efficient operation of the equipment or system. This format is most likely not in a form easily readable by humans. This makes it difficult for a human to interact with the information already stored in the database. Work has been done to allow a human to easily query information in a database and display the retrieved information.
[0012] One method for extracting and displaying information from a database is to use the OPENLink toolkit application. Use of this application presents the information to the technician in a form which is coordinated with the use of that information in the OPENLink system. In addition, this application provides protection from inadvertently changing the data in the database. However, as described above, this permits inspection and editing of database information related to only limited portions of a single interface at a time, and therefore does not permit the user to see relationships among data related to a plurality of interfaces. Thus, in order for a technician to see overall relationships, information related to each individual interface must be accessed separately, making this a slow tedious job.
[0013] Another method for extracting and displaying information from a database is to use a general purpose database management program, such as Paradox, manufactured by Corel Corporation, or Access, manufactured by Microsoft Corporation. Such products can access tables in a database and create a datasheet or data table view of the tables. Alternatively, such products can be used to generate reports on the database tables using filters and relating information in different tables. The user may then look through the displayed forms, tables or reports to identify parameters and relationships within a table or among tables. However, using this method requires a high level of knowledge about the OPENLink system and the database management program. In addition, the general purpose database management systems access the actual tables in the OPENLink database system, making it possible for a user to inadvertently change data in the database tables. Even worse, such a change may be made without coordination with other related data in the database, which would be provided by the OPENLink toolkit application. While the latter problem may be solved by using a copy of the database, copies of the tables run the risk of becoming outdated if they are not timely synchronized. Finally, this technique does not show database information in context with the information's characteristics and relationships, stored in the database.
[0014] Further work has been performed to enhance the ability to extract and display information from a generic database. For example, U.S. Pat. No. 6,246,410, issued Jun. 12, 2001 to Bergeron et al. and entitled METHOD AND SYSTEM FOR DATABASE ACCESS discloses a system for extracting, displaying and either replacing or updating the contents of a database table. When first invoked, an existing table may be selected, and the fields in the selected table are displayed for a user, who can select fields of interest and even associate an icon with those fields. Then, in use, a palette containing the icons related to the selected fields is displayed, and the user may drag data to or from those icons to transfer data either to or from the database and/or to manipulate the data in the database table. This method is limited to a single table. It also does not show relationships among data in the same or different tables, nor the characteristics of the data. Also, this method accesses the active data in the table, making it possible for a user to inadvertently change the data.
[0015] U.S. Pat. No. 6,038,558, issued Mar. 14, 2000 to Powers et al., and entitled EXTENSIBLE DATABASE RETRIEVAL AND VIEWING ARCHITECTURE discloses a system for accessing information in a database according to a user produced plan. This plan can include retrieval, processing and storage steps. This patent further discloses a method for generating steps which may be incorporated into the plans. This system may be adapted to information in multiple tables in a database. However, this patent does not disclose any specific steps, and in particular, does not disclose any steps for determining relationships among the data in the database.
[0016] A system which can access information in a database which is not inherently meant for humans, which can derive and sort data in a database, which can identify relationships among data stored in the database, which can display the data and relationships in a manner easily understood by humans, and which is protected against inadvertent change of data in the database is desirable.
BRIEF SUMMARY OF THE INVENTION
[0017] In accordance with principles of the present invention a method for deriving and sorting information from an information repository including data elements individually associated with corresponding record identifiers, includes the following steps. First, the repository information is parsed to identify relationships, including a common name portion between record identifiers to identify a relationship between corresponding data elements of said repository. Sorting identifiers, indicating related data elements, are created and collated. Information is then retrieved from the repository information in a desired order using the sorting identifiers.
BRIEF DESCRIPTION OF THE DRAWING
[0018] In the drawing:
[0019] [0019]FIG. 1 is a diagram similar to an entity-relationship diagram illustrating various information stored in a database and showing relationships among the information;
[0020] [0020]FIG. 2 is a data flow diagram illustrating an overview of the method of the present invention;
[0021] [0021]FIG. 3 is a more detailed data flow diagram illustrating details of the method of the present invention;
[0022] [0022]FIG. 4, FIG. 7 and FIG. 9 are screen displays of dialog boxes generated according to the method of the present invention;
[0023] [0023]FIG. 5 is a data storage diagram of information in a portion of the database illustrated in FIG. 1 useful in understanding the operation of the method of the present invention;
[0024] [0024]FIG. 6 is a diagram illustrating a portion of a display of information from the database in hierarchical form;
[0025] [0025]FIG. 8 and FIG. 10 are diagrams illustrating portions of a report of information related in an input-output form.
DETAILED DESCRIPTION OF THE INVENTION
[0026] [0026]FIG. 1 is a diagram similar to an entity-relationship diagram illustrating a portion of the information stored in an OPENLink system database 100 and showing information entities and relationships among the entities. One skilled in the art of database design and implementation will understand that the information in the database is stored in a plurality of tables, and that there is no inherent relationship among the tables, such as is illustrated in FIG. 1. These relationships are developed by the database designer when designing the structure of the database, and then imposed by access programs, such as the OPENLink toolkit application described above.
[0027] In FIG. 1, each rectangle, or set of rectangles, represents information defining or related to a common entity, each entity containing a plurality of entries, and each entry containing a plurality of data elements. Lines between entities represent relationships between the connected entities. An indicia ‘1-M’ on a line indicates a one-to-many relationship, meaning that each entry in the originating entity can be related to multiple entries in the terminating entity; an indicia ‘M-1’ indicates a many-to-one relationship, meaning that multiple entries in the originating entity can be related to one entry in the terminating entity; and an indicia ‘M-M’ indicates a many-to-many relationship, meaning that each entry in the originating entity can be related to multiple entries in the terminating entity, and each entry in the terminating entity can be related to multiple entries in the original entity, all in a known manner.
[0028] As described above, the OPENLink database 100 contains information related to a plurality of interfaces 102 . Each interface entry 102 contains, or ultimately is related to, all the information necessary to transfer data from one electronic data system to another electronic data system, as described above. Also as described above, each interface 102 comprises data related to receiving data from the first electronic data system in a predetermined data format, over a predetermined connection via a predetermined protocol, and transmitting that data to the second electronic data system in a second predetermined data format, over a second predetermined connection via a second predetermined protocol.
[0029] In FIG. 1, each interface entry 102 is related to one or more transaction entries 106 , and each transaction entry 106 can be related to one or more interface entry 102 . More specifically, each interface entry 102 is related to one source transaction entry 106 and one destination transaction entry 106 . Each transaction entry 106 , in turn, is related to data defining the data format of either the received data or the transmitted data, in a manner to be described in more detail below. Each interface entry 102 is also related to a single event path entry 104 and each event path entry 104 can be related to multiple interface entries 102 . Each event path entry 104 can be related to multiple transaction entries 106 . More specifically, the event path entry 104 contains information specifying which transaction entry 106 is the source transaction 106 for that interface entry 102 and which transaction entry 106 is the destination transaction entry 106 for the related interface 102 entry.
[0030] Each transaction entry 106 is related to one or more segment entries 108 , and each segment entry 108 can be related to one or more transaction entries 106 . Each segment entry is related to one or more field entries 110 . Each field entry 110 is related to one or more component entries 112 . Each component entry 112 is related to one or more sub component entries 114 . The segment 108 , field 110 , component 112 , and sub component 114 entries all relate to the data format of the related transaction entry 106 , and are related in a hierarchical manner from the segment 108 at the highest level to the sub component 114 at the lowest level.
[0031] Each interface entry 102 is also related to one or more map entries 116 , and each map entry 116 may be related to one or more interface entries 102 . Each map entry 116 is also related to one or more entries in the respective transactions 106 , segment 108 , field 110 , component 112 and sub component 114 entities. More specifically, one map entry 116 specifies the data format defining entries in the respective transactions 106 , segment 108 , field 110 , component 112 and sub component 114 entities for the source transaction 106 , and a second map entry 116 specifies the data format defining entries in the respective transactions 106 , segment 108 , field 110 , component 112 and sub component 114 entities for the destination transaction 106 . All of this related information is used to convert the data format from the transmitting system to the data format of the receiving system.
[0032] Each interface entry 102 is also related to one or more connection entries 118 , and each connection entry 118 can be related to one or more interface entries 102 . Each connection entry 118 is related to one or more protocol entries 120 , and each protocol entry 120 may be related to one or more connection entries 118 . The information contained in or pointed to by the connections entity 118 relates to the communications media. The information contained in or pointed to by the protocol entity 120 all relates to the protocol used to transmit data transmitted over the communications medium.
[0033] The present invention solicits instructions from a user related to the type of information desired, then extracts and analyzes data from the database, and displays the desired information in a manner easily understood by the user. The process of analysis and extraction includes not only the data in the database 100 , but also the relationships among the data and the characteristics of the data, in a manner to be described below.
[0034] [0034]FIG. 2 is a data flow diagram illustrating an overview of the method 200 of the present invention. In FIG. 2, the OPENLink database 202 is actively coupled to a dynamically maintained image 204 of that database. This dynamically image 204 of the database 202 is not a copy, but an image for which all changes made to the database 202 by any means outside of the method of the present invention are automatically reflected in the image 204 . However, any changes made by the method of the present invention are not reflected back to the original database 202 . This protects the database from inadvertent changes while allowing the data display always to include the latest data.
[0035] The image database 204 is analyzed by the method of the present invention, in a manner to be described in more detail below, to generate reference tables 206 . Information in these reference tables is then used to access further information in the database image 204 , and the data in the reference tables 206 are combined 208 with the further information from the database image 204 to generate human readable output 210 for the user. The user output 210 may be in the form of a display of a data form, a data table, or a hierarchical directory listing on a display device, such as a computer monitor, or a print out on paper. The display may also be stored in digitized form in a file for future review and analysis by the user.
[0036] [0036]FIG. 3 is a more detailed block diagram illustrating details of the method 200 of the present invention. In FIG. 3, those steps which are the same as those illustrated in FIG. 2 are designated by the same reference number and are not described in detail below. In FIG. 3, in step 302 , data is solicited from the user to select an interface entry 102 (of FIG. 1) from among the plurality of interface entries 102 in the interface table 102 . FIG. 4 is a screen display of a dialog box 400 used for step 302 . In FIG. 4, a text combo box 402 allows a user to specify a desired interface. The arrow at the right side of the combo box 402 , when pressed, displays a list of all the interface entries 102 in the OPENLink database image 204 . The user may select one of the interfaces 102 from this list, or type in the name of the desired interface 102 in the text portion of the combo box 402 . The text combo box 404 solicits information from the user indicating where the results of the analysis are to be displayed and/or stored. The arrow to the right of the combo box 404 displays a list of possible destinations, and the user may select from that list. Text combo boxes 406 and 408 solicit user information related to the type of report desired. Respective arrows allow the user to select from lists of possible report types. A button 410 allows a user to select a different OPENLink database to analyze.
[0037] As described above, transaction entries 106 (of FIG. 1) have a many-to-many relationship with interface entries 102 . Information in the event path table 104 contains the names of the inbound, or source, transaction entry 106 , and the outbound or destination transaction entry 106 related to each interface entry 102 . Two queries of the event path table 104 are executed: one to identify source transaction entries by interface; and one to identify destination transaction entries by interface. The results of these queries are saved for reference in later processing. Information in the association table 304 includes all information relating records from one table to corresponding records in another table. More specifically, the association table 304 contains data which relates segment entries 108 (of FIG. 1) to transaction entries 106 . A query is executed on the association table 304 to list segments by transaction. This information is also saved for reference in later processing.
[0038] Because, as described above, the information in the segment 108 , field 110 , component 112 and sub component 114 tables are not inherently related, no information is stored anywhere giving their hierarchical relationship. One skilled in the art, referring to FIG. 1 will understand that each segment is a collection of fields, each field is a collection of components and each component is a collection of sub components. The method of the present invention analyzes the data in the database image 204 to determine the hierarchy implied by this arrangement. This is done by constructing an index based on the stored information representing the relationships between the segments 108 , fields 110 , components 112 and sub components 114 .
[0039] [0039]FIG. 5 is a data storage diagram of information in a portion of the database image 204 illustrated in FIG. 2 and FIG. 3 useful in understanding the operation of the method of the present invention. FIG. 5 a illustrates a portion of a segment table entry 108 , FIG. 5 b illustrates a portion of a field table entry 110 , FIG. 5 c illustrates a portion of a component table entry 112 and FIG. 5 d illustrates a portion of sub component table entry 114 . Only those portions of the table entries in FIGS. 5 a - d which are necessary to understand the present invention are illustrated. In FIG. 5, each entry is illustrated as a row. Each row consists of one or more columns each containing a data element in which the name of the data element is on top and the value of the data element is on the bottom. Although shown contiguously in a particular order at the beginning of the row in FIG. 5, one skilled in the art will understand that the illustrated columns may be located in the row at any location, in any order, and may have other columns (not shown) placed between them.
[0040] In FIG. 5 a , the segment table entry 108 contains a “Seg Name” column which contains the name of the segment, “Alpha” which identifies this record. In FIG. 5 b , the field table entry 110 contains a “Field seg name” column which contains the name of the segment to which this field belongs, “Alpha”; and also a “Field ID” column which contains a field identification (ID) number, “2”, which indicates that this field is the second field in its segment. In FIG. 5 c , the component table entry 112 contains a “Comp seg name” column which contains the name of the segment to which this component belongs, “Alpha”; a “Comp Fld ID” column which contains the ID number of the field to which this component belongs, “2”; and also a “Comp ID” column containing a component identification number, “3”, which indicates that this component is the third component in its field. In FIG. 5 d , the sub component table entry 114 contains a “Sub comp seg name” column which contains the name of the segment to which this sub component belongs, “Alpha”; a “Scm Fld ID” column which contains a field ID number, “2”, which indicates the ID number of the field to which this sub component belongs; a “Scm Cmp ID” column which contains a component ID number, “3”, which indicates the ID number of the component to which this sub component belongs; and also a “Scm ID” column which contains a sub component identification number, “1”, which indicates that this sub component is the first sub component in its component. This arrangement is very efficient, and easily used by electronic equipment, but does not store information in a human readable form.
[0041] To generate a hierarchical listing of the entries in these i tables, an index is created by forming unique sorting identifiers, or keys, for all the specified records in these tables, then merging the sorting identifiers into a new reference table, called the data elements table and sorting that table. First, each ID number in the respective tables is reformatted into a common format. More specifically, the ID numbers are reformatted into numbers having the same number of digits. Zeroes are prepended to pad any shorter numbers out to the desired number of digits. That is, if the desired number of digits is three, “2” is padded with prepended zeroes to make “002”. One skilled in the art will understand that ID numbers referring to different tables may be padded to different numbers of digits. That is, the field ID numbers may be padded to three digits, while the component ID numbers and sub component ID numbers may be padded to two digits, for example.
[0042] Then a unique sorting identifier is generated for each entry in each table in the following manner. For the segment table entries 108 , the sorting identifier is an indicator consisting of the segment name stored in the “Seg Name” column. For the field table entries 110 , the sorting identifier is an indicator consisting of the concatenation of the field segment name in the “Field seg name” column and the padded field ID number in the “Field ID” column, separated by a “*” character. For the component table 112 , the sorting identifier is an indicator consisting of the concatenation of the component segment name in the “Comp seg name” column, the padded component field ID number in the “Comp Fld ID” column, and the padded component ID number in the “Comp ID” column, all separated by “*” characters. For the sub component table 114 , the sorting identifier is an indicator consisting of the concatenation of the sub component segment name in the “Sub Comp seg name” column, the padded component sub component field ID number in the “Scm Fld ID” column, the padded sub component component ID number in the “Scm Cmp ID” column, and the sub component ID number in the “Scm ID” column, all separated by “*” characters.
[0043] More specifically, the sorting identifier for FIG. 5 a is “Alpha”, the sorting identifier for FIG. 5 b is “Alpha*002”, the sorting identifier for FIG. 5 c is “Alpha*002*003”, and the sorting identifier for FIG. 5 d is “Alpha*002*003*001”. All of the sorting identifiers are merged into a single entity, which may be a table, a file or a directory. In the illustrated embodiment, the sorting identifiers are merged into a table, called the data element table 306 , illustrated in FIG. 5 e. Then they are sorted alphanumerically. When these sorting identifiers are sorted alphanumerically, the associated entries in the respective tables represented by those sorting identifiers are automatically sorted into hierarchical order, as illustrated by the data elements table 306 in FIG. 5 e . The data elements table 306 is one of the reference tables 206 illustrated in FIG. 2 and FIG. 3. The sorting identifiers are also stored in respective “Sort ID” columns, designated for the sorting identifier, in each of the segment entry 108 (FIG. 5 a ), field entry 110 (FIG. 5 b ), component entry 112 (FIG. 5 c ) and sub component entry 114 (FIG. 5 d ) in the image database 204 . By storing the sorting identifiers in their associated entries, pointers may be generated which point to the associated entries in the corresponding data tables, thus enabling retrieval of other data elements, characteristics and parameters from the record pointed to.
[0044] [0044]FIG. 6 is a diagram illustrating a portion of a display of information from the database in hierarchical form. As may be seen from FIG. 6, the display of hierarchical information is in order from top to bottom, with subordinate data indented to show its level. As may be seen at the left side of the heading, the source transaction is named “GENERIC ORDER” 0 602 , and the segment name is “ORDER_DATA_SEC” 604 . The remainder of the page is a list of field names, component names and sub component names, also as illustrated at the left side of the heading. More specifically, at the top of the list, a field 606 in the segment ORDER_DATA_SEG is ORDER START TIME. A component 608 of that field is ORDER START TIME_COMP. A first sub component 610 of that component is HOURS, and a second sub component 612 of that component is MINUTES. The remainder of the heading provides column headings for other information which may be found in the entries for the listed field, component and sub component. For example, the top most sub component 614 , ORDER START YY, is related to the transaction table entry 2_CHAR_YEAR 616 . Such a display allows a user to easily see the hierarchical relationships among all the data in the segment 106 , field 108 , component 110 , and sub component 112 tables.
[0045] It is further possible to generate a display of information in the OPENLink database related by being in the same class of data elements. In the OPENLink database all data elements of the same class are stored in a single table, regardless of what other information those data elements are related to. For example, all data elements containing information about characteristics of all fields in the database are stored in the fields table 110 . Similarly, all data elements containing information about characteristics of all connections are stored in the connections table 118 and all data elements containing information about characteristics of all protocols are stored in the protocols table 120 . Thus, to generate a list of all data elements of the same class, a listing of the information in the table containing information of that class may be extracted, sorted (if desired) and displayed.
[0046] It is also possible to generate a display of information from the OPENLink database related by being in an input-output relationship, for example, input and output connections and/or protocols. As described above with reference to FIG. 1, the interface table 104 is in a many-to-many relationship with the connections table 118 . As described above with reference to FIG. 3, the association table 304 contains information for all associations in the database image 204 . More specifically, the association table contains data relating each interface table entry 102 to a source connection entry 118 and to a destination connection entry 118 . Two queries are performed on the association table: one for source connections by interface, and a second one for destination connections by interface. The results of these queries are stored for later reference.
[0047] Each entry in the connection table 118 , in turn, is in a many-to-many relationship with the protocols table 120 . That is, each connection may receive data in different protocols. In the illustrated embodiment, each connection is related to at least a primary and alternative protocol. The association table also contains data relating each entry in the connection table entry 118 to one or more protocols table entries 120 . Two queries are performed on the association table: one for source protocols by connection and a second one for destination protocols by connection. The results of these queries are stored in the connections and protocols table 310 , which is a part of the reference tables 206 .
[0048] Referring again to FIG. 4 the user may request a report related to connections and protocols by clicking a “Go!” button 412 next to the dialog box 408 specifying the “Connections and Protocols” report. In response, source and destination connections information, and protocols information related to those connections, all related to the selected interface, is displayed. FIG. 7 is a screen display of a dialog box 700 displaying the currently selected interface 102 (of FIG. 1) in text box 702 . The source and destination connection entries 118 for this interface are displayed in text boxes 704 and 706 respectively. In addition, the primary protocol and alternate protocol (if any) for both the source connection entry and destination connection entry are illustrated in text boxes 708 , 710 , 712 , and 714 . The source and destination connections and protocols are displayed side-by-side to illustrate their relationship.
[0049] Other controls on the dialog box 700 allow the user to find more information about the displayed connections and protocols. For example, source display button 716 and associated print check box 718 , and destination display button 720 and associated print check box 722 allow the user to display or print the parameters of the associated connection. Tab buttons 724 and associated print/save check boxes 726 permit a user to display, print and/or save respective listings of further information, characteristics, and parameters related to the displayed connections. Interface button 728 permits the user to select a different interface, as illustrated in FIG. 4. Protocols button 730 permits the user to display information related to the displayed protocols in a manner to be described in more detail below. Batch print and batch save buttons 732 and 734 permit the user to print and save information in batch mode.
[0050] The user may request a display of properties of the related source and destination connections 118 . FIG. 8 illustrates a display 800 of information relating the source and destination connections. In the heading, the name of the interface is listed 802 . The left hand column 804 of FIG. 8 lists the property name, the middle column 806 lists the values of the properties for the source destination, and the right column 808 lists the values of the properties for the destination connection. At the top of the middle column 806 and right column 808 are the names of the source 810 and destination 812 connection entries.
[0051] Referring again to FIG. 7 the user may request a report related to protocols by clicking the “Protocols” button 730 . In response, protocol information related to the displayed connections is displayed. FIG. 9 is a screen display of a dialog box 900 . Those elements which are the same in FIG. 9 as in FIG. 7 are designated by the same reference number and are not described in detail below. The upper portion of the dialog box 900 is the same as that illustrated in FIG. 7 The lower part includes controls for displaying information related to the displayed protocols. A radio button control 902 allows a user to select one of the displayed protocols. The name of the selected protocol is displayed in the text box 904 .
[0052] Other controls on the dialog box 900 allow the user to find more information about the displayed protocols. For example, the buttons 906 in the “Protocol parameters” section 908 allow a user to select data, characteristics, and/or parameters of the selected protocol to display. The corresponding check boxes 910 permit the user to mark the selected data, characteristics, and/or parameters to be printed or saved. The batch print button 732 will print a report listing the data, characteristics, and/or parameters whose corresponding check boxes 910 have been checked, and the batch save button 734 will save the selected data, characteristics, and/or parameters to a file.
[0053] [0053]FIG. 10 illustrates a display 1000 of information relating the source protocol. In the heading, the names of the interface 1002 ; the source connection 1004 ; the destination connection 1006 ; and the protocol type 1007 are all displayed. In FIG. 10, the protocol is a TCP/IP protocol. The left hand column 1008 of FIG. 10 lists the property name, and the right column 1010 lists the values of the properties for the destination connection. The name of the protocol 1012 is displayed at the top of the right column 1012 .
[0054] One skilled in the art will understand that the process described above is performed automatically. No data need be manually entered by a user. Instead, when user input is solicited, the user selects entries from a series of lists, checks boxes or radio buttons, or clicks buttons presented to him. In addition, no changes are made to the actual OPENLink database. Instead, only the image of the database is manipulated, although any changes made to the actual database are immediately reflected in the image database. | A method for deriving and sorting information from an information repository including data elements individually associated with corresponding record identifiers, includes the following steps. First, the repository information is parsed to identify relationships, including a common name portion between record identifiers to identify a relationship between corresponding data elements of said repository. Sorting identifiers, indicating related data elements, are created and collated. Information is then retrieved from the repository information in a desired order using the sorting identifiers. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of Federal Republic of Germany Application No. P 40 01 817.2 filed Jan. 23, 1990, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for feeding fiber tufts such as cotton or chemical fiber tufts to a fiber processing machine such as a card, a roller card unit, a cleaner or the like.
The apparatus has a reserve chute chargeable with fiber tufts, a take-in mechanism such as a slowly rotating feed roll, a countersupport cooperating with the feed roll for forming a nip to advance the fiber material therebetween, an opening device, such as a rapidly rotating opening roll arranged immediately downstream of the feed roll and a feed chute which receives the fiber material from the feed roll and the opening roll.
In a known device where the gap defined by the feed roll and the countersupport is constant (for example, 5 mm), only a predetermined fiber flow rate, for example, 360 kg/h per m width may be achieved. Further, upon changes in the type of the fiber material and the behavior of the fiber, problems are often encountered concerning the clamping in the nip defined by the feed roll and the countersupport, since the clamping behavior differs dependent upon the hardness or softness of the fiber material.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, achieves an alteration of the fiber material quantity passing through the nip defined by the feed roll and the countersupport and, at the same time ensures a secure clamping of the fiber material.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber tuft feeder includes a reserve chute; a feed roll supported in the reserve chute at an outlet thereof; a countersupport cooperating with the feed roll for defining therewith a nip through which the feed roll draws fiber tufts from the reserve chute; an opening roll supported immediately downstream of the nip for receiving fiber tufts from the nip; and a feed chute having an inlet connected to the outlet of the reserve chute. A relative motion of the feed roll and the countersupport toward and away from one another is permitted for varying the distance between the feed roll and the countersupport by the fiber tufts passing therebetween. Further, a spring is provided which resiliently urges the feed roll and the countersupport towards one another.
By virtue of the invention which thus provides for a spring-biased relative displacement of the feed roll and the countersupport towards or away from one another, there is achieved an automatic alteration of the intake gap (nip), making possible, for example, a larger throughput, such as, for example, 500 kg/h per m width or more. It is a further advantage of the invention that for each type of material the feed roll securely clamps the fiber material against the countersupport, that is, a more uniform throughput of material is effected. A manual adjustment or re-adjustment of the feed roll may thus be dispensed with. It is a further advantage of the invention that the displacements of, for example, the feed roll may be utilized as a measuring magnitude for a regulated setting member.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1a is a schematic side elevational view of a tuft feeder incorporating a preferred embodiment of the invention.
FIG. 1b is a top plan view of a component of the construction shown in FIG. 1a.
FIGS. 2-6 are schematic side elevational views of five additional preferred embodiments of the invention.
FIG. 7 is a schematic side elevational view of a tuft feeder different from that shown in FIG. 1a and incorporating the preferred embodiment of FIGS. 1a and 1b.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1a, there is illustrated therein a tuft feeder adapted for use to advance a fiber lap to a carding machine. The tuft feeder which may be of a general construction corresponding to an EXACTAFEED FBK model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany, has a vertically oriented reserve chute 1 which is charged with fiber tuft from above, for example, from an overhead distributor duct 1a after the material has passed through a condenser (not shown). In an upper zone of the reserve chute 1 air outlet openings 1b are provided through which the conveying air stream passes after separation of the fiber tufts and enters a suction device 1c as indicated by the arrow A.
The lower end of the reserve chute 1 is obturated by a feed roll 2 which rotates counterclockwise as indicated by the arrow 2a and which cooperates with a fixed feed lip 13. The feed roll 2 and the feed lip 13 together define a nip (fiber guiding channel) 12a. Immediately downstream of the fiber guiding channel 12a--as viewed in the direction of fiber advance--there is arranged an opening roll 3 which rotates clockwise as indicated by the arrow 3a and which may have pins or a sawtooth clothing on its surface. One part of the circumferential surface of the opening roll 3 bounds an upper, intake end of a feed chute 4. The opening roll 3 advances the fiber material into the feed chute 4. The feed lip 13 has a terminal edge 13a oriented in the direction of rotation of the adjacent portions of the feed roll 3.
The feed chute 4 has at its lower end two cooperating delivery rolls 5 which rotate as designated by the respective arrow and which withdraw the fiber material from the feed chute 4 and advance the same as a fiber lap on a feed tray 5a to the non-illustrated carding machine.
The walls of the feed chute 4 are, along a length portion in the lower part thereof, provided with air outlet openings 6. The upper end of the feed chute 4 communicates with a duct 7 whose upper end adjoins the pressure side of a blower 8. The rotating feed roll 2, in cooperation with the feed lip 13, and the opening roll 3 continuously deliver, at a determined flow rate, fiber material into the feed chute 4 and, at a similar flow rate, fiber quantities are withdrawn by the delivery rolls 5 from the feed chute 4 and deposited on the feed tray 5a.
To uniformly densify and to maintain constant the fiber quantities, the blower 8 generates a compressing air stream B which is directed downwardly into the feed chute 4. The blower 8 draws air from a suction channel 9 whose lower end communicates the air outlet openings 6 provided in the feed chute 4 and drives compressed air down through the duct 7 through the fiber column in the feed chute 4 and out of the air outlet openings 6 as indicated by the arrows C.
The opening roll 3 is surrounded by a housing 10 formed of two arcuate wall portions 10a and 10b while the feed roll 2 is surrounded by a wall 11, as shown in FIG. 2. The wall 11 as well as the wall portions 10a, 10b conform to the curvature of the feed roll 2a and the opening roll 3, respectively. The housing portions 10a and 10b are separated from one another by a clearance 12b which forms the upper, intake end of the feed chute 4 and through which thus the fiber material is advanced into the feed chute 4 by the opening roll 3. The densifying air flow B proceeds codirectionally with the rotation of the adjoining circumferential portion of the opening roll 3.
As shown in FIG. 1b, the opposite stub shafts 2c of the feed roll 2 are supported in respective rotary bearings 16 supported with the intermediary of respective compression springs 14 at two fixed surfaces 15 which form part of the walls of the reserve chute 1.
Reverting once again to FIG. 2, each rotary bearing 16 is held on the respective support 15 by means of a bar 29 which is surrounded by a compression spring 14 and which passes through an opening 30 provided in the support 15. At the end of the bar 29, remote from the rotary bearing 16, there is a plunger armature 17a which cooperates with a solenoid 17b. The assembly 17a, 17b forms an inductive path sensor 17 which is connected with a regulatable drive motor 19 for the feed roll 2 with the intermediary of a regulator 18. If, for example, the fiber quantity passing through the nip 12a increases, the feed roll 2 is radially displaced in the direction of the arrow D whereupon the compression spring 14 exerts a counterforce in the direction of the arrow E. The counterforce is thus applied to the feed roll 2 which then firmly clamps the fiber material against the feed lip 13 thus preventing the opening roll 3 from tearing an entire batch of fibers from the outlet side of the nip 12a. In this arrangement both the feed roll 2 and the opening roll 3 rotate in the same sense in a counter-clockwise direction.
Turning to FIG. 3, in the embodiment shown therein there is provided a lever arm 20a, one end of which is held in a stationary pivotal support 31. The lever arm 20a is thus able to execute swinging motions thereabout towards or away from the feed lip 13 as indicated by the arrows F, G. The other end of the lever arm 20a is connected by means of a tension spring 21a with a stationary support 22. The lever arm 20a supports a bearing bracket 20b which holds the stub shaft 2b of the feed roll 2. Further, the mid zone of the lever arm 20a engages a stationary abutment 24, thereby ensuring a minimum clearance for the fiber guiding channel (nip) 12a. Advantageously, the feed lip 13 is provided, on its surface oriented towards the feed roll 2, with a low-friction coating 13b, such as a Teflon layer.
Turning to the embodiment illustrated in FIG. 4, there is provided a lever arm 23a which is at one end articulated to a stationary pivot 35. At the opposite end the lever arm 23a carries the rotary bearing 16a of the feed roll 2. The lever arm 23a is, by means of a compression spring 25a, held on a stationary support 26, biased against a stationary abutment 24. The lever arm 23a is pivotal in the direction of the arrows I, H.
Turning to the embodiment illustrated in FIG. 5, there are provided two feed rolls 2' and 2". The feed roll 2" is stationarily supported and constitutes a countersupport for the feed roll 2' to define a nip 12c therewith. The rotary bearing 16 of the feed roll 2' is movably supported by means of the compression spring 14 on a stationary support 15 for excursions radially towards or away from the feed roll 2".
Turning now to the embodiment illustrated in FIG. 6, the feed roll 2 is stationarily supported and cooperates with a feed lip 13' which is pivotally secured at one end at 32. A compression spring 27 is, with one end, in engagement with a stationary support 28 and presses, with its other end, the feed lip 13' towards the feed roll 2.
FIG. 7 shows a fiber feeder in which the fiber tufts fall from the opening roll 3 onto a conveyor belt 34 to form a deposited layer thereon. The feed roll 2 is movably supported similarly to the embodiment described in connection with FIG. 1a. Between the opening roll 3 and the conveyor belt 30 the fiber tufts are in a free fall through a feed chute, such as a space 33 without pneumatic densification as it was the case in the construction described in connection with FIG. 1a.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A fiber tuft feeder includes a reserve chute; a feed roll supported in the reserve chute at an outlet thereof; a countersupport cooperating with the feed roll for defining therewith a nip through which the feed roll draws fiber tufts from the reserve chute; an opening roll supported immediately downstream of the nip for receiving fiber tufts from the nip; and a feed chute having an inlet connected to the outlet of the reserve chute. A relative motion of the feed roll and the countersupport toward and away from one another is permitted for varying the distance between the feed roll and the countersupport by the fiber tufts passing therebetween. Further, a spring is provided which resiliently urges the feed roll and the countersupport towards one another. | 3 |
TECHNICAL FIELD
[0001] The present application relates to a mining method.
BACKGROUND
[0002] In the mining technology, compared to the underground mining method, the generally adopted open-pit mining method at present has the advantages of full resource utilization, low cost, high recovery rate, fast construction of mines, high output, a better working condition, and a safer working environment. However, the open-pit mining method has the disadvantages of being severely limited by natural occurrence conditions. In addition, during the course of mining, large area of fertile farmlands are occupied, and noticeable anthropogenic changes occur to the ecological environment of the mining region, which are manifested in destructions to the landform, heavy metal pollution, and aggravated water loss and soil erosion. Furthermore, due to the fact that open-pit mines are mostly located at the ecologically fragile arid/semi-arid regions, the functional life support system of the open-pit mining region is lost, in particular, the vegetation system is damaged, thereby further increasing the vulnerability of the ecological environments and the degeneration rate, as well as threatening severely the ecological safety of the mining region.
[0003] Although the underground mining method is more environment-friendly, the increased mining difficulty and the more hostile environment of the underground mining method compared with the open-pit mining method raises a higher requirement for the mining equipment, the operator qualification, and the mining process. For example, in some mining regions, permanent frozen earth with thickness of 50 to 98 m and comprising quaternary humus soils, sandy soils, partial bed rocks and the likeis widely spread and, which likely results in the problem of deteriorated engineering geology, a building cycle of at least 5 years within such mining regions and high investment cost. Therefore, it is hard for enterprises to sustain. Moreover, a main shaft, an auxiliary shaft, and a ventilating shaft are typically required to be dug in the conventional underground mining process, resulting in crisscrossed underground tunnels. As a result, the damaged underground after mining cannot be recovered and the secondary disaster brought by the subsidence of the mined region cannot be avoided. In particular, the grassland landform damaged by the gangue field cannot be restored and the stacked wastes have to be left permanently in the mining region, which is adverse to the recovery of the ecological environment. Additionally, some other secondary disasters, such as gas and coal dust, roof collapse, wall caving, water leakage and the like, may also be induced by the underground mining method.
[0004] Therefore, developing an environment-friendly coal mining method that enables cost saving, simple operations and safe production is a challenging problem to be solved.
SUMMARY
[0005] With respect to the problems of landform destruction and environment pollution caused by the prior art coal mining method, the present application provides a safe and efficient mining method.
[0006] To this end, the mining method provided by the present application may comprise: dividing a mining region into a plurality of federated mining regions; performing an open-pit mining operation in each of the federated mining regions and forming a pit in each of the federated mining regions; performing an underground mining operation on a slope of the pit and forming a plurality of excavated tunnels; and backfilling a pit of a previous federated mining region with a spoil of a subsequent federated mining region.
[0007] In an embodiment of the present application, a spoil of a first federated mining region may be filled into a last federated mining region after completing a mining work in the last federated mining region.
[0008] In an embodiment of the present application, the slope of the pit may be formed into a stepped platform.
[0009] In an embodiment of the present application, the plurality of excavated tunnels are sequentially or randomly formed.
[0010] In an embodiment of the present application, the above-mentioned method may further comprise: processing the spoil into a paste; and filling the plurality of excavated tunnels with the paste through a filling pump and/or by gravity.
[0011] In an embodiment of the present application, a safety angle of the slope of the pit may be equal or less than about 40°.
[0012] In an embodiment of the present application, the underground mining operation may be performed in an end-slope mining manner.
[0013] In an embodiment of the present application, the performing the underground mining operation may comprise: performing a horizontal mining operation or a vertical mining operation according to a mine distribution structure of the federated mining region.
[0014] In an embodiment of the present application, the above-mentioned method may further comprise: performing a surface vegetation operation after the backfilling of the federated mining region is completed.
[0015] According to the above-mentioned method, when a subsequent federated mining region is being mined, the previously mined federated mining region may be filled with the discarded rock-soil and waste-residues generated in this federated mining region. For example, when a second federated mining region is being mined, a first federated mining region may be filled with the discarded rock-soils and waste-residues generated in the second federated mining region, and so on. As such, the original landform of the previous federated mining region may be recovered in time during the mining process. Besides, vegetation, such as trees, may be planted in the filled federated mining region when the mining work is being performed in other regions, which further afforests the federated mining region and protects the environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The drawings are provided for a further understanding of the solution proposed by the present application and constitute a part of the specification. The drawings serve to explain the present application together with the specific embodiments of the present application, but not to limit the present application. In the drawings:
[0017] FIG. 1 is a sectional view of an exemplary mining region where a mining method according to an embodiment of the present application may be implemented;
[0018] FIG. 2 is a top view of an exemplary mining region where a mining method according to an embodiment of the present application may be implemented;
[0019] FIG. 3 is a schematic diagram illustrating a mining process using an end-slope coal mining machine;
[0020] FIG. 4 is a schematic diagram illustrating a filling paste processing method according to an embodiment of the present application; and
[0021] FIG. 5 schematically illustrates a skip mining and filling sequence within a built pit according to an embodiment of the present application.
[0000]
Reference numerals
1. Open-pit mining region
2. Mining region of end-slope coal mining machines
3. End-slope coal mining machine
4. Pasty grout
5. Vegetation
6. Surface soil layer
7. Filling station
8. Filler
9. Filling pipe
10. Blocking wall
11. Underground mining sequence number
DETAILED DESCRIPTION
[0022] The particular embodiments of the present invention will be described in details hereinafter with reference to the accompanying drawings. It should be appreciated that the particular embodiments described herein serve to only illustrate and explain the present invention, but not to limit the present application.
[0023] As shown in FIG. 1 , first, a mining region of an open-pit mine is divided into several smaller mining units, i.e., a plurality of federated mining regions. Each of the federated mining regions undergoes open-pit mining by utilizing excavators and mine trucks and a pit is formed therein. For example, the upper opening of the open pit may be formed with a size of 600 m×600 m, an area of 0.36 km 2 , a drawdown of 200 m, a safety angle of a slope of 40° or less, and a lower width of a foundation pit of 120 m, for a mining region that has a coal seam inclined to the middle to form a V-shape in the north-south direction and has a coal strip with a width of 1 km in the north-south direction and a length of 5 km in the west-east direction.
[0024] Next, an underground mining operation is performed on the slope of the pit and a plurality of excavated tunnels are formed. According to an embodiment of the present application, the slope of the pit may be formed as a stepped platform. As shown in FIG. 2 , a safety platform with a particular size is built every certain decrease in altitude. For example, a safety platform with a width of 10-20 m is built every decrease of 10 m in altitude. The safety platform may be used for building a transport channel while preserving a working location for, e.g., an end-slope underground mining operation. The end-slope equipment may be disposed, for example, at the front of a seam to be mined. The underground mining of surrounding seams within the pit is performed with underground mining equipment. The particular operating scheme of the underground mining depends on a seam area, a seam extension direction and a seam inclination angle. For example, the underground mining may be horizontally or vertically performed, and it is possible only to mine for coal but not to peel rocks during mining courses. It should be noted that, each end-slope tunnel is disposed to be mined nearly horizontally for both a steeply inclined coal seam and a nearly horizontal coal seam. The only difference lies in the mining location for a subsequent tunnel relative to that of the previously excavated tunnel, i.e., it may be a horizontal arrangement or a vertical arrangement. The horizontal arrangement or the vertical arrangement mentioned herein refers to the location layout of the end-slope underground mining operations. However, the mining within each tunnel is definitely performed in a nearly horizontal direction. Generally, only coal is extracted while rocks are unpeeled during an end-slope mining process.
[0025] Typically, an open-pit mining process is performed prior to an end-slope underground mining process for each federated mining region. However, according to actual mining conditions, the end-slope underground mining process may be performed after the open-pit mining process is completed, and the end-slope underground mining process may be performed concurrently with the open-pit mining process when the open-pit mining process is performed down to a certain depth, i.e. “multi-pit federated mining”.
[0026] FIG. 3 is a schematic diagram illustrating a mining process using an end-slope coal mining machine. As shown in FIG. 3 , an end-slope coal mining system is utilized on a certain working platform to perform mining operations to predetermined depths for the upper surface and the lower surface of the coal seam area, respectively (e.g., 120 m for the upper mining surface, and 600 m for the lower mining surface).
[0027] After the mining in the first federated mining region is completed, an open pit and tunnels are built in a second federated mining region and similar mining operations are performed therein.
[0028] Next, the pit of the first federated mining region is filled with spoil, e.g., rock-soil, waste-residues and the like, generated through the mining work performed in the second federated mining region in order to recover the original landform in time during the mining process.
[0029] Then, a third federated mining region undergoes mining in a similar way as mentioned above. The mined region of the second federated mining region is filled with the spoil generated through the mining operation performed in the third federated mining region. And so on, until all of the coal mining operations are completed. After the mining operation performed in the last federated mining region is completed, the last federated mining region is filled with the spoil of the first federated mining region in order to completely recover the original surface appearance. The spoil of the first federated mining region may be stacked at a temporary waste dump to be used as backfill for the last federated mining region. Vegetation, such as trees, may be planted after the pit is filled in order for further afforestation and protection of environment.
[0030] According to an embodiment of the present application, the spoil may be further processed into paste, which is used to fill excavated tunnels through a filling pump and/or by gravity. Solid wastes, such as coal gangues, rock-soils and the like, may be, for example, processed into pasty grout on the ground, and then, as shown in FIG. 4 , the paste is used to fill excavated tunnels of the pit through the filling pump and/or by gravity. In an embodiment, the paste is transferred to the underground via a pipe and fills the mined region in time so that an overlaying rock stratum is supported and the movement of the overlaying rock stratum is limited by the paste filling, thus ensuring a safe surrounding rock environment for coal mining tunnels all the time and increasing the mining rate of coal resources. Meanwhile, surface subsidence and secondary geological disasters that are likely to result, which other mining processes cannot avoid, are prevented. It should be noted that, the paste filling is generally applied to a thick coal seam or an inclined coal seam (deemed as an ultra-thick coal seam), while a thin horizontal coal seam may not need to be filled as long as there are temporary coal pillars and permanent coal pillars for rectangularly arranged end-slope underground mining.
[0031] A plurality of excavated tunnels may or may not be formed in sequence in order to ensure enough solidification time for the filler before the filler begins to function. For example, the underground mining may be performed in accordance with the skip mining sequence as shown in FIG. 5 .
[0032] The mining method provided by the present application employs schemes of cyclical mine constructing, simultaneous mining, and alternate backfilling. Besides, the coal mining and paste filling techniques are suitably combined with the excavating technique. Accordingly, a higher rate of mine recovery is achieved while the backfilling is completed, the mining region is afforested and the ecological environment of the mining region is protected. Furthermore, the mining method provided by the present application reduces both the transport distance and the excavated volume and thus reduces the production cost of a mining enterprise.
[0033] Therefore, the recovery multi-pit federated mining method provides an effective technical solution to resolve the conflict between resource exploit and environment protection and provides an example for the country to construct environment-friendly mining regions. This is of strategic importance to the promotion of resource exploit in ecologically fragile areas of the nation, as well as the development of environment protection techniques.
[0034] Although the preferred embodiments of the present invention have been described above in details with reference to the drawings, the present application is not limited to the particular details of the above embodiments. A variety of simple variations may be made to the technical solutions of the present invention within the technical concept of the present application, and all of these simple variations fall into the scope of the present invention. | The present invention provides a mining method. The method includes: dividing a mining region into a plurality of federated mining regions; performing an open-pit mining operation in each of the federated mining regions and forming a pit in each of the federated mining regions; performing an underground mining operation on a slope of the pit and forming a plurality of excavated tunnels; and backfilling a pit of a previous federated mining region with a spoil of a subsequent federated mining region. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a divisional application of U.S. Ser. No. 09/648,689, filed on Aug. 25, 2000 now U.S. Pat. No. 6,655,853.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the interconnection of microelectronic chips. The interconnections may be between chips on a multi-chip module, between several multi-chip modules, or even between distant points on a larger chip. More particularly, it pertains to the use of optical wires bonded on those chips to interconnect the chips. The interconnections by means of optical fibers are made to substitute for the electrical wire interconnections. Each optical wire terminates at a small laser chiplet on one end and a photodetector chiplet on the other end. Each chiplet is flip-chip mounted onto the larger electronic chips and each contains a vertically coupled laser or photodetector and solder bumps on one face and a deflecting mirror and a V-groove (into which one end of the optical fiber is inserted) on the opposite face.
2. Description of the Related Art
In a high speed mulitchip module (MCM) environment, chip-to-chip connections are usually made using bond wires, with microstrip lines on the MCM substrate used to interconnect chips that are farther apart.
Presently, electrical bond wires are used to interconnect microchips. Using the electrical wires has serious drawbacks. The electrical wires are sensitive to electromagnetic interference and themselves create such interference which poses especially serious problems for distribution of timing signals. The electrical wires must be located at the edges of chips. Signal attenuation and phase delay depend upon the length of the electrical wires. Thus, depending on the lengths of the electrical wires and their locations in the module, it may be difficult to achieve equal attenuation and/or equal signal phase delay among multiple wires, if needed.
In addition, in many cases signal bandwidths of several Gigahertz are desirable but cannot be achieved if electrical wires are used because electrical bond wires act as open antennae at high frequencies and introduce noise coupling among the wires. For example, bond wires of 500 micrometers in length and 1 mil (0.001 inch) diameter carrying 10 milliamperes of current will produce appreciable (100 millivolts or more) coupling or cross-talk at 10 Gigahertz even when they are spaced several pitch distances apart, a typical pitch being 100 to 150 micrometers. This effect will substantially limit the maximum speed of a typical MCM module having hundreds of bond wires from several chips. The cross-talk is even more severe when the chips are located farther apart and require longer bond wires.
Therefore, there is a need to have interconnects between microchips which:
(a) are insensitive to electromagnetic interference; (b) need not be located at the edges of a chip but rather can be placed for optimal utility to the circuit function; (c) can be given the same or other pre-specified lengths regardless of the placement in the module; and (d) are capable of signal bandwidths up to 20 Gigahertz without causing the cross-talk problem.
Optical bond-wire interconnections satisfy all these requirements. Previously, optoelectronic devices such as vertical-cavity lasers and photodetectors have been bonded onto microelectronic chips to provide free-space optical interconnections and the results were reported, for instance, by D. A. Louderback, et. al., in “Modulation and Free-Space Link Characteristics of Monolithically Integrated Vertical - Cavity Lasers and Photodetectors with Microlenses” , IEEE Journal of Selected Topics in Quantum Electronics, Vol. 5, No. 2 (1999).
However, for such free-space interconnections, the optoelectronic devices must be installed in a way that they face one another. Moreover, their relative locations must be precisely controlled to ensure optical alignment. As a result, in free-space optical interconnections, the optoelectronic devices must be located on different multi-chip modules that are held in immediately adjacent slots of a rack.
With optical interconnect wires bonded directly onto microelectronic chips there is almost no constraint on the locations of the chips to be interconnected. The chips may reside on the same multi-chip module or may be disposed many meters apart. These chips can even be members of different instruments or computation units; however, if the optical-fiber band-wire is subject to movement, then some mechanical means is preferably provided to relieve the optical fiber and chiplets from excessive strain.
In the prior art, optical fibers are typically coupled to optoelectronic devices using an accompanying sub-mount, such as a machined piece of a metal, or ceramic, or a V-grooved silicon substrate, when both the optical fiber and the optoelectronic device chip are mounted on the sub-mount. Directly attaching and optically aligning an optical fiber to an optoelectronic chip would be most beneficial.
There exists no known prior art for fiber-based optical interconnects bonded directly onto microelectronic chips. Yet, as discussed above, the need for such is acute.
For the foregoing reasons, there is a necessity for optical bond-wire interconnections. The present invention discloses such interconnections.
SUMMARY OF THE INVENTION
The present invention is directed to an optical bond-wire interconnect and to a method of manufacturing of the interconnect. It can be used instead of electrical bond-wires but can be much longer than the electrical bond-wires. For instance, length of an electrical wire typically does not exceed maximum length of 1 centimeter and is usually shorter. An optical bond-wire can reach lengths of the order of hundreds of meters.
Each optical bond-wire comprises a segment of optical fiber that is attached at its two ends by means of terminations to the microelectronic chip or chips. The two terminations of the optical bond-wire are a laser chiplet on one end of the optical bond-wire and a photodetector chiplet on the other end. Each chiplet can be as small as 250 by 250 micrometers and is connected to two electrical lines—one line is the signal to be sent via the interconnect and the other line is a return or ground.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will be better understood with regard to the following description, appended claims, and accompanying drawings where
FIG. 1 is a schematic diagram showing an optical bond-wire interconnection for electrical signals.
FIG. 2 is a schematic diagram showing a method for connecting an optical fiber to the optoelectronic termination laser or photodetector.
FIG. 3( a ) is a picture of an etched mirror fabricated by wet-chemical etching into gallium-arsenide.
FIG. 3( b ) is a picture of a V-shaped holder fabricated by wet-chemical etching into gallium-arsenide.
FIGS. 4( a )– 4 ( c ) are schematic diagrams showing an example of the optical design for an optoelectronic termination.
FIGS. 5( a )– 5 ( g ) are schematic diagrams showing step-by-step method of fabrication of an optical bond-wire interconnection of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A preferable optical bond-wire interconnection for electrical signals is schematically illustrated on FIG. 1 . Optical bond-wires 3 may be used to interconnect monolithic microwave integrated circuits (MMIC) 2 , for example. The MMICs can be located on the same multichip module (MCM) 1 or on different MCMs. As can be seen from FIG. 1 , the length of optical bond-wires 3 can be substantially longer than that of electric wires 4 . There is no need for MMICs to be immediately adjacent in the case of optical bond-wire interconnections. As pointed out above, the length of optical bond-wires can reach hundreds of meters.
A segment of optical fiber is attached at its two ends by means of terminations to the microelectronic chips. The two terminations of the optical bond-wire are a laser chiplet on one end of the optical bond-wire and a photodetector chiplet on the other end. A connection of the optical bond-wire 3 to an optoelectronic termination is shown on FIG. 2 . The termination comprises a laser or photodetector 5 which is optically coupled to the optical fiber 3 and electrically coupled to the MMIC 2 . Both the laser and photodetector are edged coupled devices or, preferably, vertically coupled devices, such as vertical-cavity surface emitting laser (VCSEL) and PIN photodiode detector (hereinafter, PIN) or metal-semiconductor-metal (MSM) photodetector, respectively. The optical fiber 3 is preferably mounted onto the backside of the optoelectronic laser or photodetector chiplet 8 . Other non-preferred methods of mounting the optical fiber 3 include mounting where the optical fiber comes directly from the top of the chiplet 8 and mounting by etching an opening in the back of the substrate followed by direct insertion of the optical fiber.
After the optical fiber 3 has been mounted onto the backside of the optoelectronic laser or photodetector chiplet 8 , it is attached and held in place, preferably, using adhesives such as UV-curable epoxy resins commonly known to those reasonably skilled in the art.
The optical path is defined in such a way that light is deflected from the optical fiber bond-wire 3 , through the substrate and to the photodetector 5 , or vice versa in the case of the termination being the laser 5 . The substrate materials of the chiplets 8 are preferably gallium arsenide or indium phosphide.
Electrical signals and power to and from the optoelectronic chip 8 are delivered via, preferably, solder bumps 9 . As an alternative to the solder bumps 9 , gold/gold compression bonds can also be used instead. A chiplet 8 comprises at least three, and preferably four, solder bumps 9 , at least two of which are electrically connected to the microelectronic chip or the MMIC 2 .
A preferred kind of the solder bumps is precision electroplated solder bumps disclosed in U.S. patent application Ser. No. 09/522,803, currently pending. Other kinds of solder bumps commonly used by those reasonably skilled in the art may also be used. The solder bumps 9 also provide mechanical support for the chiplet 8 and its physical adhesion to the MMIC 2 .
Standard methods known to those reasonably skilled in the art are used to fabricate the optical fiber 3 and to cleave the fiber into the desired length for the bond-wire. Commercially available optical fiber is used. In particular, for the design shown on FIGS. 4( a )– 4 ( c ), a multi-mode optical fiber manufactured by Fiberguide Industries Corp. of New Jersey, is used. The optical fiber has a fairly large numerical aperture, preferably 0.35 or more.
Standard methods known to those reasonably skilled in the art are also used to fabricate the solder bumps 9 , as well as the laser and photodetectors 5 . A method for fabrication of the preferred solder bumps, the precision electroplated solder bumps, is disclosed in U.S. patent application Ser. No. 09/522,803, currently pending.
Laser and photodetector units 5 are available from University of California at Santa Barbara of Santa Barbara, Calif. The lasers and photodetectors 5 to be used are those which operate at an optical wavelength for which the substrate material of the chiplet 8 is transparent.
Suitable VCSELs are emitting at such wavelengths so that the selected substrates be transparent and the signal be detectable by the photodetectors. In particular, in case of gallium arsenide substrates, the preferred VCSELs are those emitting preferably at a wavelength of about 980 nanometers or about 1,300 nanometers and in case of indium phosphide substrates—at a wavelength of about 1,300 nanometers or about 1,550 nanometers.
For photodetectors, those that are sensitive in the range of wavelengths between about 980 nanometers and about 1,550 nanometers are suitable for both gallium arsenide and indium phosphide substrates.
The optical bond-wire interconnect further comprises, preferably, a mirror 7 and a V-shaped groove 11 , as shown on FIG. 2 , for holding the optical fiber 3 . The face of the mirror 7 slopes downward and outward from the surface of the wafer. At the same time, the walls of the V-shaped groove 11 slope downward and inward.
The mirror 7 and the groove 11 are preferably fabricated simultaneously and are positioned perpendicularly to each other. This perpendicular positioning of the mirror 7 and the groove 11 is not required but is strongly preferred. Depending on the design of the device, those reasonably skilled in the art will modify the relative positioning of the mirror 7 and the groove 11 and may choose an angle other than 90° between them.
The process of such simultaneous fabrication is only possible due to the fact that both gallium arsenide and indium phosphide substrates, on which the mirror 7 and the groove 11 are formed, preferably have a zinc-blende crystallographic structure. A consecutive fabrication of the mirror 7 and the groove 11 is also possible, but the simultaneous fabrication is easier to achieve and allows automatic alignment, which the consecutive fabrication does not provide. The zinc-blende structure is not required but is preferred as it makes the fabrication process easy. Those skilled in the art may modify the process and choose a structure other than the zinc-blende structure.
First, the laser or photodetector 5 is fabricated on a first side of a wafer, or substrate 18 , preferably, on a gallium arsenide or indium phosphide substrate, as shown on FIG. 5( a ). The process for such fabrication comprises the epitaxial growth of the laser or photodetector 5 material. An etch-stop layer 17 is grown first, underneath the device layers and on the substrate wafer 18 . The second side of the wafer 18 is then thinned and polished which step determines the depth of the mirror channel to be discussed below.
Next, the mirror 7 and the V-groove 11 , as shown on FIG. 2 , are preferably formed on the back side of the wafer. Such step of the formation of the mirror 7 and the V-groove 11 , as shown on FIG. 2 , preferably comprises the following sub-steps.
First, a thin film of preferably silicon nitride 19 is deposited on the back side of the wafer, with the thickness preferably greater than about 300 nanometers, as shown on FIG. 5( b ). Following the deposition of the silicon nitride film 19 , a thin layer of photoresist 20 is deposited and patterned on top of the silicon nitride film 19 . The photoresist material is a typical and commonly known material used by those skilled in the art and is applied according to well known techniques also know to those reasonably skilled in the art. The thin film 19 of silicon nitride can be deposited by the method of plasma-enhanced chemical vapor deposition, by sputtering or by high temperature chemical vapor deposition.
As shown on FIG. 5( c ), T-shaped openings are next patterned into the silicon nitride film 19 by photolithographic techniques known to those reasonably skilled in the art and standard wet or dry etching processes of the silicon nitride also known to those reasonably skilled in the art. The “T” shape of the openings is preferred, but some other shapes, for example “I” shape, are also possible.
The “T” on the back side of the wafer 18 is precisely aligned with the laser or photodetector 5 formed on the top side followed by the formation of the mirror 7 and the V-groove 11 , as shown on FIG. 2 , in the top and the trunk of the “T” respectively. The preciseness of the alignment is preferably within a few micrometers deviation and the alignment is achieved and measured using standard techniques and instruments known to those reasonably skilled in the art.
The mirror 7 and the V-groove 11 are preferably formed by wet-chemical etching, as shown on FIG. 5( d ). A preferred etchant for both gallium arsenide and indium phosphide substrates 18 is about 2% solution of bromine in methanol. An acceptable alternative etchant for gallium arsenide substrate 18 is a mixture of hydrogen peroxide and an acid, such as hydrochloric acid. The ratios between the components in the etchant mixtures are common and known to those skilled in the art.
Well-defined etched profiles and the smooth surfaces obtained with the use of H 2 O 2 —HCl mixture are shown on FIG. 3 . The mirror 7 and the V-groove 11 , shown on FIG. 2 , are precisely aligned along specific crystallographic directions. For instance, if the back side of the substrate is a ( 100 ) crystallographic surface, the V-groove 11 is aligned along the ( 01 ) direction and the mirror 7 is aligned along the ( 0 ) direction. This crystallographic alignment can be accomplished manually or with the use of standard instruments according to standard techniques known to those skilled in the art.
Reproducible etching is done by controlling the undercutting achieved by proper choice and fabrication of the thin-film masking material. Such choice and fabrication are known to those skilled in the art. FIG. 3 also illustrates the amount of undercutting. Etching of the mirror 7 and the V-groove 11 is continued until the etch-stop layer 17 is exposed.
After the formation of mirror 7 and the V-groove 11 , the photoresist layer 20 and the silicon nitride layer 19 are etched away using common and known etching techniques. This step is followed by the fabrication of solder bumps 9 on top (first) side of the wafer 18 , as shown on FIG. 5( e ).
Multiple chiplets 8 can be fabricated on one wafer 18 followed by the dicing of the chiplets 8 from the wafer 18 into separate laser chiplets 51 or photodetector chiplets 52 . Finally, the optical fiber 3 is inserted into the V-groove 11 and attached to a chiplet 8 as shown on FIGS. 5( f ) and 5 ( g ) for the laser chiplets and for the photodetector chiplets, respectively.
EXAMPLE 1
An example of an optical design is shown on FIGS. 4( a )– 4 ( c ). This example is introduced solely for the purposes of illustration of a possible design and is not to be construed a limitation.
The design shows relative positions of the optical fiber 3 and the optoelectronic laser or photodetector 5 . This design can be used to specify the photolithographic fabrication masks and the etching parameters.
For a bromine-methanol etchant described above, and under the etching conditions used for this example, the resulting mirror 7 is inclined at an angle of about 55° and deflects the optical beam into the wafer substrate. The resulting V-groove 11 has sidewalls inclined at an angle of also about 55°. The optical fiber 3 has a core diameter of about 100 micrometers and a cladding diameter (not shown) of about 200 micrometers. To ensure that the core of the optical fiber 3 is entirely beneath the surface of the wafer 12 , the optical fiber 3 is set into V-groove 11 in such a way so that the optical fiber's 3 optical axis is located at a depth 13 of about 60 micrometers.
The width 14 and the depth 15 of the V-groove 11 are about 384 micrometers and 234 micrometers, respectively, as shown on FIG. 4( a ).
Since the etching rate of the V-groove 11 slows considerably once the point of the “V” has been formed, the depth 16 of the mirror channel [ FIGS. 4( a ) and 4 ( b )] is greater than the depth 15 of the V-groove 11 and is about 247 micrometers. An etch-stop layer 17 , is preferably grown epitaxially.
The etch-stop layer 17 has a thickness within a range of between about 0.01 nanometers and about 0.5 nanometers, preferably, within a range of between about 0.02 nanometers and about 0.2 nanometers, and is made of preferably aluminum arsenide for the gallium arsenide substrate 18 and of preferably indium aluminum arsenide for the indium phosphide substrate 18 .
When the mirror 7 is being etched, the etching is allowed to continue until the etch-stop layer 17 is reached. This technique ensures that the bottom surface of the mirror channel is flat and smooth because the etching would otherwise produce a non-flat surface at the bottom of the mirror channel. Following the etching process, the etch-stop layer 17 is optionally removed by a known method.
The distance between the etch-stop layer 17 and the light-emitting or light-absorbing area of the optoelectronic device 5 is designed to be between about 1 and about 5 micrometers, preferably, about 3 micrometers. The locations of the optoelectronic devices 5 are illustrated on FIG. 4( b ) (for a photodetector) and FIG. 4( c ) (for a laser). The space where the light travels can be sealed, for example with an epoxy sealant.
For typical applications where the optical bond wires 3 have lengths of up to about several meters, and the signal bandwidth or pulse rate is below about 20 Gigahertz, a multimode optical fiber can be used, preferably having a numerical aperture of about 0.4. The fiber core diameter can be as low as 50 micrometers and the cladding diameter is preferably between about 125 and about 200 micrometers.
The photodetector 5 should have a size at least as large as the fiber core in order to capture all the light from the fiber. The diameter of the laser 5 is preferably between about 10 and about 30 micrometers.
Having described the invention in connection with several embodiments thereof, modification will now suggest itself to those skilled in the art. As such, the invention is not to be limited to the described embodiments except as required by the appended claims. | Optical bond-wire interconnections between microelectronic chips, wherein optical wires are bonded onto microelectronic chips. Such optical connections offer numerous advantages compared to traditional electrical connections. Among other things, these interconnections are insensitive to electromagnetic interference and need not be located at the edges of a chip but rather can be placed for optimal utility to the circuit function. In addition, such interconnections can be given the same or other pre-specified lengths regardless of the placement in the module and they are capable of signal bandwidths up to 20 Gigahertz without causing a cross-talk problem. A method of fabrication of such optical interconnections using optical fiber, a laser or photodetector and etched mirror and etched V-shaped grooves. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a solid-state imaging device which is applicable to camera systems such as video cameras, monitor cameras, door checker cameras, on-vehicle cameras, cameras for TV telephone and cameras for multimedia, and a method for driving the same. In particular, the present invention relates to a solid-state imaging device which contributes to the reduction of voltage and power consumption of a camera system, and a method for driving the same.
2. Description of the Related Art
FIG. 4 shows the structure of a conventional solid-state imaging device. As shown in FIG. 4, the solid-state imaging device includes a plurality of photoelectric conversion elements 110 arranged in a matrix, a plurality of vertical transfer sections 130, and a horizontal transfer section 140. The photoelectric conversion elements 110 act as light receiving elements. Each of the vertical transfer sections 130 is composed of a charge-coupled device (hereinafter, referred to as CCD) disposed along a column of the photoelectric conversion elements 110. The horizontal transfer section 140 is disposed at the bottom ends of the vertical transfer sections 130.
Signal charges stored in the photoelectric conversion elements 110 are transferred to the vertical transfer sections 130 once every field period. The vertical transfer sections 130 then sequentially transfer the injected signal charges in a vertical direction (i.e., in a direction in which the vertical transfer sections 130 elongate) before the start of the next field period. The horizontal transfer section 140 receives the signal charges output sequentially from the vertical transfer sections 130 and transfers the signal charges horizontally in series.
The signal charges transferred from the horizontal transfer section 140 are output as signal outputs by a signal output circuit. FIG. 5 schematically shows the configuration of the conventional signal output circuit.
The signal output circuit shown in FIG. 5 includes a reset circuit 1, a floating diode 2, and an amplification circuit 3. The reset circuit 1 applies a reset voltage Vr of about 15 V to the floating diode 2 prior to the detection of charges, so that a terminal voltage of the floating diode 2 is set at the reset voltage Vr. Thereafter, the charges transferred from the horizontal transfer section 140 are accumulated in the floating diode 2. As a result, the terminal voltage of the floating diode 2 changes. The amplification circuit 3 receives the terminal voltage of the floating diode 2, and outputs a signal in accordance with the change in voltage. Thereafter, the reset circuit 1 reapplies the reset voltage Vr to the floating diode 2, so that the charges transferred from the horizontal transfer section 140 are transferred to the floating diode 2 again.
The floating diode 2 includes a semiconductor substrate and a diffusion layer N + which is in a potentially floating state formed on the semiconductor substrate. The diffusion layer N + and a P-well of the semiconductor layer formes a PN junction, thereby forming a diode. The diode also serves as a capacitor.
A change in voltage Vq of the floating diode 2 is expressed by the following Expression 1:
Vq=Q/C [Expression 1]
where C is a capacitance of the floating diode 2, and Q is the amount of charges transferred from the horizontal transfer section 140 to the floating diode 2.
Since the floating diode 2 has a remarkably high output impedance, it is not possible to output signals. Therefore, in order to lower the output impedance, a plurality of source follower circuits 4 and 5 are provided in parallel for the amplification circuit 3. A signal corresponding to a change in voltage Vq is output through the source follower circuits 4 and 5.
A constant current source 8 is connected to a source of a transistor 6 of the source follower circuit 4, while a constant current source 9 is connected to a source of a transistor 7 of the source follower circuit 5. Each of the constant current sources 8 and 9 is constituted by a transistor.
The reason that a plurality of source follower circuits are provided in parallel is as follows.
First, an output impedance R out of the source follower circuit is expressed by Expression 2 below:
R.sub.out ∝[(W/L)×I].sup.-1/2 [Expression 2]
where W is a gate width of a transistor of the source follower circuit, L is a gate length thereof, and I is a current flowing from the drain to the source.
As is apparent from Expression 2, the output impedance R out of the source follower circuit can be lowered by increasing a value of (W/L)×I.
However, if the gate width W is increased, the capacitance C of the floating diode 2 in Expression 1 above is accordingly increased. Since a change in voltage Vq is reduced thereby, increasing the gate width W is not desirable for lowering the output impedance of the source follower circuit. In fact, the gate width W should be made as small as possible so that the transistor does not suffer from the effects of noise or the like.
In order to lower the output impedance R out , it may be possible to reduce the gate length L or increase the current I. However, the reduction of the gate length L or the increase of the current I is limited by noise effects.
Even if the source follower circuit is employed, it is not possible to sufficiently reduce the output impedance R out with a single source follower circuit. Therefore, a plurality of source follower circuits are provided in parallel, so the output impedance is gradually reduced by passing the input signal through the plurality of source follower circuits.
Specifically, a plurality of source follower circuits are designed so that the value of (W/L)×I increases by passing the input signal through the source follower circuits to reduce the output impedance. In accordance with such a configuration, the last source follower circuit requires a current of 3 to 4 mA or more.
For example, Japanese Laid-Open Publication Nos. 3-274811, 5-251677, and 6-70239 disclose such a solid-state imaging device employing a plurality of source follower circuits.
In the case where the plurality of source follower circuits 4 and 5 are employed, it is preferred to set a power supply voltage at a high level. The reason for this is as follows. A DC current voltage level is lowered as it flows from the input to the output of the source follower circuit. If the current voltage drops below a certain voltage (that is, the lower limit voltage below which the constant current sources 8 and 9 constituted by transistors do not operate), the source follower circuits 4 and 5 do not operate. The range of the DC voltage level allowing the source follower circuits to operate is increased at a higher power supply voltage. Therefore, setting a power supply voltage at a high level is advantageous in terms of dynamic range.
In order to preserve such a high power supply voltage Vod1, a relatively high reset voltage Vr, that is, 15 V on the floating diode 2 as described above, is used. As a result of this, the system can be simplified.
However, in the case where the power supply voltage Vod1 is set at a high value, the power consumption is disadvantageously increased because the current passing through the source follower circuits is increased in order to lower the output impedance R out of the source follower circuits.
SUMMARY OF THE INVENTION
A solid-state imaging device of the present invention includes: a plurality of photoelectric conversion elements; a transfer section for transferring charges generated by the photoelectric conversion elements; a floating diode for converting the charges transferred by the transfer section to voltage signals; and an amplification section including a plurality of source follower circuits, each amplifying the voltage signals generated by the floating diode, wherein different power supply voltages are supplied to the respective source follower circuits, and the power supply voltages are reduced as a DC current flowing through each of the respective source follower circuits increases.
In one embodiment of the invention, transistors, each constituting one of the source follower circuits, have respectively different thresholds, and the threshold of the transistors of the source follower circuits are increased as the DC current flowing through each of the source follower circuits increases.
According to another aspect of the invention, a solid-state imaging device includes: a plurality of photoelectric conversion elements arranged in a matrix; a transfer section for transferring charges generated by the photoelectric conversion elements; a floating diode for converting the charges transferred by the transfer section to voltage signals; and an amplification section for amplifying the voltage signals, including a first source follower circuit through which a first current flows and a second source follower circuit through which a second current flows, the second current having a value higher than a value of the first current, wherein a first voltage for operating the first source follower circuit is applied to the first source follower circuit, and a second voltage for operating the second source follower circuit is applied to the second source follower circuit, and wherein the second voltage is set lower than the first voltage.
In one embodiment of the invention, the first source follower circuit is formed by a first transistor, and the second source follower circuit is formed by a second transistor, and a threshold of the second transistor is higher than that of the first transistor.
In another embodiment of the invention, the amplification section further includes a third source follower circuit through which a third current flows, the third current being higher than the second current flowing through the second source follower circuit, and a voltage for allowing the third source follower circuit to operate, which is applied to the third source follower circuit, and is set lower than the second voltage applied to the second source follower circuit.
In still another embodiment of the invention, the first source follower circuit is formed by a first transistor, the second source follower circuit is formed by a second transistor, and the third source follower circuit is formed by a third transistor, and wherein a threshold of the third transistor is higher than that of the second transistor, and a threshold of the second transistor is higher than that of the first transistor.
In still another embodiment of the invention, the second voltage applied to the second source follower circuit is lower than 15 V.
According to still another aspect of the invention, a method for driving a solid-state imaging device including: a plurality of photoelectric conversion elements arranged in a matrix; a transfer section for transferring charges generated by the photoelectric conversion elements; a floating diode for converting the charges transferred by the transfer section to voltage signals; and an amplification section for amplifying the voltage signals, including a first source follower circuit through which a first current flows and a second source follower circuit through which a second current flows, the second current having a value higher than a value of the first current, the method includes the steps of: applying a first voltage to the first source follower circuit for allowing the first source follower circuit to operate, and applying a second voltage to the second source follower circuit for operating the second source follower circuit, wherein the second voltage is set so as to be lower than the first voltage.
In one embodiment of the invention, the second voltage applied to the second source follower circuit is lower than 15 V.
Thus, the invention described herein makes possible the advantages of: (1) providing a solid-state imaging device employing a plurality of source follower circuits while restraining the power consumption; and (2) providing a method for driving such a solid-state imaging device.
These and other advantages of the present invention will become apparent to those skilled in the art upon reading and understanding the following detailed description with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a CCD solid-state imaging device used in a first example according to the present invention.
FIG. 2 is a circuit diagram showing a signal output circuit of the CCD solid-state imaging device in the first example according to the present invention.
FIG. 3 is a circuit diagram showing a signal output circuit of a CCD solid-state imaging device in a second example according to the present invention.
FIG. 4 is a block diagram of a conventional solid-state imaging device.
FIG. 5 is a circuit diagram showing a conventional signal output circuit of the conventional solid-state imaging device of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described with reference to the drawings.
EXAMPLE 1
FIG. 1 shows the structure of a CCD solid-state imaging device of Example 1. As shown in FIG. 1, the CCD solid-state imaging device includes a plurality of photoelectric conversion elements 110 arranged in a matrix, a plurality of vertical transfer sections 130, and a horizontal transfer section 140. The photoelectric conversion elements 110 act as light receiving elements. Each of the vertical transfer sections 130 is composed of a CCD disposed along a column of the photoelectric conversion elements 110. The horizontal transfer section 140 is disposed at the bottom ends of the vertical transfer sections 130.
Signal charges stored in the photoelectric conversion elements 110 are transferred to the vertical transfer sections 130 once every field period. The vertical transfer sections 130 then sequentially transfer the injected signal charges in a vertical direction (i.e., in a direction in which the vertical transfer sections 130 elongate) before the start of the next field period. The horizontal transfer section 140 receives the signal charges output sequentially from the vertical transfer sections 130 and transfers the signal charges horizontally in series.
The CCD solid-state imaging device of Example 1 includes a signal output circuit for outputting a signal charge transferred from the horizontal transfer section 140 as a signal output as shown in FIG. 2. The signal output circuit shown in FIG. 2 is connected to the output section of the horizontal transfer section 140. The signal output circuit includes a reset circuit 1, a floating diode 2, and an amplification circuit 3. The amplification circuit 3 includes a first source follower circuit 4 and a second source follower circuit 5 provided in parallel.
The reset circuit 1 applies a reset voltage Vr of about 15 V to the floating diode 2 prior to the detection of charges, so that a terminal voltage of the floating diode 2 is set at the reset voltage Vr. Thereafter, the charges transferred from the horizontal transfer section 140 are accumulated in the floating diode 2. As a result, the terminal voltage of the floating diode 2 changes. The amplification circuit 3 receives the terminal voltage of the floating diode 2, and outputs a signal in accordance with the change in voltage. Thereafter, the reset circuit 1 reapplies the reset voltage Vr to the floating diode 2, so that the charges transferred from the horizontal transfer section 140 are transferred to the floating diode 2 again.
In Example 1, a power supply voltage Vod2 which is lower than the reset voltage Vr is used as the power supply voltage for the second source follower circuit 5 of the amplification circuit 3. In this regard, the signal output circuit of Example 1 differs from the conventional signal output circuit (see FIG. 5) using the reset voltage Vr of 15 V as the power supply voltage of the second source follower circuit 5.
However, the first source follower circuit 4 uses the reset voltage Vr of 15 V as the power supply voltage Vod1 as in the conventional signal output circuit. Since a current flowing through the first source follower circuit is small, i.e., about 200 to 300 μA, the remarkable reduction in power consumption cannot be expected even if the power supply voltage Vod1 of the source follower circuit 4 is lowered.
On the other hand, since a current of about 3 to 4 mA flows through the second source follower circuit 5, the power consumption which is obtained by multiplying the current and voltage can be reduced by lowering the power supply voltage Vod2 of the source follower circuit 5.
The power supply voltage Vod2 of the second source follower circuit 5 can be determined in the following manner.
First, in order to allow the second source follower circuit 5 to perform a normal operation, it is sufficient to allow a transistor 7 to operate within its current saturation range. The condition thereof is expressed by the following Expression 3:
(Vod2-Vos)≧(Vg-Vos)-Vth2 [Expression 3]
where Vos is the source voltage of the transistor 7, Vg is the gate voltage, and Vth2 is the threshold of the transistor 7.
When the source voltage Vos is deleted from Expression 3, the following Expression 4 is obtained.
Vod2≧Vg-Vth2 [Expression 4]
Within the range determined by Expression 4, a saturated current is allowed to flow at any power supply voltage Vod2 of the second source follower circuit 5. If the power supply voltage Vod2 is minimized within the range determined by Expression 4, it is possible to restrain the power of the source follower circuit 5.
For example, assuming the gate voltage Vg is 10 V and the threshold value Vth2 is 1 V, the power supply voltage Vod2 equal to or larger than 9 V can be obtained based on Expression 4 above. Therefore, if the power supply voltage Vod2 is set at 9 V, it is possible to minimize the power consumption of the second source follower circuit 5 while maintaining the saturated current of the transistor 7.
If it is assumed that the current I flowing through the second source follower circuit 5 is 4 mA, the power consumption of the source follower circuit 5 is (9 V×4 mA), that is, 36 mW. On the other hand, in the conventional example as shown in FIG. 5, since the reset voltage Vr of 15 V is used as the power supply voltage of the source follower circuit 5, the power consumption is (15 V×4 mA), that is, 60 mW. As is apparent from the comparison of the power consumption, the power consumption in Example 1 is smaller than that of the conventional example. The difference in power consumption is 24 mW.
On the basis of Expression 4 above, it is possible to lower the power supply voltage Vod2 by increasing the threshold Vth2. Thus, it is also possible to reduce the power consumption by increasing the threshold Vth2.
For example, if the transistor 7 having a threshold Vth2 of 5 V is employed, the power supply voltage Vod2 equal to or larger than 5 V is obtained based on Expression 4 (in this case, the gate voltage Vg is equal to 10 V). If the current I flowing through the second source follower circuit 5 is set at 4 mA, the power consumption is further reduced to (5 V×4 mA), that is, 20 mW. Thus, a difference between the power consumption of Example 1 and the power consumption (60 mW) of the conventional example shown in FIG. 5 is 40 mW; the power consumption is reduced to about one-third of that of the conventional example.
Accordingly, if the power supply voltage Vod2 is reduced as small as possible and the threshold Vth2 of the transistor 7 is increased based on Expression 4 above, the power consumption is greatly reduced.
EXAMPLE 2
FIG. 3 is a circuit diagram showing a signal output circuit of Example 2 according to the present invention. Example 2 differs from Example 1 in that a third source follower circuit 11 is further provided for in the amplification circuit 3.
In Example 2, the power supply voltage Vod2 of the second source follower circuit 5 is made as small as possible based on Expression 4 above as in Example 1. A power supply voltage Vod3 of the third source follower circuit 11 is made as small as possible based on Expression 5 below:
Vod3≧Vg3-Vth3 [Expression 5]
As a result, the power consumption is also reduced in the third source follower circuit 11. Moreover, if the threshold Vth3 of a transistor 12 of the third source follower circuit 11 is increased so as to further reduce the power supply voltage Vod3, the power consumption can be further reduced.
It is apparent that the same effect can be obtained by additionally providing a fourth source follower circuit, a fifth source follower circuit and the like.
As described above, according to the present invention, the power supply voltages of the source follower circuits are lowered as the DC current flowing through each of the source follower circuits increases. Therefore, the power consumption for each additional source follower circuit is reduced.
Moreover, higher thresholds for the transistors of the source follower circuits are used as the DC current flowing through each of the source follower circuits becomes larger. The power supply voltage required to allow the transistors to operate in a saturated range is lowered thereby so as to make it easy to reduce the power supply voltage.
Various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be broadly construed. | A solid-state imaging device of the present invention includes: a plurality of photoelectric conversion elements; a transfer section for transferring charges generated by the photoelectric conversion elements; a floating diode for converting the charges transferred by the transfer section to voltage signals; and an amplification section including a plurality of source follower circuits, each amplifying the voltage signals generated by the floating diode, wherein different power supply voltages are supplied to the respective source follower circuits, and the power supply voltages are reduced as the DC current flowing through each of the respective source follower circuits increases. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of skateboards, and more specifically to a kit and method of manufacture of a skateboard deck.
BACKGROUND OF THE INVENTION
[0002] Traditionally skateboard decks, such as street decks, long boards, and luge boards, have been manufactured from hardwood veneer layers using industrial presses. These presses push two molds, a positive and a negative form, similar to the shape of a modem skateboard deck against a number of layers of veneer and glue. Once the glue has dried the molds are separated and the skateboard deck is removed, finished, and mounted on skateboard hardware.
[0003] It has been noted that avid skateboarders frequently break their skateboards in use, and require replacement decks, although the hardware portion (such as the trucks, including the wheels) are still in good condition. Some skateboarders also wish to customize their decks by building their own, or decorating the outer surfaces. However, at present skateboarders must either obtain a complete replacement skateboard, including hardware, which increases the cost of a replacement; or obtain a pre-manufactured deck, which is pre-shaped and pre-finished. Equipment such as the industrial press needed to manufacture a custom skateboard deck is typically inaccessible to the average skateboard user, who requires instead a less expensive, more accessible means of manufacturing a skateboard deck which may later be customized or finished and mounted on skateboard hardware.
SUMMARY OF THE INVENTION
[0004] Accordingly, the present invention provides a skateboard deck and a method of manufacturing a skateboard deck from a plurality of layers of veneer or other suitable material without the use of an industrial press or two-sided mold. A one-sided mold having a contoured surface is provided with a plurality of precut layers. The layers are stacked on the mold with an adhesive interposed between adjacent layers, and the mold and layers thus stacked are placed in a flexible-walled, air-impermeable environment. Air in the environment is evacuated until exterior pressure on the environment causes the layers to conform to the contours of the mold, and the adhesive is allowed to set before the layers are removed from the environment.
[0005] A feature of the invention is that the air may be evacuated by means of a hand operated, non-electric pump.
[0006] Still another feature of the invention is that alignment of the layers on the mold may be achieved by means of alignment pins mounted on the contoured mold surface which correspond to pre-drilled holes in the layers; or by means of an elastic or tie restraint.
[0007] Another feature of the invention is a kit for the manufacture of a skateboard deck using this method, comprising the precut layers, a flexible-walled, air-impermeable environment with valve means for evacuating air, and a one-sided, contoured mold.
[0008] Yet another feature of the invention is a skateboard, comprising a deck manufactured using this method mounted on appropriate skateboard hardware.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In drawings which illustrate by way of example only a preferred embodiment of the invention,
[0010] [0010]FIG. 1 is a perspective view of a preferred embodiment of the skateboard deck mold.
[0011] [0011]FIG. 2 is a cross-sectional view of diagram of a mold-layer assembly after air evacuation and adhesive setting from the axis A shown in FIG. 1.
[0012] [0012]FIG. 3 is a perspective view of a preferred embodiment of the vacuum container and valve.
[0013] [0013]FIG. 4 is a perspective view of the mold-layer assembly and vacuum container with the air evacuated from the container.
[0014] [0014]FIG. 5 a is a perspective view of a preferred embodiment of the vacuum bag clip.
[0015] [0015]FIG. 5 b is a cross-sectional view of the vacuum bag clip engaging the vacuum bag.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to FIG. 1, the skateboard deck 10 (not shown in FIG. 1) of the present invention is manufactured with a one-sided mold 30 . The mold 30 is shaped such that it generally follows the shape of the deck 10 to be manufactured. The upper surface 36 of the mold 30 is contoured as a negative of the finished skateboard deck 10 shape. To facilitate manufacture of the deck 10 , a first and second alignment pin 32 , 34 are mounted on the mold 30 such that they protrude from the upper surface 36 .
[0017] In a preferred embodiment, the mold 30 is manufactured from a sturdy but lightweight material such as extruded, expandable, or closed cell polystyrene foam or high density urethane with sufficient density and rigidity such that it does not deform or break during the assembly of the deck 10 . Such materials may be easily shaped to the form of the mold 30 ; extruded polystyrene foam, for example, may be cut to shape; expandable polystyrene and polypropylene may be injection or blow molded. Alternatively, the mold 30 may also be formed from molded pulp paper or plaster, or cut from balsa wood. However, with a material such as plaster, the mold 30 will then have a significantly greater weight. If the mold 30 is manufactured from a foam product, the alignment pins 32 , 34 may be mounted in the mold 30 after the shape is formed; if the mold 30 is cast in a material such as plastic, paper, or plaster, the alignment pins 32 , 34 are cast or mounted in the mold 30 before the material is set.
[0018] Turning to FIG. 2, the deck 10 is composed of several layers of material 22 a through 22 g, comprising skate face, skate core, and x-band layers. Preferably the layers 22 a through 22 g are formed of rotary cut hard maple veneer. For strength and flexibility, preferably seven layers of {fraction (1/16)}″ veneer are used to form the layers 22 a though 22 g, although fewer or more layers with other thicknesses may be used. The layers may also be composed of other materials such as other woods, bamboo veneer, aluminum, and composites such as carbon fiber. The layers, however, should be sufficiently thin so that the mold 30 is not distorted during the deck manufacturing process. Each of the layers 22 a through 22 g are precut with substantially similar shapes that correspond to a skateboard deck shape, as well as to the mold 30 .
[0019] The outer skate face layers 22 a, 22 g are preferably cut from best quality veneer with no defects and, if cut from a wood, with the grain running in the lengthwise direction. The outer faces of the skate face layers 22 a, 22 g, which in the assembled deck 10 do not contact any other layers 22 b through 22 f, may optionally be finished with decorative markings after the deck 10 is assembled.
[0020] The skate face layers 22 a, 22 g sandwich an assembly of skate core layers 22 b, 22 d, 22 f and x-band layers 22 c, 22 e. The skate core layers 22 b, 22 d, 22 f are formed of lengthwise grain veneer and are alternated with the x-band layers 22 c, 22 e, cut from crosswise grain veneer. Where material with a grain is used, the crosswise grain of the x-band layers 22 c, 22 e provide strength to the assembled deck 10 . The cosmetic quality of the interior layers 22 b through 22 f may be inferior to the cosmetic quality of the skate face layers 22 a, 22 g.
[0021] Each of the veneer layers 22 a through 22 g is provided with pre-drilled holes (not all shown) to facilitate mounting skateboard hardware after the deck 10 is assembled. The pre-drilled holes are aligned when the deck 10 is assembled. Two of the pre-drilled holes 24 (not shown) and 26 serve as alignment guides during assembly, and correspond to the alignment pins 32 , 34 mounted on the mold 30 .
[0022] In assembly, the layers 22 a through 22 g are adhered using a suitable adhesive for the deck material. In the preferred embodiment, a crosslinking polyvinyl acetate emulsion adhesive for high density hardwood veneer such as Multibond® SK8 from Franklin International, a two-part epoxy such as West System® epoxy, or a polyurethane adhesive is used such as GorillaGlue®. Adhesive is applied to the upper faces of each of layers 22 a through 22 f as they are each mounted on the mold 30 and over the alignment pins 32 , 34 . This mold-layer assembly is then inserted into the vacuum container 50 , shown in FIG. 3.
[0023] The vacuum container 50 is preferably a bag formed of flexible nylon/polyethylene laminate or vinyl material and is of sufficient size to admit the insertion of the mold-layer assembly. The container 50 is initially sealed on all but one side to permit insertion of the mold-layer assembly. If the container 50 is manufactured from a roll of nylon/polyethylene laminate tubing, then one open end 54 may be heat sealed or otherwise sealed with an airtight seal. Once the mold-layer assembly is inserted in the container 50 , the remaining open end 62 may be sealed using a removable, airtight clamp (described below), or using another means of achieving an airtight seal such as an adhesive tape or reclosable slide fastener.
[0024] The container 50 is also provided with an air evacuation aperture 56 , to which is mounted in an airtight seal a one-way check valve means 60 for blocking the passage of air into the container 50 . In one embodiment, tubing 58 is mounted at one end through the aperture 56 using an airtight adhesive and is connected at its other end to the valve 60 .
[0025] The aperture 56 is preferably positioned in the container 50 such that when the mold-layer assembly is inserted in the container 50 in the position delineated by the dotted line in FIG. 3, the aperture 56 disposed against the mold-layer assembly. Positioning of the aperture 56 against the mold-layer assembly permits air to be evacuated though the aperture 56 , as described below, since the mold-layer assembly is somewhat porous. If the mold 30 is manufactured from a substantially non-porous material, such as plaster, then the side of the mold 30 may be scored to provide channels (not shown), or breather material may be interposed between the aperture 56 and the mold 30 (not shown) to permit the passage of air from within the container 50 through the aperture 56 .
[0026] The remaining open end 62 of the container 50 may be sealed using a removable clamp 70 , shown in FIGS. 5 a and 5 b, so that the container 50 may be used for the manufacture of subsequent decks 10 . The clamp 70 comprises a cradle 72 and a rod 74 which fits in snap-fit relation into the cradle 72 , each of which extend for at least the width of the container opening 62 . To releasably seal the container 50 , the end 62 of the container 50 is placed on the cradle 72 , and the rod 74 is snapped into place in the cradle 72 , thus securing the container 50 therebetween, as can be seen in FIG. 5 b. The clamp 70 thus provides a releasable airtight seal for the opening 62 . Alternatively, the open end 62 may be sealed using a resealable low-tack adhesive tape which also provides an airtight seal.
[0027] In order to evacuate air from the sealed vacuum container 50 , a vacuum pump means is used. As shown in FIG. 4, in the preferred embodiment an inexpensive hand pump 80 is mounted on the check valve 60 to evacuate the air, and is removed once the air is evacuated from the container 50 . The check valve 60 prevents air leakage once the hand pump 80 is removed.
[0028] Thus, to assemble the skateboard deck 10 , the layers 22 a through 22 g are stacked in the desired order for mounting on the mold 30 , such that the first skate face layer 22 a is mounted on the mold 30 first. A coating of adhesive is applied to the interior of the skate face layer 22 a; this layer 22 a is then mounted on the mold 30 with the adhesive-coated side facing up, such that the alignment holes 24 , 26 are aligned on the alignment pins 32 , 34 . A coating of adhesive is then applied to the surface of the next layer, 22 b, such that when the layer 22 b is mounted on the mold 30 and aligned, the adhesive-coated surface again faces up, and the non-coated surface of the layer 22 b contacts the adhesive-coated surface of the previous layer 22 a. This process is followed for the remaining layers, except for the second skate face layer 22 g. This last layer 22 g is placed on the mold 30 and alignment pins 32 , 34 without a final coating of adhesive.
[0029] The mold-layer assembly is then placed inside the vacuum container 50 . Preferably, for added security against misalignment, the assembly may be temporarily secured with elastic bands or other tie fasteners 82 during the remainder of assembly. At this stage, the layers 22 a through 22 g are substantially unbent and do not conform to the contours of the surface 36 of the mold 30 . The vacuum container 50 is sealed using the bag clamp 70 or other sealing means, and the air is evacuated through the aperture 56 by means of the vacuum pump 80 such that pressure is applied against the layers 22 a through 22 g and they conform to the contoured surface 36 . Preferably, a pressure of approximately 26 Hg, which is effectively approximately 15 psi, is applied. By maintaining a vacuum within the container 50 , the layers 22 a through 22 g will continue to be contoured against the mold 30 . The adhesive is then allowed to set. If air inadvertently leaks into the container 50 while the adhesive is setting, the vacuum pump 80 may be temporarily reattached to evacuate the air.
[0030] Thus, the skateboard deck 10 is manufactured in the following process:
[0031] A mold and skate face, skate core, and x-band layers are provided. Adhesive is applied to the interior of a first skate face layer, and the first skate face layer is mounted on the mold with the adhesive-coated face up. Adhesive is then applied to subsequent layers on the face that will not be in contact with the glue from the previous layer mounted on the mold, and the subsequent layers are mounted in the appropriate order on the mold with the adhesive-coated side facing up, until the second skate face layer remains. This final layer is mounted on the mold without the application of additional adhesive. The layers are aligned on the mold either by means of alignment pins, or by temporarily fixing the layers in place using a removable restraint. The mold-layer assembly thus produced is placed in the vacuum container; the container is sealed, and air is evacuated to apply pressure to the mold-layer assembly and cause the layers to conform to the contours of the mold. The adhesive is allowed to set before the mold-layer assembly is removed from the vacuum environment and the deck is removed from the mold. The deck may then be finished, for example by smoothing the edges and decorating and sealing or finishing the surfaces of the deck. Skateboard hardware may then be attached.
[0032] Various embodiments of the present invention having been thus described in detail by way of example, it will be apparent to those skilled in the art that variations and modifications may be made without departing from the invention. The invention includes all such variations and modifications as fall within the scope of the appended claims. | A skateboard deck and a method of manufacturing a skateboard deck is provided without requiring the use of industrial-grade machinery. Precut layers of veneer or other suitable material are coated with adhesive and stacked on a one-sided, negative-contoured mold and placed in a flexible-walled, airtight container from which the air is evacuated, so as to place pressure on the container and force the layers to conform to the contours of the mold. The air evacuation may be accomplished by means of a hand operated, non-electric vacuum pump. | 1 |
FIELD OF THE INVENTION
This invention relates to the construction of sleeved-type garments. More particularly, the term "sleeved-type garment" is used broadly to include shirts, blouses, sweaters, dresses, jackets, suits, coats, jumpsuits, underclothing, and similar garments which have a body portion covering at least the upper portion of the torso and sleeve portions individually covering at least an upper portion of the arms of the wearer. This invention is applicable to garments for men, women, children and infants.
In addition to every-day clothing, this invention is particularly applicable to garments for active physical use such as sportswear, uniforms and occupational clothing, and to garments for the handicapped and injured. These can include clothing for camping, mountain climbing, skiing, skating, ice hockey, tennis, gymnastics, basketball, football, baseball; astronauts, musicians, dancers, armed services, police, fireman, etc.
BACKGROUND OF THE INVENTION
Conventional shirt-type garments have their sleeves positioned so as to extend outwardly in opposite directions from the trunk portion at 180° from each other. In other words, the central axis of the sleeves in conventional shirt-type garments can be thought of as lying in a single lateral plane through the body (i.e. the plane through the trunk which separates the anterior and posterior portions thereof). Thus, if the median plane of the body divides the body into left and right halves, then the lateral plane is perpendicular thereto. A one-piece pattern which illustrates this construction is the so-called kimono sleeve (as shown in FIG. 4A). The sleeves are in the lateral plane of the body and extend out horizontally at shoulder level. The kimono sleeve pattern is the basis from which conventional shirt-type garments comprised of multi-piece patterns are made. Two such variations are the so-called set-in sleeve and the so-called raglan sleeve. In each of these variations the central axis of the sleeves is angled below the horizontal of the shoulders, but they are still in the lateral plane of the body.
This setting of the sleeve direction within the lateral plane in the design of conventional sleeved-type garments implicitly assumes that the arms move equally in all directions around the body. If the natural arm movement range were equal in all directions then, indeed, the most logical placement of the sleeves in relation to the body would be in the lateral plane making the center of the movement range symmetric between front and back.
In conventional garments while the armholes may be cut out more from the front than from the back, the sleeves are conventionally set in to fit arms positioned at the sides, rather than to fit arms positioned in a substantially forward position.
In early pressurized space suits made of fabric which is inflexible when inflated, the sleeves appear to have been necessarily set at a relatively fixed forward position (in order to be at all functional). Applicant, long after making her invention, came across a recent reference to a discussion of the first functional Wiley Post 1939 pressurized suit on page 29 of the book "Suiting Up for Space" by Lloyd Mallan (New York: The John Day Co., 1971). The description in this book of the construction of this suit is very vague. In any event, in subsequent decades, no one has ever thought that such relatively rigid positioning could be adapted to be useful for more conventional garments made from flexible materials. Such early space suits were apparently not concerned with accomodating the range of natural motions, but rather with a set functional position under essentially inflexible restrictions.
The sleeved-type garments which are the subject of this invention are open to the ambient atmosphere, unlike the aforementioned completely functionally rigid and sealed pressurized space suits. A gas and/or water impermeable wet suit, even with relatively tight cuffs, could still be encompassed within the "atmospherically open" sleeved-type garments of the present invention, because the cuffs and neck openings are not significantly sealed from the outside atmospheric pressure.
SUMMARY OF THE INVENTION
Applicant, apparently for the first time in this ancient clothing art, has focused on the fact that while one's arms have a large range of movement around the body, this freedom of movement is not equal in all directions. One can easily hug oneself in front across the chest, but cannot normally hug oneself in back. Arms have a greater comfortable movement range toward the front of the body than toward the back, making the center of natural movement range asymmetric between front and back (see FIG. 1).
In the present invention, the sleeves are fitted to accomodate arms positioned substantially forward of the lateral plane through the body in a position which preferably corresponds to the approximate center of the range of arm movements. A garment made according to this invention is fitted to arm positions preferably ranging between about 18 degrees and about 45 degrees forward of the lateral plane for a garment intended for normal everyday use. This design reduces bunching up in one direction and pulling of fabric in the other, and is the basis for applicant's forward directed sleeve sleeved-type garment. One of the preferred ways of accomplishing the forward direction in the sleeve is by moving the low point of the armhole forward, while leaving the high point in the lateral plane of the body. Examples of this are illustrated and discussed below. Although not preferred, it is possible to practice this invention in its broader aspects by using armholes cut symmetrically at the sides but with sleeves that are asymetrically shaped so as to give the desired forward angle.
From the simple one-piece pattern embodying this invention, multi-piece pattern variations can be made which place the seams in similar ways as in the set-in sleeve and the raglan sleeve of conventional garments, or in a great variety of designer styled or occupationally dictated additional new ways, all having a forward positioned sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
In this specification and in the accompanying drawings, I have shown and described preferred embodiments of my invention and have suggested various alternatives and modifications thereof; but it is to be understood that these are not intended to be exhaustive and that many other changes and modifications can be made within the scope of the invention. The suggestions herein are selected and included for purposes of illustration in order that others skilled in the art will more fully understand the invention and the principles thereof and will thus be enabled to modify it in a variety of forms, each as may be best suited to the conditions of a particular use.
FIG. 1 shows a plan view of the human body with the position of the arms in the center of the natural range of arm movement, and showing on line A--A the lateral plane through the body, and as line B the range of natural arm movement (with line C as the center in front and line D as the back limit of comfortable arm extension);
FIG. 2 is a side view and
FIG. 3 is a front view of the human body showing how the center of the armpit shifts towards the front as the arm is raised above the head.
For purposes of simplicity and clarity, FIGS. 4A to 7CCC show simplistic "basic block" patterns in flat configurations (without any shape or drape). Such patterns may be used as a template or tool from which other patterns may be developed.
FIG. 4A shows a one-piece pattern of conventional sleeved-type garments with the center line F of the sleeves following the lateral plane through the body.
FIG. 4B shows the front view and
FIG. 4C shows the back view of the assembled garment made from the pattern shown in FIG. 4A. Except for the lower front neckline, the front and back of the body and sleeves are interchangeable. The low point G of the armhole is at the side at an equal distance between center front C and center back.
FIG. 5A shows a one-piece pattern for making a sleeved-type garment in accordance with the present invention wherein the center line F of the sleeves is forward of the lateral plane through the body.
FIG. 5B shows the front view and
FIG. 5C shows the back view of the assembled garment made from the pattern shown in FIG. 5A. The front and back of the body and sleeves are not interchangeable. The low point G of the armhole is at the side front closer to center front C than to center back.
FIGS. 6A and 7A show two different alternative one-piece patterns for making sleeved-type garments in accordance with the present invention.
FIGS. 6B and 6C show the front and back views of the assembled garment made from the pattern shown in FIG. 6A.
FIGS. 7B and 7C show the front and back views of the assembled garment made from the pattern shown in FIG. 7A.
FIG. 6AA shows one variation of sleeve construction from that of the one-piece pattern shown in FIG. 6A.
FIGS. 6BB and 6CC show a front and back view respectively of an assembled garment made from the pattern of FIG. 6AA.
FIGS. 7AA and 7AAA show two variations of sleeve construction from that of the one-piece pattern shown in FIG. 7A.
FIGS. 7BB & 7CC and 7BBB & 7CCC show assembled garments made respectively from the pattern in FIGS. 7AA and 7AAA.
In the foregoing figures, the dotted lines represent fold lines. No such fold lines appear in the following figures (do not confuse the dotted lines shown in these latter figures, in which the dotted lines depict stitching).
The remaining figures show examples of three-dimensional practical adaptations of the previously illustrated "basic block" patterns:
FIG. 8 shows a two-piece pattern variation based on the one-piece pattern shown in FIG. 5A for making a sleeved-type garment in accordance with the present invention.
FIGS. 8A, 8B and 8C respectively, show a one-piece pattern, a three-piece pattern and a five-piece pattern, which illustrate a few of the design variations which are possible.
FIGS. 9 to 11 show a back, front and plan view of the assembled garment made from the pattern of FIG. 8.
FIGS. 9A to 11A, 9B to 11B and 9C to 10C are similar to FIGS. 9 to 11, but based respectively on the patterns of FIGS. 8A, 8B, and 8C.
FIG. 12 shows a one-piece pattern variation based on the pattern shown in FIG. 7AA for making a sleeved-type garment in accordance with the present invention.
FIGS. 13 and 14 show the back and front view of the garment made from the pattern shown in FIG. 12;
FIGS. 15A and 15B show a two-piece pattern variation based on the one-piece pattern shown in FIGS. 6A or 6AA for making a sleeved-type garment in accordance with the present invention.
FIGS. 16 an 17 show the front and back view of the garment made from the pattern in FIGS. 15A and 15B.
FIGS. 18A and 18B show a two-piece pattern variation similar to the patterns shown in FIGS. 15A and 15B having an extra seam for a closer fit at the armhole.
FIGS. 19 and 20 show the back and front view of the garment made from the pattern shown in FIGS. 18A and 18B.
FIG. 21 shows a two-piece pattern variation based on the one-piece pattern shown in FIG. 5A but with a more pronounced (45°) forward sleeve angle and with a partial elbow seam in the sleeve sections which gives the lower part of the sleeve a further (221/2°) forward angle.
FIGS. 22 and 23 show the back and front view of the garment made from the pattern shown in FIG. 21.
DETAILED DESCRIPTION
A simple one-piece pattern embodying a basic construction of the present invention is shown in FIG. 5A.
Two additional one-piece pattern variations of a forward positioned sleeve according to applicant's invention are shown in FIGS. 6A and 7A. In the variations shown in FIGS. 6AA, 7AA, and to a lesser degree 7AAA, the center line of the sleeves appears to be in or parallel to the lateral plane. However, when the garment is sewn together the sleeve has an orientation forward of the lateral body plane. Thus, except for seam placement, the finished garments in FIGS. 6B and 6BB are the same in shape. This is also true for FIGS. 7B and 7BB.
The central axis of the sleeve (or at least the upper portion thereof, if the sleeve has a set bend as in FIG. 23) is perhaps a better indicator of the forward direction of a given sleeve than is the center line F. The central axis is the line of symmetry that a sleeve has when worn (as opposed to being merely folded flat). The forward orientation of the garment is then the angle in the horizontal plane that the central axis of the sleeve makes with the lateral plane of the garment's body portion when the sleeve is in its fitted position (i.e., the position of minimum stress or "pull" on the fabric). If the garments were capable of being inflated, the sleeves would assume the aforementioned "fitted position".
FIGS. 5B, 6B and 7B all show garments with forward angled sleeves; the difference among these being in the degree of vertical freedom. The garments of FIGS. 5A and 6A have more upward freedom, while that of FIG. 7A has a more natural downward freedom of movement. Another difference is that the garment in FIG. 6B shows a partial armhole seam H on the side of the sleeve closest to center front C, while the garment in FIG. 7B shows a partial armhole seam I on the side of the sleeve closest to center back. A further difference is that FIG. 6A shows the center line F following the seam edges of the sleeve section. FIGS. 5A, 5B, 6A, 6B, 7A and 7B all show the low point G of the armhole in exactly the same place.
This serves to illustrate that even with the same forward slanted armhole, there can be variations in the vertical component of the forward sleeve angle. Note also that by shifting the low point G further around, the horizontal forward sleeve angle can be significantly increased (as illustrated in FIG. 21). It will be understood that point G in FIG. 5A is equivalent to point 36 in FIGS. 8 to 11 and to point 86 in FIGS. 21 to 23. However, as the seam line is shifted, the position of the "low point" becomes blurred, and the point in question may better be called the underarm point (i.e., the underarm point on a seam line where transition from the sleeve to the body of the garment occurs). See for example, points 36b and 66 in FIGS. 10B, 15B, and 16.
In FIGS. 8 through 23, actual garments are shown in juxtaposition to the patterns from which they are made. To aid in the better understanding of the construction of each garment, the various portions of the garment are indicated by appropriate reference numerals; such as 30, 50, 60, 70, and 80 for the front panel; 31, 51, 61, 71, and 81 for the back panel; 32 and 82 for the lower back panel (if separate); 33, 53, 63, 73, and 83 for the sleeve; 34, 54, 64, 74, and 84 for the shoulder point; 35 and 85 for the back seam intersection; 36, 56, 66, 76 and 86 for the underarm point, 37c for the yoke (see FIG. 8C), 38c for the point of joinder of the yoke seam with the armhole seam, and 39c for the point of intersection of the yoke seam and the front opening. See also curvature points 44 and 46 in FIGS. 15A to 17 and 18A to 20, respectively (which help to show how the pattern is assembled into the finished garment). Points 45 and 47 show the back yoke position in the same respective drawings.
In FIGS. 21 to 23, 80 is just the upper panel, 90 is the lower front panel, and 92 is the partial elbow seam.
As best seen in FIG. 23, the sleeve 83 has a dart in it, resulting in an elbow seam 92. This gives a fit to the sleeve where the forearm is at a relaxed angle to the upper arm (here illustrated as at 221/2° from the straight arm position). For working at a desk or the like, this can be a more common orientation of the arms and is therefore preferred in such circumstances.
A prime (') is used to indicate portions on the left side and to differentiate from corresponding portions on the right side of the garment. These are used in FIGS. 8 to 23 in particular. In FIGS. 8A, 8B and 8C where similar portions have the same reference numerals, the letters a, b and c have been added, respectively, to differentiate among the corresponding figures.
The armpit is at the side of the body when the arm is hanging at the side, but when the arm is raised straight above the head or is moved forward, the articulation of the arm and the stretching of the back muscles causes the armpit to shift to the front so that it cannot be seen from the back (FIGS. 2 and 3). This shift results in the need for additional fabric at the back sleeve and upper rear body area. A similar, less pronounced, shift also occurs at the shoulder level.
Conventional sleeved-type garments place the low point of the armhole at the side at equal distance from center front and center back. When the arms move forward, this underarm point of the conventional garment remains fixed at the side and causes substantial pulling across the back of the garment. This has been compensated for by the use of placques, shirring, elastic inserts, "formless" fullness, and the like; but none appear to have ever anticipated applicant's design.
In a preferred embodiment of this invention, the low point of the armhole is placed at the side front, in the center of the armpit when the arm is raised. Shifting the low point of the armhole forward, while leaving the high point at the side, results in a better fitting, more comfortable garment with reduced stress placed on the underarm point. Also, by bringing the side body seam and the underarm sleeve seam through the center of the armpit it is possible to provide the necessary shaping for up and down expansion in the armpit. This can avoid pulling out ones shirt tails (see for example FIG. 10A).
The genius of applicant's unique design is in basing the fit of the garments on the averaged dynamic body position and changing muscle shape as well as on mere static body dimensions.
The human body comes in a variety of shapes and sizes but has one universal way of moving. Garments which fit the natural way of moving, as well as the size and shape of the wearer, provide a new dimension for a better fitting, more comfortable garment with advantageously less pull and less bunching of the fabric.
Conventional sleeved-type garments fit a body at rest with the arms at the sides, concentrating on body size and leaving enough room for required movement. The fit is based on the exterior dimension of the body and on shaping of the seams. Thus, the conventional garment is cut to fit a relatively extreme position in the range of natural arm movements. In contrast, applicant's garments are cut with the sleeve naturally positioned forward of the lateral plane at an angle which is more in the center of natural movement, with a shorter angular distance needed to move to any of the natural extreme arm positions (such as raised arms, hanging arms, and hugging arms). With less angular movement needed there will be less bunching and less pull.
Thus, an added benefit is that a garment made according to applicant's invention need not depend for flexibility mainly on the type of fabric from which it is made, because applicant's also has greater moveability inherent in the fit than does a conventional garment.
It will be appreciated that the design of garments according to this invention are based on an asymmetric structure.
Conventional sleeved-type garments have always been based on a pattern having a symmetry in the lateral plane. Before there were designers, regional costumes were based on a structure where the front and back of a sleeved-type garment were interchangeable, and the garment could be worn with either side toward the front. Designers continue to use this basic structure, varying the shape and fit, but keeping an essentially symmetric approach.
Applicant's invention provides the basis for new designs by allowing room for arms to move forward, making an asymmetric structure with front and back not interchangeable. This allows new shapes for sleeved-type garments which have a definite difference between front and back. Seams can be placed in new ways and fabric can be cut from new angles, providing a great variety of new designs. Thus, though the invention is a technical innovation, it lends itself to unique fashion improvements.
The amount of fabric required to make a conventional sleeved-type garment and a garment from the present invention is essentially the same. The difference is that a garment made from this invention utilizes this amount of fabric in a more economical way be placing the fabric where it is needed the most for body movement. In some cases this also results in using less fabric than would be required for making a conventional shirt (for example by requiring less overall fullness and better form fitting).
Because the forward sleeve fits the range of natural arm movements, stresses at the armhole are less than for the conventional design. Stresses are conventionally taken up by adding additional material and shaping at the armhole. This latter procedure requires that seams be in their conventional positions, such as in the set-in sleeve and the raglan sleeve, each of which use a minimum of four pattern pieces. Since the forward sleeve has lower stresses and typically will not need additional material and shaping at the armhole, this invention lends itself to one-piece patternmaking (also to two-piece patterns where the body and sleeve are in one piece).
One-piece patterns have fewer seams than multi-piece patterns and take less sewing time thereby reducing the cost of manufacturing a garment.
One-piece patterns give an overview of the total garment area thereby opening up new possibilities of design and manufacturing in terms of seam placement. Seams can be placed to allow fabric patterns to join in a decorative way or as decorative elements themselves, or be positioned to best absorb stresses, or minimize fabric wastage.
Other advantageous uses include use in insulating garments. Insulation in garments depends on a continuously maintained thickness of trapped air surrounding the torso and limbs. As the arms move toward the front in conventional sleeved-type garments, there is typically substantial pulling across the back causing the air to be pressed out (and also pulling at the armhole cutting off an exchange of trapped air between the sleeves and the body section). This invention is thus particularly suitable for garments worn in the cold and designed for vigorous physical activity, such as in skiing and mountain climbing. | Garments covering the arms and upper torso made of a one-piece or multi-piece pattern in which the central axis of the sleeves are naturally positioned forward of the lateral plane of the body (rather than with the conventional fitted position placement in the lateral plane). The low point of the armhole is advantageously at the side front in the center of the armpit when the arm is raised. The garment is fitted to accommodate arms positioned at an angle substantially forward of the lateral plane of the body, preferably ranging between about 18° and about 45°. Contrary to conventional wisdom, the garments fit a body position which is in the center area of the natural arm movement range relative to the torso and which is naturally unsymmetric between front and back. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to U.S. Prov. Ser. No. 61/990,198 filed May 8, 2014, U.S. Prov. Ser. No. 61/944,802 filed Feb. 26, 2014, and U.S. Prov. Ser. No. 61/969,563 filed Mar. 24, 2014, the entire contents of each of which are incorporated herein fully by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to artificial plants or trees, and to an improved artificial tree apparatus that is easily assembled, disassembled, and transported by any means including by rail and fork-truck, and which may be of any suitable size and height from a few centimeters to twenty meters or even more depending upon a user's desire. More specifically, the present invention is directed to portable and retractable artificial trees having separable, modular tree portions mechanically connectable, controllable and lockable between trunk and branch portions, and which may be controlled by direct wire control, by remote control (wireless via Radio Frequency (RF), Infra-Red (IR), BlueTooth®, or any other remote control convention), and via one or a series of process controllers by remote signals sent over an electronic medium (e.g., control signals sent via an Internet portal from a distant unit, desk-top, hand-held-PDA-type unit, or otherwise).
[0004] 2. Description of the Related Art
[0005] Artificial trees are well known. Most artificial trees comprise a multiplicity of separate branches each formed of a plurality of plastic needles held together by twisting a pair of wires about them. In other instances, the branches are formed by twisting a pair of wires about an elongated sheet of plastic material having a large multiplicity of transverse slits. In still other artificial trees, the branches are formed by injection molding of plastic.
[0006] Irrespective of the form of branch, the most common form of artificial tree comprises a wooden simulated trunk having a plurality of spaced apart apertures for reception of branches therein to thereby hold the branches in radially extending relation to the trunk to form the artificial tree. For purposes of storage, the branches are removable, requiring the repositioning of the branches on the trunk each time the tree is reassembled. The difficulty of this task is, however, somewhat reduced by color coding the apertures on the trunk with the ends of the branches.
[0007] To provide a tree which can be stored without occupying an unduly large amount of space and yet to avoid the need for totally dismantling the tree and re-assembling for further use, it has been previously proposed to permanently pivotally affix the artificial branches of an artificial tree to the trunk thereof to permit movement of the branches between an outwardly deployed position and a storage position in which the branches lie close to the trunk and thereby occupy a comparatively small space. However, such trees require elaborate assembly techniques, and somewhat complex structure, thereby rendering both of these prior art patents of little importance in commercial development of artificial trees.
[0008] Also known are artificial trees with foldable branches. The structures disclosed therein, however, require that the trunk be apertured to permit insertion of either the rear ends of the branches or of a branch connecting member therein. In addition, the structure requires some form of bifurcation at the ends of the branches, which bifurcation requires special tooling not heretofore employed in the making of artificial trees.
[0009] To avoid the necessity of aperturing the trunk, it has been suggested to provide a branch holder which may be secured to the trunk of the tree and to which a branch or branches may be secured for pivotal movement between an extended position and a collapsed position. For example, a branch holder for pivotally securing a single branch to the trunk has been provided. However, the separate manipulation of branches for deployment and storage is time consuming and conducive to uneven deployment of the branches.
[0010] Artificial trees constructed of metal and/or plastic have become more commonly substituted for natural evergreen trees when decorating homes, offices, and other spaces, both indoors and outdoors. Such artificial trees generally include multiple tree sections joined at the trunk and held erect by a floor-based tree stand. Sometimes, consumers wrap strings of lights about the artificial tree (e.g., a Christmas tree) to enhance the decorative quality of the tree display. Some artificial trees are “pre-lit” trees to ease the burden on consumers of decorating the tree with strings of lights. Typical pre-lit trees include an artificial tree with multiple standard light strings distributed about the exterior of the tree. Wires of the light string are clipped to branch structures, while plug ends dangle throughout the branches.
[0011] Often, in both non-pre-lit and pre-lit trees, the connection of light strings spans more than one trunk section. If a particular trunk section is allowed to spin, the wiring of the light strings can become twisted. When twisted, light strings are at risk of plug and end connector damage and are even at risk of breaks. Safety can therefore be compromised if a trunk section is allowed to spin. Further, if a particular trunk section is allowed to spin, the tree can be difficult to decorate, as it can be difficult to arrange light strings or ornaments on a moving section of tree. Additionally, trees are often placed in the corners of rooms or up against walls. Once decorated, it is desirable for the sections of the tree to remain fixed, as the wall-facing or corner-facing sides are often left undecorated. It is therefore beneficial for artificial tree trunk sections to remain fixed in place.
[0012] Similarly, a sloppy fit between trunk sections can create wobble or unwanted tilt between sections. This can leave the tree unstable and at risk of toppling if bumped or touched. Also, a non-vertical section is undesirable from an aesthetic perspective, as a slanted tree looks visually less impressive than a perfectly vertical tree. Therefore, it is desirable to have an extremely tight fit between tree trunk sections which ensures a completely vertical tree.
[0013] Additionally, as the popularity of both pre-lit and non-pre-lit artificial trees has grown, so to have the bulk and complexity of artificial trees. Not only has the number and density of branches of a typical artificial tree increased, but, for pre-lit trees, the increase in number and density of branches likewise increases the number of lights and light strings. As a result, the weight and bulk of artificial trees has increased, thus making it difficult to lift and align individual trunk sections when assembling the tree.
[0014] Further adding to the difficulty of lifting and aligning individual trunk sections is the advent of the locking trunk section. Manufacturers have created a number of artificial trees that have locking trunk sections. These trunks have either a protrusion or void, respectively, and are insertable in only one rotational alignment into the corresponding void or protrusion, respectively, of the receiving trunk portion. Such a design provides a friction fit such that the two trunk portions cannot spin relative to one another. However, as mentioned above, because of the weight and bulk of the artificial trees, it is often difficult to perfectly align the individual trunk sections. Consumers must first locate the alignment mark on the receiving portion, then locate the corresponding alignment mark on the insertable portion, and finally adjoin the two perfectly in the identified alignment. Thus, it is desirable for trunk sections to fit universally in any rotational orientation with the receiving portion of the receiving trunk to provide a secure, tight fit between trunk sections.
[0015] Some known inventions have attempted to make artificial trees more convenient to put together. For example, a simple artificial tree with one embodiment having multiple tree sections that join together is known. The tree includes single bulbs at each end of a branch, with bulb wiring extending from inside a trunk through hollow branches. A bayonet fitting is used to adjoin the sections, a top section having a projecting pin, and a bottom section having an L-shaped bayonet slot. The two sections are coupled by aligning the projection pin with the bayonet slot and rotating to interlock the sections, thereby bringing a pair of spring contacts into alignment with a pair of terminals to make an electrical connection.
[0016] Another known artificial tree is a pre-lit tree made in sections which may be folded for easy storage. The individual tree sections include a threaded male end and a threaded female socket end. The male end of a tree section is screwed into the female end of another section. Wiring for the lights passes from the trunk through holes in branches and connects with individual lights at an interior of the branch. When the tree is screwed together, an electrical connection is made.
[0017] In another example of an artificial tree an internal sleeve sized to receive a tree trunk is utilized. The sleeve is coupled to a base section and positioned to receive the tree trunk. The sleeve is provided with longitudinally aligned friction strips that are spaced apart and tapered in height to increase the amount of friction presented to an inserted trunk. When the trunk cylinder is inserted into the sleeve, the friction strips of the sleeve press against the wall of the trunk to secure the tree.
[0018] One such combination artificial tree-lighting arrangement includes a generally elongated tree trunk. The combination also includes a plurality of connecting components mountable on the tree trunk and a plurality of display components mountable on the connecting components. Each display component has tree limbs and lighting cables extending therefrom. The lighting cables are provided with decorative lights. An electrical circuitry connectable to an electrical power source is attachable to the connecting components. The electrical circuitry includes a connecting component-to-light coupling arrangement for electrically coupling the connecting components to the decorative lights. The connecting component-to-light coupling arrangement allows the display components to rotate relative to the connecting components about a rotation axis substantially parallel to the trunk longitudinal axis while maintaining the electrical coupling between the connecting components and the decorative lights.
[0019] Another such artificial tree includes a plurality of twigs, a channel element, a number of inserts, and a hook-like member. Each twig is inserted through an aperture in the insert and the insert, in turn, is placed in and secured in the channel element. The hook-like member has a short side used to secure the branch to an artificial trunk and a long side secured in the channel element. Optical fibers are associated with the twigs of the panel branch. Each optical fiber is threaded through an aperture in an insert and gathered into a bundle. A socket with a light source is provided to receive the bundle of optical fibers such that the branch is lighted.
[0020] There also exists an illuminated artificial tree having a display position and a folded position constructed of an odd number of upright wire mesh panels hingedly attached at their vertical inner edges, the panels including a first end panel, a second end panel and a plurality of intermediate panels between the first and second end panels. A string of decorative lights are attached in a plurality of spaced, reversed loops, the string extending from adjacent the lower edge of the first panel around the intermediate panels to the second panel, then upwardly along the outer edge of the second panel, and then back around the outer edges of the intermediate panels to the first panel, thereby permitting folding of the tree without removal of the light string.
[0021] Another artificial tree structure with decorative lamps includes a plurality of hollow tubes or iron wires of various lengths, in the shape of tree branches, arranged from top to bottom around the main trunk supported by detachable legs. On each side sticks are installed a plurality of iron wires to form the shape of tree branches. The exterior of the hollow tubes or iron wires is wound by dense tree leaves. The lamps installed in the hollow tubes or on the iron wires are serially connected to become decorative lamp strings. The decorative lamp strings are then combined in parallel connection, running down the main trunk to be connected to a control box and a power transformer. The structure described above provides the artificial tree with decorative lamps, using the control box to produce music and lighting effects of different luminosity and flashing speeds.
[0022] Still another artificial tree includes a central trunk, a number of main branches suspended from an upper portion of the trunk in a downwardly and outwardly inclined orientation, and a preformed tree top section extending upwardly from the upper portion of the trunk. Each main branch includes a number of sub-branch clusters and a bundle of fiber optic conduits which terminate in the sub-branches. The bundles of fiber optic conduits are received in an opaque enclosure housing a high intensity light source, which enclosure is attached to the upper portion of the trunk. Electric lights are disclosed as an alternative means to illuminate the tree. The trunk includes upwardly open hook elements which receive pin elements within the interior of rigid support members of the main branches. Each sub-branch cluster is pivotally connected to an associated rigid support member to articulate between a collapsed position for storage and shipping, and an extended position for display.
[0023] Yet another artificial tree comprises both an artificial tree, having a stand and trunk with attachable branches, and various electrical components. The trunk portion of the tree is composed of a plurality of coupled sections which are joined together in a vertical orientation, and each of which has holes for branches to be inserted. The trunk pieces also have electrical sockets which are internally connected to the base of the trunk. The base of the trunk has attached to it another electrical socket and a master power cable. In use, the tree is assembled as any standard artificial tree, connecting trunk pieces together, and inserting into them branches of various sizes. Any conventional ornament or lighting fixture may be hung on these branches, and plugged into the trunk for power requirements. A stand at the base of the trunk provides stability, and internal circuit breakers provide assurance against fire. A line from the trunk is plugged into a powered electrical to provide power to the entire tree.
[0024] Also known is an illuminated artificial tree in which a plurality of branches extend from a trunk of the tree, each branch being formed by spirally winding a strip assembly of a plurality of juxtaposed fiber optic elements and simulated pine needles on an elongated support wire. The fiber optic elements and simulated pine needles extend around the wire in adjacent relation to provide an interspersed array of pine needles and fiber optic elements all along the length of the branch. The fiber optic elements are illuminated at the base of the tree to provide points of light substantially all around each branch along its entire length. A number of branches are assembled along the trunk from the top down.
[0025] The foregoing generally reflects the current known state of the art. However, such known trees still require significant manipulation and handling of the tree sections to securely align and couple the sections together. Further, such known trees fail to disclose adequate mechanical coupling and connection devices and methods that allow for a universal, snug fit that meet the needs of consumers utilizing artificial trees. It is believed that none of the above discloses, teaches, suggests, shows, or otherwise renders obvious, either singly or when considered in combination, the invention described and claimed herein.
[0026] Accordingly, there is a need for an improved artificial tree that is automatically or manually easily retractable so as to minimize or prevent damage due to, for example, wind by improving the control of the artificial branch limbs and leaf limbs on such artificial trees. Further, there is also a need to improve the efficiency of assembly, retraction, storage and portability of artificial trees.
ASPECTS AND SUMMARY OF THE INVENTION
[0027] The present invention substantially meets the aforementioned needs of the industry. An apparatus for a portable and retractable artificial tree, the apparatus comprising a plurality of trunk members having a generally cylindrical body with an outer wall and an inner cavity, the trunk members each having an upper portion and lower portion, wherein the upper portion of a first one of the trunk members has an outside diameter for interconnecting with the lower portion of a second one of the trunk members when brought into juxtaposition with each other; a plurality of branch assemblies each connected to an opening on the outer wall of at least one of the trunk members; and a plurality of lever arms disposed within the inner cavity having upper ends pivotably attached to the branch assemblies to allow control of the branch assemblies by movement of the lever arms in vertical paths within the inner cavity. The tree has an elongated trunk and a series of branch assemblies spaced upon its trunk mechanically and electrically interconnected to a base device for retracting, expanding, or otherwise controlling the branch assemblies. Optionally, the base controller may retract, expand, reposition or otherwise control a plurality of secondary branch assemblies (or leaf or power generation (solar-type) assemblies) positioned along each of the branch assemblies. The invention also allows for operational and manipulation control by direct wired control, by remote control (wireless via Radio Frequency (RF), Infra-Red (IR), BlueTooth®, or any other remote-control convention), or via one or a series of process controllers by remote signals sent over an electronic medium (e.g., control signals sent via an internet portal from a distant unit, desk-top, hand-held-PDA-type unit, or otherwise).
[0028] Preferably, the artificial tree branch assembly contains a plurality of secondary branch assemblies, where the secondary branch assemblies are either uniformly or non-uniformly spaced apart from one another upon each of the branch assemblies. Also, in the expanded state the branch assemblies extend outwardly at an angle of between about 30 to 90 degrees with respect to the trunk. When in a narrow state the branch assemblies extend outwardly at an angle of between about 0 to 30 degrees with respect to the trunk.
[0029] Another embodiment of the present invention provides a portable and retractable artificial tree transformable between a narrow vertical state and an expanded state, wherein the artificial tree comprises a generally cylindrical rigid trunk having upper and lower ends, the trunk having an outer wall and an inner cavity; a base constructed to engage the lower end to support the trunk in a substantially vertical upright position; a plurality of branch assemblies interconnected with the trunk through openings in the outer wall; and a plurality of lever arms disposed within the inner cavity having upper ends pivotably attached to the branch assemblies to allow movement of the lever arms in vertical paths within the cavity and provide movement of the branch assemblies; wherein each the branch assembly is pivotably attached to at least one of the plurality of lever arms by extending through a borehole in the trunk; and whereby controlled sliding movement of the lever arms causes the branch assemblies to be displaced from the trunk upwardly angled therefrom to produce an expanded state of the tree, and opposite controlled movement of the lever arms causes the branch assemblies to be drawn close to the trunk in substantially parallel alignment therewith to produce a narrow state of the tree.
[0030] According to another embodiment of the present invention, a coupling mechanism like a securing sleeve or securing plug is provided to assist in joining two sections of artificial tree trunk. The sleeve or plug is receivable in a lower trunk portion and subsequently provides an aperture for receiving an upper trunk portion. The sleeve is made, for example, of plastic or rubberized material, thus making it more malleable than the metal or other nonmalleable trunk material. As such, the sleeve is able to form to the shape of both trunk portions and within any gaps present due to imperfections in the machining process to provide a more secure fit than coupling the trunk portions directly. As such, the sleeve provides a locking mechanism for the connected trunk portions. Thus, trunk portions are not allowed to spin relative to one another and remain fixed in place. There is no risk of light string damage due to twisting of the trunk sections. Additionally, the tree is easier to decorate, as the sections remain in one secured configuration. Further, one decorated, the tree is fixed in place. Also, such a fit provides for a perfectly upright tree. No tilt or wobble between trunk portions is allowed, thus making for a more visually appealing and safer tree.
[0031] The present invention relates to an apparatus for a portable and retractable artificial tree, the apparatus comprising a plurality of trunk members having a generally cylindrical body with an outer wall and an inner cavity, the trunk members each having an upper portion and lower portion, wherein the upper portion of a first one of the trunk members has an outside diameter for interconnecting with the lower portion of a second one of the trunk members when brought into juxtaposition with each other, a plurality of branch assemblies each connected to an opening on the outer wall of at least one of the trunk members, and a plurality of lever arms disposed within the inner cavity having upper ends pivotably attached to the branch assemblies to allow control of the branch assemblies by movement of the lever arms in vertical paths within the inner cavity.
[0032] Also provided is an artificial tree apparatus wherein the first trunk member upper portion comprises a reduced diameter and a detent for interconnection with the second trunk lower portion having a guide slot, wherein at least one of the branch assemblies further comprises one or more secondary branch assemblies connected to the lever arms through openings in the one of the branch assemblies. In addition, the lever arms may control the vertical movement of the branch assemblies and/or the vertical or lateral movement of the secondary branch assemblies. The detent on the upper portion of one of the trunk members is positioned for alignment with a recess in the lower portion of the second one of the second trunk member. The lever arms are preferably located in the inner cavity and are accessed through the outer wall.
[0033] The artificial tree apparatus may further comprise a base device for maintaining the trunk in a substantially vertical position, the base device housing a controller for controlling the branch assemblies using the lever arms. Preferably, a lower most portion of the trunk is attached to the base device, and an electrical line may be positioned in the inner cavity, and wherein the outer wall may include one or more electrical receptacles connected to the electrical line.
[0034] Also disclosed is a portable and retractable artificial tree transformable between a narrow vertical state and an expanded state, wherein the artificial tree comprises a generally cylindrical rigid trunk having upper and lower ends, the trunk having an outer wall and an inner cavity; a base constructed to engage the lower end to support the trunk in a substantially vertical upright position; a plurality of branch assemblies interconnected with the trunk through openings in the outer wall; and a plurality of lever arms disposed within the inner cavity having upper ends pivotably attached to the branch assemblies to allow movement of the lever arms in vertical paths within the cavity and provide movement of the branch assemblies; wherein each the branch assembly is pivotably attached to at least one of the plurality of lever arms by extending through a borehole in the trunk; and whereby controlled sliding movement of the lever arms causes the branch assemblies to be displaced from the trunk upwardly angled therefrom to produce an expanded state of the tree, and opposite controlled movement of the lever arms causes the branch assemblies to be drawn close to the trunk in substantially parallel alignment therewith to produce a narrow state of the tree.
[0035] The artificial tree according to the invention further includes each branch assembly containing a plurality of secondary branch assemblies, or leaf assemblies. Preferably, the secondary branch assemblies are non-uniformly spaced apart from one another upon each of the branch assemblies, while the branch assemblies are uniformly spaced upon the trunk. In an expanded state the branch assemblies extend outwardly at an angle of between about 30 to 90 degrees with respect to the trunk. On the other hand, in a narrow state the branch assemblies extend outwardly at an angle of between about 0 to 30 degrees with respect to the trunk.
[0036] The artificial tree according to the invention further optionally may include any form of tree or leaf type (from conifer, to deciduous, to palm, etc.) without departing from the scope and spirit of the present invention, and may also be of any suitable size, from small (several centimeters—for counter use) to many meters (even more than twenty-meters (60 feet) or more for use in large building atriums or for sporting events or entertainment events.
[0037] The artificial tree according to the invention further optionally may include in addition to the secondary branches and foliage, the use of power generation systems that are interconnected with the operational control systems for the device, for example, such as the use of solar-cells (crystalline or amorphous silica, or otherwise) on the ‘leaf’ shapes so that the proposed artificial tree may generate power sufficient to power operation of the proposed system. It will be additionally understood, that the artificial tree according to the invention may be powered by self-generated power (via solar systems or wind systems or battery linkages for the same) or by external power (via a remote power supply or via supplied battery power).
[0038] Optionally, the artificial tree according to the present invention also provides a universal fit between trunk sections (i.e., for easy interconnection with other artificial trees). Consumers do not need to locate any alignment marks between insertable trunk portions and receivable trunk portions in order to lock the two portions. In one embodiment of the present invention, a “blossom” shape allows for as many as six different rotational configurations for insertion and locking of the insertable trunk portion to the receivable trunk portion. In another embodiment of the present invention, a hexagonal shape allows for a similar six different rotational configurations. In such embodiments, the consumer can assemble two trunk portions by first resting the insertable upper portion on top of the receivable lower portion (with sleeve) and making minor rotations until the insertable upper portion slides into the receivable lower portion. No visual alignment is necessary; insertion and locking can be done only on feel, which can be important when bulky and heavy branches weigh down each trunk section. In other embodiments, other shapes are also considered.
[0039] The present invention is directed to an artificial tree trunk that includes a first trunk portion that may be mechanically coupled to a second trunk portion via an intermediate securing sleeve. The first trunk portion is substantially hollow and generally includes a plurality of branch rings attached to the outside wall of the trunk and at least one notch located on the end distal the end secured to a base or stand. The notch and substantially hollow trunk are able to receive a securing sleeve. The securing sleeve includes at least one flange of the same shape as the notch of the first trunk portion such that the sleeve is insertable and securable to the first trunk portion. The length of the sleeve is shaped to contour the shape of the second trunk portion such that the first trunk portion and second trunk portion make a snug fit and cannot rotate relative to each other. The second trunk portion is substantially hollow and generally includes a plurality of branch rings attached to the outside wall of the trunk. The end of the second trunk portion insertable into the securing sleeve and first trunk portion is shaped such that, once inserted, the first trunk portion and second trunk portion make a secure fit and cannot rotate relative to each other. Each branch ring on both the first and second trunk portions generally contains a plurality of veins for receiving individual tree branches. Each vein contains an aperture for inserting a locking pin to thereby secure each branch to each vein.
[0040] Optionally, the present invention can include a securing plug operably couplable to the second trunk portion and a third trunk portion insertable into the securing plug. In such an embodiment, the second trunk portion has at least one notch located on the end distal the end secured to the first trunk portion. The notch and substantially hollow trunk are able to receive a securing plug. The securing plug includes at least one flange of the same shape as the notch of the second trunk portion such that the plug is insertable and securable to the second trunk portion. The plug contains an aperture for receiving the third trunk portion. The third trunk portion generally has branches operably coupled to the third trunk portion. In another embodiment, the third trunk portion has a branch ring, square, or any other useful shape that mirrors the shape of the third trunk portion, with veins and apertures for securing branches, just as described in the first and second trunk portions.
[0041] The present invention is not limited to the above-described embodiments. For example, while the above description recites first, second, and optionally, third trunk portions, in fact, the present invention is designed such that it is scalable to both taller and shorter implementations. In one example, in a room with 20-foot ceilings, a tree having more than three trunk portions may be desired. Having more trunk portions not only allows the tree to be built taller, but can aid in assembly and disassembly. In such an embodiment, a securing sleeve is provided not only at the junction of the first trunk portion and the second trunk portion, but also for the second trunk portion and a third trunk portion, the third trunk portion and a fourth trunk portion, and so on. The fit provided by the securing sleeves and securing plugs ensures that the entire tree remains stable and each trunk portion cannot rotate relative to any other trunk portion. In another example, a shorter tree having only two trunk portions is considered, whereby a single securing sleeve at the junction between first and second trunk portions is needed. Such trees may be useful for rooms with shorter ceilings, or for placement on tables or stands.
[0042] In another embodiment, the present invention comprises a locking artificial tree trunk. The tree trunk includes a first generally cylindrical, hollow trunk portion including an upper end, the upper end defining a notch; a second generally cylindrical trunk portion including a body portion, a lower end having an insertable portion, and an upper end; and a coupling mechanism including a body portion and an upper portion having a tab, and defining a channel for receiving the insertable portion of the lower end of the second trunk portion. The body portion is inserted substantially into the upper end of the first trunk portion with the tab of the upper portion aligned with the notch, thereby preventing rotation of the coupling mechanism within the upper end of the first trunk portion.
[0043] In another embodiment, the present invention includes an artificial tree. The tree includes a locking artificial trunk, the trunk including: a first generally cylindrical, hollow trunk portion including an upper end, the upper end defining a notch; a second generally cylindrical trunk portion including a body portion, a lower end having an insertable portion, and an upper end; and a coupling mechanism including a body portion and an upper portion having a tab, and defining a channel for receiving the insertable portion of the lower end of the second trunk portion. The sleeve body portion is inserted substantially into the upper end of the first trunk portion with the tab of the upper portion aligned with the notch, thereby preventing rotation of the coupling mechanism within the upper end of the first trunk portion. The tree also includes a plurality of branch-support rings affixed to the first and second trunk portions, a plurality of branches connected to the plurality of branch-support trunk rings, and a base defining a receiver having an inside diameter larger than an outside diameter of the lower portion of the first trunk portion such that the first trunk portion is insertable into the receiver of the base.
[0044] In yet another embodiment, the present invention comprises a multi-positional interlocking artificial tree trunk. The tree trunk includes a first generally cylindrical, hollow trunk portion including an upper end, a second generally cylindrical trunk portion including a lower end having an insertable portion, and an upper end. The trunk also includes a coupling mechanism inserted substantially into the upper end of the first trunk portion, the coupling mechanism including a body portion and an upper portion, and defining a channel for receiving the insertable portion of the lower end of the second trunk portion. The insertable portion forms an insertable, non-circular cross-section and the channel defines a non-circular channel cross-section that is complementary to, and circumferentially larger than, the insertable cross-section such that the insertable portion is insertable into the channel to secure the first trunk portion to the coupling mechanism in one of a plurality of relative rotational positions, thereby preventing rotation of the second trunk portion relative to the coupling mechanism.
[0045] The present invention further provides an artificial tree apparatus having a plurality of tree trunk segments that couple together to provide electrical power to receptacles on each of the segments. The apparatus includes a first trunk segment having a cylindrical body with an outside wall and an internal cavity. The first trunk segment has an upper portion and lower portion, the upper portion having an outside diameter, a raised decent on the outside wall, and an end face bearing an electrical connector such as a socket. A second trunk segment also has a cylindrical body with an outside wall and an internal cavity, and also has an upper portion and lower portion, this lower portion having an inside diameter marginally greater than the first trunk segment upper portion outside diameter so that the first trunk segment upper portion can slide into and engage the second trunk segment lower portion. The second trunk segment lower portion has a notch or guide slot in the outside wall, and a recessed end face bearing an electrical connector such as a plug. An electrical line is connected to the first trunk segment electrical connector, such that when the first trunk segment upper portion is brought into juxtaposition with the second trunk segment lower portion, the detent on the first trunk segment upper portion can be brought into alignment with and slidably engage with the guide slot on the second trunk segment lower portion to permit connection of the first trunk segment electrical connector (socket) with the second trunk segment electrical connector (plug).
[0046] The recessed location of the plug on the second segment protects the plug prongs, and connection with the corresponding socket on the first segment is only possible when the detent on the first segment has been aligned with the guide slot on the second segment. That is, the plug and socket are positioned within their respective trunk segments so that not until the detent and guide slot on the segments are properly aligned are the plug prongs and the socket holes capable of connection.
[0047] The cylindrical shapes of the corresponding tree trunk segments facilitates connection of the segments, as juxtaposition and initial insertion of the first (male) segment into the second (female) segment can be achieved at any angular position, that is, the smaller diameter male portion can freely rotate within the larger diameter female portion when they are first inserted together. However, by locating the raised detent a short distance (offset) from the socket on the end face, complete connection of the plug prongs with the socket is prevented until the two segments are rotated relative to one another until the guide slot and detent are properly aligned, ensuring that the plug prongs will then slide straight into the socket holes.
[0048] The artificial tree apparatus of the present invention thus provides an improved coupling arrangement for the trunk portions of an artificial tree in which each section, besides connecting easily, carries current and any other important electrical information or commands via the tree column. Each section is thus electrically contained, meaning that the lighting source (string), whether it be incandescent or LED plug in strings (AC) or strictly DC operated LED strings, connects/plugs into its corresponding section of the column (trunk) of the tree. This design will also work for unlit trees (where the consumer strings the tree) but is mostly considered for pre-lit trees.
[0049] Each section of the tree couples with its connecting partner, thus delivering the current through the column of the tree from a connector/controller/plug that plugs into an AC socket. This makes assembly and disassembly much easier for the user. No need to plug individual strings together or plug strings from one section of tree to another or run long electrical leaders to other areas of the tree. To assemble, just couple each section together and turn it on. Each section of column couples together mechanically and electrically. To disassemble, just fold up the branches up and de-couple each section.
[0050] One embodiment of the inventive apparatus includes a DC motor in the base that allows the tree to rotate. A wireless remote control allows the user to turn the lights on and off and turn the rotation motor on and off via the power/controller box (power transformer/light controller/tree rotation controller box). A tapered top section perfectly connects with a tree topper socket. A DC version may be different in that it has DC socket connections in the column of the tree instead of AC sockets. On this version the voltage is reduced at the controller box plugged in at the wall so all voltage beyond that point is low voltage. The controller box may contain a voice activated light controller, and in the DC version the user may be able to turn the tree lights on and off via a special touch sensor ornament (e.g., a metal snowflake) that is permanently attached to the tree.
[0051] In one embodiment, small DC connector interfaces are placed on the middle column of the tree (trunk). This enables pre lit trees that are lit with low voltage LED strings that connect directly into the middle column of the tree. If one string goes out the user can easily identify the rogue string, unplug it and replace it with a working string. Gone are the days of strings all connected together in a confusing mess. The coupling system between each section of tree in the DC version may be different than the AC version. These extra connectors allow for additional information transfer from the controller/voltage box to the tree; e.g., a touch activated on/off switch built into the tree, lighting effects, etc.
[0052] The top section of the middle column may have one or more AC type plug; this allows the user to plug some already existing low voltage device, such as an illuminated tree topper into the tree without having to run an extension cord down to the floor and into an outlet.
[0053] It is therefore an aspect of the present invention to provide a new and improved artificial tree.
[0054] It is another aspect of the present invention to provide a new and improved artificial illuminated tree that is easily assembled and disassembled.
[0055] A further aspect or feature of the present invention is a new and improved artificial tree that carries current and any other important electrical information or commands via the tree column.
[0056] An even further aspect of the present invention is to provide a novel artificial tree where the lighting source plugs into its corresponding section of the column (trunk) of the tree.
[0057] It is accordingly an aspect of the present invention to provide an artificial tree which can be easily erected from a collapsed compact storage state.
[0058] It is a further aspect of this invention to provide an artificial tree as in the foregoing aspects whose branches are sufficient in number and distribution to provide a tree having a full and uniform appearance.
[0059] It is another aspect of the present invention to provide an artificial tree of the aforesaid nature of rugged and durable construction amenable to low cost manufacture.
[0060] The above and other beneficial aspects and advantages are accomplished in accordance with the present invention by an artificial tree comprising an elongated rigid trunk having upper and lower extremities, a base adapted to engage the lower extremity in a manner to support the trunk in a vertically upright disposition in the erected state of the tree, and a series of branch assemblies positioned upon the trunk, each assembly comprising an upper collar slidably disposed upon the trunk, a number of first lever arms uniformly disposed about the trunk, having upper extremities pivotably attached to the upper collar in a manner permitting movement of the arms in vertical paths, the arms being downwardly angled away from the trunk to lowermost extremities, a lower collar affixed to the trunk, a second lever arm associated with each first lever arm in vertically coplanar relationship, each second lever arm having a lower extremity pivotably attached to the lower collar in a manner permitting movement of the arm in a vertical path, the second arms being upwardly angled away from the trunk to an uppermost extremity which pivotably engages the associated first lever arm, an elongated branch element pivotably attached to the lowermost extremity of each first lever arm and extending between an outermost extremity and an innermost extremity located below the first lever arm, and a third lever arm pivotably interconnected to each second lever arm and the innermost extremity of the associated branch element to form a parallelogram having pivotal movement at its four apexes, whereby sliding movement of the upper collar downwardly upon the trunk toward the lower collar causes the branch elements to be laterally displaced from the trunk and upwardly angled therefrom to produce the erected state of the tree, and opposite movement of the upper collar causes the first, second and third lever arms and branch elements to be drawn close to the trunk and in substantially coaxial alignment therewith, producing the storage state of the tree, the dimensions of each branch assembly of the series being such that the outermost extremities of the branch elements in the erected state extend further from the trunk in descending the members of the series.
[0061] In preferred embodiments of the invention, the trunk is of circular cylindrical configuration. There is preferably a plurality of branch assemblies uniformly spaced upon the trunk. Each branch assembly preferably has numerous secondary branch elements or leaf elements. The secondary branch elements may have the form and appearance of the final branches of the tree, or they may merely constitute the support for imitative tree branch material. In the erected state, the branch elements extend upwardly at an angle of between about 30 to 90 degrees with respect to the trunk, while in the narrow or retracted state the branch elements extend upwardly at an angle of between about 0 to 30 degrees with respect to the trunk.
[0062] Other novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings, in which preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for illustration and description only and are not intended as a definition of the limits of the invention. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming part of this disclosure. The invention resides not in any one of these features taken alone, but rather in the particular combination of all of its structures for the functions specified.
[0063] There has thus been broadly outlined the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form additional subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based readily may be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0064] The above and other aspects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] A further understanding of the present invention can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated preferred embodiment is merely exemplary of methods, structures and compositions for carrying out the present invention, both the organization and method of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention.
[0066] For a more complete understanding of the present invention, reference is now made to the following drawings in which:
[0067] FIG. 1 shows a front view of the portable and retractable artificial tree according to the preferred embodiment of the present invention, illustrating the base housing unit, control mechanism, the tree trunk and the branch assemblies;
[0068] FIG. 2 shows an enhanced view of the control mechanism positioned inside the base housing unit shown in FIG. 1 , and the control mechanism may be provided with remote control features, direct wire control features, or mechanical control features;
[0069] FIG. 3 shows a perspective view of the artificial tree in accordance with the present invention, depicting the tree trunk in a substantially vertical position with respect to the base housing unit and the branch assemblies extending from the substantially vertical tree trunk;
[0070] FIG. 4 shows a side elevation view of one embodiment of the branch assemblies for use on the artificial tree according to the preferred embodiment of the present invention further illustrating secondary branch assemblies or leaf assemblies extending from a branch assembly which extends from the tree trunk;
[0071] FIG. 5 shows an enhanced view of a portion of the branch assembly shown in FIG. 4 further illustrating the internal lever arms for controlling the secondary branch assembly;
[0072] FIG. 6 shows a partial enhanced view of a portion of the tree trunk and one branch assembly illustrating the directional movement of the branch assembly with respect to the position of the tree trunk;
[0073] FIG. 7 shows a front partial cross-sectional view of the artificial tree according to the present invention depicting the tree trunk in a substantially vertical position with respect to the base housing unit, the branch assemblies extending from the substantially vertical tree trunk, and the secondary branch or leaf assemblies extending from the branch assemblies, further showing the lever arms connecting the branch and leaf assemblies to the control mechanism inside the base unit;
[0074] FIG. 8 shows a front perspective view of an artificial tree trunk assembly on a base unit according to an alternative embodiment of the present invention, without the branch assemblies or leaf assemblies installed;
[0075] FIG. 9 shows a front perspective view of an artificial tree trunk assembly on a base unit according to yet an alternative embodiment of the present invention, with some branch assemblies and leaf assemblies installed thereon;
[0076] FIG. 10 shows a perspective view of an embodiment of two interconnecting tubular components for use as the artificial tree trunk assembly in accordance with an alternative embodiment of the present invention;
[0077] FIG. 11 shows a front perspective view of the artificial tree in accordance with the present invention, depicting the tree trunk in a substantially vertical position with respect to the base housing unit and the branch assemblies extending from the substantially vertical tree trunk, each branch assembly further having secondary branch or leaf assemblies extending from therefrom, further illustrating the branch assemblies in a retracted position;
[0078] FIG. 12 shows and enhanced view of the artificial tree shown in FIG. 11 with the branch assemblies in an extended (or non-retracted) position;
[0079] FIG. 13 shows a front view of the portable and retractable artificial tree according to the preferred embodiment of the present invention, illustrating the base housing unit, control mechanism, the tree trunk and the branch assemblies; and
[0080] FIG. 14 shows an enhanced view of the control mechanism positioned inside the base housing unit shown in FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0081] As required, a detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, systems, compositions and operating structures in accordance with the present invention may be embodied in a wide variety of sizes, shapes, forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention.
[0082] Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, below, etc., or motional terms, such as forward, back, sideways, transverse, etc. may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner.
[0083] Referring first to FIGS. 1-7 where like reference numerals refer to like components in the various views, there is illustrated therein a new and improved artificial tree apparatus 10 . Initially, FIG. 1 shows a front view of the portable and retractable artificial tree 10 according to the preferred embodiment of the present invention, illustrating the base housing unit 2 , control mechanism 12 , the tree trunk 14 and the branch assemblies 16 . While FIG. 1 shows the artificial tree apparatus 10 of the invention as assembled but without secondary branch assemblies or leaf assemblies (see FIGS. 4-5 and 9 ), as shown, the tree 10 includes a single tree trunk 14 or may comprise a plurality of tree trunk segments, each preferably carrying one or more branch supports 22 for connection to artificial branch assemblies 16 , and one or more optional electrical sockets (not shown, see FIG. 8 ). The lower most part of tree trunk 14 may also include a fuse and/or fuse box or holder positioned adjacent tree stand or base unit 2 .
[0084] Artificial tree assembly 10 includes a trunk portion 14 . In some embodiments, artificial tree trunk 2 may include a plurality of trunk portions, such as first and second trunk portions 14 a , 14 b shown in FIG. 10 , and may be secured by coupling mechanism. When tree trunk 10 is assembled, as depicted, trunk portion 14 or portions 14 a , 14 b are configured along a common vertical axis and held in a general vertical orientation. To maintain the general vertical orientation, a lower end of trunk portion 14 is insertable into an opening 6 in the cover 4 of base or stand portion 2 that supports the entire tree assembly 10 . Such a base 2 preferably includes a receiver, such as a channel or other opening, as understood by those skilled-in-the-art, for receiving a bottom portion of trunk portion 14 , the receiver having an inside diameter equal to or slightly larger than, an outside diameter of the bottom portion of trunk portion 14 . As seen in FIGS. 1-2 , base unit 2 further comprises a branch control mechanism 12 preferably positioned in a secure manner on an underside of the cover 4 of base unit 2 . Control mechanism 12 may be connected to a computer or other known control device for instructing the control mechanism 12 to move the branch assemblies 16 and/or secondary branch assemblies 26 having leaves 26 thereon.
[0085] As depicted in FIG. 7 , shown is a partial cross-sectional view of the artificial tree 10 in a substantially vertical position with respect to the base housing unit 2 , the branch assemblies 16 extending from the substantially vertical tree trunk 14 , and the secondary branch or leaf assemblies 26 extending from the branch assemblies 16 . Also shown are the lever arms 18 , 28 , 36 connecting the branch 16 and leaf 26 assemblies to the control mechanism 12 inside the base unit 2 . As seen, preferably, control mechanism 12 controls one or more lever arms 36 positioned coaxial within trunk 14 , and which are integrally connected with each of the branch assemblies 16 to control the lateral, vertical, rotational, and/or angular movement thereof with respect to the trunk 14 . As seen in FIG. 6 , control mechanism 12 (shown earlier) can enable lateral 34 or angular 32 movement of the branch assemblies 16 .
[0086] It will be recognized that control mechanism 12 may include a plurality of operatively dependent components understood by those of skill in the art but not shown here. Included optionally would be a mechanical controller system for movement control driven by a computerized process controller (computer, memory function, input program and controllers, etc.), an input module (for receiving wired, wireless (internet, hand held, etc.), and other control signals) and for driving the mechanical controller system according to the memory input or the received control signals.
[0087] The trunk portion 14 , as depicted, preferably comprises a generally cylindrical, hollow structure including a lower end, an upper end, outer wall, and a plurality of branch-support interfaces 22 . The lower end of the trunk portion 14 may be tapered or not tapered for ease of coupling to the cover 4 of the base unit or stand portion 2 . A plurality of branch-support rings or coupling members 22 may include multiple branch receivers extending outwardly and away from first trunk portion 14 . In some embodiments, the branch coupling members 22 define a channel for receiving a primary branch assembly 16 . Each branch generally includes primary branch extension 216 and may also include multiple secondary branch extensions 26 extending away from branch extension 16 . The branch assemblies 16 are preferably connected to trunk portion 14 at a branch receiver 22 at various locations along the trunk 14 . Primary branch assemblies 16 may be bent or otherwise formed to define a loop or circular opening such that primary branch assembly 16 may be secured to branch receiver 22 by way of threading or a pin extending through branch receiver 22 and connected to the lever arm 18 or 36 within trunk 14 and connected to and controlled by mechanism 12 . In this way, a branch assembly 16 may be allowed to pivot, extend, retract, or otherwise move with respect to the trunk 14 to expand or retract the branches of the tree 10 .
[0088] It will also be appreciated, in an alternative embodiment that branch assemblies 16 may alternatively contain power-generation means such as solar arrays, optionally in the form of leaf-shapes that may generate power for the proposed controller mechanism 12 or for other uses to operate and initiate light sequences, communication systems (noting on-off, pivoting, opening/closing, etc.).
[0089] In the embodiment of the invention depicted in FIGS. 4-5 , shown is a side elevation view of the branch assemblies 16 for use on the artificial tree 10 according to the preferred embodiment of the present invention. Also shown are secondary branch assemblies or leaf assemblies 26 extending from a branch assembly which extends from the tree trunk 14 . As seen in FIG. 5 , internal lever arms 28 are provided for controlling the secondary branch assembly 26 and extend coaxially within branch assemblies 16 to interconnect with leaves 24 or other choice foliage (and optionally solar arrays if needed) or end covering via secondary branch assemblies 26 at interface 30 . Lever arm 28 within branch assembly 16 is then connected at one end to central lever arm 18 positioned coaxially within tree trunk 14 , as seen in FIG. 7 , which in turn is connected to control mechanism 12 . Such interconnection between the branch assemblies 16 , 26 and the lever arms 18 , 28 allows control mechanism 12 to control the positioning and movement of the various branch assemblies 16 , 26 throughout the tree assembly 10 . If the user desires the tree 10 to be in its fully extended or expanded state that control mechanism will direct such movement of the branch assemblies.
[0090] Conversely, the user can direct the control mechanism to position the tree 10 in its fully retracted state. Such instructions may be provided manually by a user through, for example, a wired or wireless interface, including without limitation, a tablet, a computer, smart phone device, etc., or such instructions may be provided automatically via a pre-programming of the alternative process controller (see above) if certain conditions are met. For example, a sensor (in communication with the process controller) may be employed on the tree 10 to detect an increase in wind conditions thereby informing control mechanism 12 to retract certain or all of the branch assemblies 16 , 26 so as to minimize potential damage to the tree 10 due to high winds. Other weather related conditions, i.e., rain, snow, heat, cold, etc., received via the sensor array to a controlling mechanism may also be used to direct control mechanism 12 to reposition any or all of the branch assemblies 16 , 26 . Also, it is disclosed that control mechanism may be configured to control all branch assemblies 16 , 26 as one single unit, or may be configured to control each separate branch assembly 16 , 26 on its own separate and apart from control of each other branch assembly 16 , 26 . It is also adaptively envisioned that the control mechanism and system may be configured to orient any solar cell array features in a preferred solar-orientation for optimal energy generation.
[0091] Referring next to FIGS. 8-10 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved artificial tree apparatus 100 / 200 . FIG. 8 shows a front elevation view of the artificial tree assembly 100 positioned on a base unit 102 according to an alternative embodiment of the present invention, without the branch assemblies or leaf assemblies installed. FIG. 9 shows a front elevation view of an artificial tree assembly 200 on a base unit 202 according to yet an alternative embodiment of the present invention, with some branch assemblies 216 and leaf assemblies 226 installed thereon. While FIG. 8 shows the artificial tree apparatus 100 of this invention as assembled but without branches assemblies, as shown, the tree 100 includes a single tree trunk 114 or may comprise a plurality of tree trunk segments 114 , each preferably carrying one or more branch supports 122 for connection to artificial branches (not shown here), and one or more optional electrical sockets 106 . The lower most part of tree trunk 114 may also include a fuse and/or fuse box or holder positioned adjacent tree stand or base unit 102 .
[0092] Turning now to FIG. 9 , an alternative embodiment of an artificial tree trunk 200 of the present invention is depicted. Artificial tree trunk 200 includes first trunk portion 214 . In some embodiments, artificial tree trunk 200 may include a plurality of trunk portions, such as first and second trunk portions 14 a , 14 b shown in FIG. 10 , and may be secured by coupling mechanism. When tree trunk 200 is assembled, as depicted, trunk portion 214 or portions 14 a , 14 b are aligned along a common vertical axis and held in a general vertical orientation. To maintain the general vertical orientation, a lower end of trunk portion 214 is insertable into a base or stand portion 202 that supports the entire tree assembly 200 . Such a base 202 preferably includes a receiver, such as a channel or other opening, as understood by those skilled-in-the-art, for receiving a bottom portion of trunk portion 214 , the receiver having an inside diameter equal to or slightly larger than, an outside diameter of the bottom portion of trunk portion 214 .
[0093] The trunk portion 214 as depicted comprises a generally cylindrical, hollow structure including a trunk portion body having a lower end, an upper end, outer wall, and one or more branch-support interfaces 222 . The lower end of the trunk portion 214 may be tapered or not tapered for ease of coupling to an appropriate base or stand portion 202 . A plurality of branch-support rings 222 include multiple branch receivers extending outwardly and away from first trunk portion 214 . In some embodiments, the branch receivers define a channel for receiving a primary branch extension 216 of a branch 224 . Each branch 224 generally includes primary branch extension 216 and may also include multiple secondary branch extensions 226 extending away from branch extension 216 . Branches 224 are connected to trunk portion 214 at a branch receiver 222 a various locations along the trunk 214 . Primary branch extensions 216 of branches 224 may be bent or otherwise formed to define a loop or circular opening such that primary branch extension 216 of branch 224 may be secured to branch receiver 222 by way of threading or a pin extending through branch receiver 222 and the loop formed at trunk-end branch 224 . In this way, a branch 224 may be allowed to pivot, extend, retract, or otherwise move with respect to the trunk 214 to expand or retract the branches 224 of the tree 200 .
[0094] Referring to FIG. 10 , shown is a perspective view of an embodiment of two interconnecting tubular components 14 a , 14 b for use as the artificial tree trunk assembly 100 / 200 in accordance with an alternative embodiment of the present invention. More specifically, depicted is the coupling of two trunk segments 14 a , 14 b . First trunk segment 14 a has a generally cylindrical body with an outer wall 17 and an inner cavity 19 . The first trunk segment 14 a has an upper end and lower end, the upper end having a first outside diameter, and the lower end having a second outside diameter. Similarly, second trunk segment 14 b has a generally cylindrical body with an outer wall 17 and an inner cavity 19 . The second trunk segment 14 b has an upper end and lower end, the upper end having a first outside diameter, and the lower end having a second outside diameter. Generally, the second outside diameter of the trunk segments 14 a , 14 b is narrower than the first outside diameter of the trunk segments 14 a , 14 b such that the lower end of the first trunk segment 14 a can slide into and engage with the upper end of the second trunk segment 14 b so as to be position partially in inner cavity 17 of the second trunk segment 14 b . The upper end of the second trunk segment 14 b preferably has a notch or guide slot 13 in the outside wall 17 for engaging the lower end of the first trunk segment 14 a . Optionally, an electrical line may be connected to the first trunk segment via electrical connectors (see FIG. 8 ), such that when the first trunk segment upper portion 14 a is brought into juxtaposition with the second trunk segment lower portion 16 b , the electrical connectors can be brought into alignment to permit connection thereof.
[0095] Turning lastly to FIGS. 11-14 , shown are illustrations of the preferred embodiment of the portable and retractable artificial tree 10 in accordance with the present invention. As shown, depicted is the tree trunk 14 in a substantially vertical position with respect to the base housing unit 2 and the branch assemblies 16 extending from the substantially vertical tree trunk 14 , each branch assembly 16 further having secondary branch or leaf assemblies 26 extending therefrom. As illustrated in FIG. 11 , the branch assemblies 16 may be in a retracted or partially retracted position, or as seen in FIG. 12 , the branch assemblies 16 may be in an expanded or fully expanded position. Control mechanism 12 , as seen in FIGS. 13-14 , is preferably positioned within base unit 2 , optionally positioned on the underside of cover 4 of the base unit 2 , such that control mechanism is interconnected with lever arm(s) 18 which extends upward through an opening 6 in cover 4 to extend longitudinally within and substantially coaxial with tree trunk 14 to further interconnect with branch assemblies 16 , as described and shown herein.
[0096] It should be additionally understood by those of skill in the art having studied the disclosure herein that the proposed system may be provided in alternative and adaptive sizes. For example such trunks and system may be of a relatively small size, for example several centimeters high, or in a relatively large size, for example twenty-meters or more in height, all without departing from the scope and spirit of the present invention. This allows the present invention to be used for smaller offices, for homes, for large business-building atriums, for farming and other commercial uses, all within the scope of the present invention. As such, it will be recognized that the proposed invention may be positioned by hand (smaller size), by a user-vehicle such as a ‘fork-truck’ (for medium sizes), by larger trucks and even rail or crane delivery (for very large sizes), all within the scope and spirit of the present invention. It will also be understood, that the proposed inventive system may be used for an array of user options, from seasonal displays, to farming, to other industrial uses, and to uses intended to be substantially permanent (e.g. in buildings, for road-sound abatement, and for other needs that may last for many months or years).
[0097] Additionally, it will be recognized that each of the limbs, leaves, stalks, and arms noted herein may be manipulated for motion in the directions noted (in/out, up/down, etc.) and at a rate (speed of motion) that may be controlled according to a computer processor controller (not shown) that may be liked with and programmed for operation with the driving devices and power controls herein. It will be recognized that the computer process controller will contain all required features and functions to operate as a controlling processor (memory, capacitors, input/output ports, receiving and transmitting antenna, communication ports, stored controlling code, etc.) for such devices as may be found within those of skill in the art. Such computer processor controllers may be known to those of skill in the arts of consumer products manufacture.
[0098] In the claims, means or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
[0099] Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings sufficient to enable one of ordinary skill in the art to practice the invention, and to provide the best mode of practicing the invention presently contemplated by the inventor, it is to be understood that such embodiments are merely exemplary and that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. Accordingly, the disclosed embodiments are not mutually exclusive combinations of features; rather, the invention may comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. The scope of the invention, therefore, shall be defined solely by the appended claims.
[0100] Further, while there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics. | Portable and retractable artificial trees including a first generally cylindrical, hollow trunk portion including an upper end, the upper end defining a notch, and a second generally cylindrical trunk portion including a body portion, a lower end having an insertable portion, and an upper end. The artificial trees further include separable, modular tree portions mechanically connectable, controllable and lockable between trunk and branch portions is provided. The proposed system may be transported by any means for convenience, including by rail, fork-truck, or otherwise according to a size from a few centimeters to twenty meters or more. The tree has an elongated trunk and a series of branch assemblies spaced upon its trunk mechanically and electrically interconnected to a base device for retracting, expanding, or otherwise controlling the branch assemblies. | 0 |
BACKGROUND OF INVENTION
1. Related Applications
There are no applications related hereto heretofore filed in this or any foreign country.
2. Field of Invention
This invention relates generally to releasably interconnectable elongate repair devices to be used at least in pairs to fasten the ends of a broken wire strand together.
3. Background and Description of Prior Art
Stranded wire fences providing one wire strand or a plurality of sequentially spaced strands supported on plural spaced vertical posts are commonly used for animal barriers, definition of land boundaries and other purposes. The strands of wire in such fence structures commonly are maintained in a taut condition to provide an appropriate barrier, maintain structural integrity, and fulfill other purposes. If the taut condition is not properly maintained, the wire strands and portions of the entire fence may fail their purposes. In many common fence constructions strands forming a fence are movably supported on spaced vertical posts for tightening purposes or otherwise so that if a strand breaks it may move appreciably, not only between two posts proximate to the break, but also for some distance in each direction therebeyond.
The breaking of wire strands by reason of external forces or physical deterioration is a common occurrence in fence structures and may effect a fence structure over substantial areas to destroy or lessen its effectiveness. The repair of a broken wire strand is often difficult as the strand commonly was taut before its breaking and by reason of the general fence structure the broken ends of the wire may not be movable to an overlapping fashion to allow direct fastening by wrapping of one end of the broken strand about the other end. This problem has heretofore been recognized and various repair devices having some length and means at least one end to fasten one of the broken ends of a wire strand have become known. The instant invention provides a new and novel member of this class of repair device for broken wire strands in a fence structure.
The tension under which fence wire strands must be maintained to sustain ordinary forces that they incur, and especially to prevent animals from breaching the barrier, are substantial, often ranging to one hundred pounds or more. Any repair device for broken wire strands must interconnect the ends of the broken wire in a fashion to withstand such forces and the fastening device itself must withstand them, especially when the repair device is to be used other than in temporary fashion and after a broken wire is retightened to its original tension. Various prior repair devices have either not addressed this problem or have not addressed it adequately and have provided repair devices that are no stronger than the wire strands being joined. My invention resolves this problem by providing a compound fastener having two releasably interconnected body elements that are formed of material stronger than the wire fence strands to be interconnected so that the body of the structure and the joinder of the two body parts is stronger than the interconnected wire strand. The device also provides hook-like structures in its end parts on which broken wire strand ends are fastened by looping one or more times about the hooks to provide a strong fastening juncture that has substantially the same strength as a strand of the wire being repaired.
Because of the substantial tension under which fence wire strands are maintained, an effective repair device must provide means for securely fastening each of the ends of broken wire strands so that those ends may not move relative to the repair device after they are fastened. Prior devices often have provided no secure means to fastened ends of wire strands to the repair device but have relied merely upon the manipulation of the wire strand ends by wrapping them upon themselves to fulfill this purpose. Such fastening has often been insecure and commonly allows the overlapped wire strands to move relative to each other and relative to the fastening device, especially over a period of time, to allow tension to lessen in a repaired wire strand over a period of time. My invention alleviates this problem by fastening the broken end of a wire strand in looped fashion about an open hook which is covered by a so-called "wire nut" carried on my fastener and having internal threads with such configuration that the nut is movable over the hook structure. The looped portions of the wire strand to be repaired are engaged in the threads of the wire nut and thereby securely maintained relative to the fastening hook.
Any wire strand repair device to provide practical utility must be of simple operation and must not require the use of ancillary tools or mechanical devices which may not be available. Prior fasteners that have provided integral wire tightening mechanism are distinguishable from the instant fastener which is of a simpler and more economic nature and may be permanently left in the fence if desired. My fastener is of a small nature so that several fasteners may be carried in a small space such as a saddle bag or similar container that is commonly available to a person making emergency fence repairs and my fastener may be installed by manual manipulation without the use of any tools. My fastener provides a body of sufficient length to allow looping of each end of a broken wire strand upon itself to form a loop, and this may be readily accomplished by manual manipulation and without tools. Each portion of my fastener may be separately fastened to one end of the broken wire strand and the two fastener portions then fastened to each other by their medial hook portions. If desired a wire stretcher may be used to aid this function and create more tension in the repaired wire strand than might be created by manual manipulation.
My invention lies not in any one of these features individually, but rather in the synergistic combination of all of the structures of my fastener that necessarily give rise to the functions flowing therefrom as herein specified and claimed.
SUMMARY OF INVENTION
My fence wire strand repair device provides a compound structure having two similar releasably interconnectable portions. Each portion provides an elongate rod-like body defining a first hook in its inner end and a second hook in its outer end, all hooks being configured to be releasably interconnectable with any other hook. Each body portion movably carries a wire nut having the open end at the base of the threaded conic element extending outwardly toward the second hook. The wire nut preferably provides opposed, normally extending wings to aid manual manipulation and preferably defines a slot through the smaller portion or is formed by interconnectable parts to allow placement on the body after formation of both hook ends. The size of the second outer loop of each fastener portion is such as to fit within the larger portion of the wire nut, but larger than the channel of the wire nut to maintain it on the fastener body.
In providing such a device, it is:
A principal object to provide an elongate fence wire strand repair apparatus to extend from immovable interconnection between and releasably interconnect end portions of a broken wire strand.
A further object is to provide such apparatus that fastens the broken ends of a wire strand in a fashion that is substantially as strong as the wire strand itself.
A further object is to provide such apparatus that provides wire nuts to releasably fasten the looped end of a broken wire to prevent motion of the broken portions relative to the fastener.
A still further object is to provide such a device that may be installed without the required use of any auxiliary tools.
A still further object is to provide such a device that is of new and novel design, of rugged and durable nature, of simple and economic manufacture and otherwise well suited for the uses and purposes for which it is intended.
Other and further objects of my fastener will appear from the following specification and accompanying drawings which form a part hereof. In carrying out the objects of my invention, however, it is to be remembered that its accidental features are susceptible of change in design and structural arrangement with only one preferred and practical embodiment of the best known modes being illustrated in the accompanying drawings as is required.
BRIEF DESCRIPTION OF DRAWINGS
In the accompanying drawings which form a part hereof and wherein like numbers of reference refer to similar parts throughout:
FIG. 1 is an elevational view of the section of a typical stranded wire fence with my invention being placed therein to repair a broken wire strand.
FIG. 2 is a somewhat enlarged orthographic side view of the fastening apparatus of FIG. 1, showing its various parts, their configuration and relationship.
FIG. 3 is an enlarged vertical cross-sectional view of the right portion of the apparatus of FIG. 2, taken on the line 3--3 thereon in the direction indicated by the arrows.
FIG. 4 is a partial cross-sectional view of the right end portion of the fastener of FIG. 3, showing a looped wire strand fastenably interconnected within the wire nut.
FIG. 5 is a cut-away isometric view of a wire nut showing a separate threaded sleeve structure and a slot that allows placement of the nut on the body portion after formation of the end hooks of the body.
FIG. 6 is an orthographic end view of a wire nut formed with two releasably interconnected portions to allow placement on my fastener body after formation of the end hooks.
DESCRIPTION OF PREFERRED EMBODIMENT
My invention generally provides an elongate repair apparatus for broken wire strands of a fence that has two similar body portions 10 defining hooks at each end and movably carrying wire nut 11 between the end hook portions.
Body 10 provides medial linear portion 12 defining somewhat elongate inner hook 13 at one end and smaller more round outer hook 14 at the other end. The inner hook 13 defines rounded end portion 13a, having an inner diameter somewhat greater than the diameter of the material from which the hook is formed, and elongate overlapping end portion 13b which extends for a distance along the adjacent medial linear portion 12 of the body. The space between the adjacent surfaces of end portion 13b and linear portion 12 of the body s preferably less than the diameter of the material from which the hook is formed, to tend to maintain the hook portion of another body element in fastening engagement therein against accidental dislodgement.
Rounded outer hook 14 preferably is of a generally circular configuration and defines a medial channel somewhat larger than the diameter of the body, but preferably not much larger so that a wire nut that fits over the outer hook will not have to be larger than necessary to accomplish its fastening function. The end portion 14a of hook 14 extends adjacent the outer end of medial portion 12 of the body to again define a channel that preferably is somewhat smaller than the diameter of the material from which the body is formed. Hook 14 is so formed as to be in substantially the same plane as inner hook 13 and preferably in a position so that its center will lie on a line extending through the medial linear portion 12, as seen in FIG. 3.
Body 10 is formed from some semi-rigid, elastically resilient cylindrical material such as mild steel rod or wire stock of appropriate size. The material preferably will be of a size somewhat larger than cross-sectional size of fence wires to be repaired and should have a strength somewhat greater than those wires. For the repair of ordinary stranded barbed fence wire, the body preferably should be formed of mild steel wire of approximately four to eight gauge. Neither the size nor cross-sectional configuration of the material from which the body is formed, however, are essential to my invention and other materials having the required essential characteristics are within the ambit and scope of my invention.
The rounded outer hook 14 preferably defines an annular structure of somewhat greater extent than a semi-circle to allow secure fastening the loop of a fence wire or another repair device therein, but the extent of this arc should leave an appropriate opening through which, with some resilient deformation, a looped wire to be fastened may pass to become engaged in the hook area. The overall length body 10 between hooks 13 and 14 is not critical to my apparatus, but should be sufficient to provide a length of the fastening structure such that when two body portions are joined, the apparatus may be fastened between the ends of a broken fence wire strand with sufficient surplus of that fence wire strand to allow looped fastening about each outer end hook of my fastening apparatus. Normally for most convenient use in ordinary fences, the desired overall length of the body is approximately six inches and the overall length of a complete fastener with two interconnected body portions is approximately twelve inches, though these dimensions may vary and remain within the scope of my invention.
Wire nut 11 provides a peripherally defined, truncated conical body 15 having apex orifice 16 and base orifice 17. The conic body 15 structurally carries two diametrically opposed, perpendicularly extending finger tabs 18 to allow better gripping of the nut to aid its manipulation, particularly in a rotary fashion. The diameter of apex orifice 16 is incrementally larger than the diameter of medial linear portion 12 of the body so that the nut is supported on that portion of the body in a rotatable and slidably movable fashion. The diameter of base orifice 17 is large enough so that the inner open portion of the outer hook 14 may be carried within the medial channel 19 defined by body 15. The length of the wire nut, that is the distance between its apex orifice 16 and base orifice 17 along its axis, is approximately one and one-half times the diameter of the base orifice to provide an appropriate taper for secure fastening of a wire strand therein.
The inner surface of conic body 15 that defines medial channel 19 provides conical threads 20 to function in the fashion of the traditional wire nut to aid in maintaining the inner portion of outer hook 14 and a looped fence wire strand within the channel 19. The threads 20 may be defined as a part of the inner surface of conic body 15, as illustrated in FIGS. 3-4, or they may also be defined by a separate peripherally defined, internally threaded truncated conic structure, as illustrated in FIG. 5. This latter structure is particularly advantageous when conic body 15 is formed of plastic material as that material may not be strong and rigid enough to provide appropriate fastening of wires, but yet is of a lower cost than a wire nut formed completely of metal. In the structure of FIG. 5, the truncated conic body may be formed of plastic and the threaded conic element 21 may be formed of metal with the two subsequently joined by adhesion or other material joining methods. The nature of the threads 20 is not essential to my invention and the known principles of wire nuts operate in my invention as they do in wire nuts generally.
It is to be noted that wire nut 11 of FIGS. 1-4 is placed on the medial portion 12 of my fastener before formation of both the hooks 13, 14 to provide a fastening structure that may not be non-destructively disassembled.
A first type of wire nut that may be placed on the fastener body after formation of both end hooks is illustrated in FIG. 5. An elongate slot 24 is defined in the conic surface, with a width incrementally larger than the diameter of body 10, in orientation parallel to the axis of the conic nut, and an axial length sufficient to allow the nut to be placed on the medial body 12 by moving it inwardly over rounded outer hook 14. This slotted form of the wire nut may provide somewhat less rigidity and strength than the unslotted species.
A second type of split wire nut that may be placed on a completely formed wire fastener body is illustrated in FIG. 6. This nut provides a conical body formed by similar portions 15a and 15b each defining outer overlapping joint portion 27 at a first linear edge and inner overlapping joint portion 25 at its second linear edge to allow releasable interconnection about a fastener body. This type of wire nut is formed of resilient deformable metal having some resiliency and maintained in releasable interconnection by fastening protuberances 28 and complimentary indentations 26.
Having described the structure of my wire fastener, its operation may be understood.
A complete fastener unit comprises two similar portions, each consisting of a body 10 and wire nut 11, as illustrated in FIG. 2. To repair a broken fence wire, as illustrated in FIG. 1 of the drawings, a loop 23a is formed in the left end of a wire 22 to be repaired. This loop 23a is formed by bending the end portion of the broken wire upon itself and wrapping the end portion upon the wire strand to maintain the looped configuration. The rounded outer hook 14 of the left fastener portion is then inserted through left loop 23a of the broken wire 22, as illustrated particularly in FIG. 2. The associated wire nut 11 is then manually moved over the area of interconnection of wire loop 23a with the left fastener hook 14 until sliding motion of the wire nut is resisted. The wire nut is then manually manipulated by turning it, as aided by finger engagement with finger tabs 18, so that threads 20 in the nut engage the enclosed portions of loop 23a and hook 14, and the nut is tightened so that the looped wire is securely fastened within the wire nut and it covers the open portion of outer hook 14.
The right end of broken wire 22 is then looped upon itself to form right loop 23b and the end portion of the wire is wrapped around the wire body to secure and maintain the loop. The right body portion of the fastener is then fastened to the right loop 23a in the same fashion as described for the left loop, and the wire nut 11 on the right fastener portion is tightened to fasten about the interconnection of the right hook and wire loop 23b.
In this condition, with one end portion of my fastener fastened to each of the end portions of broken wire 22, the inner portions of both fasteners are moved toward each other and manually manipulated until their inner hooks 13 are fastenably engaged in the fashion illustrated in FIG. 2. The fastener in this state interconnects the end portions of the broken wire strand 22 being serviced. After fastening of the broken wire, desired tension may be re-established in it by the various known methods. In the original fastening, the distance between the two loops 22a and 22b may be adjusted in forming the loops, before the fastener is applied to those loops to regulate tension to some degree. After the fastener is applied, tension may be re-established in the repaired wire strand by mechanical fence tighteners, by further manipulation of loops 22a and 22b, or by various other tightening methods that have heretofore became known for the tightening stranded wire in a fence.
It is to be noted that the two body portions of my fastener may be interconnected with each other, one end of the device fastened to one end of a broken wire and the other end of the broken wire fastened lastly so that the size and position of the loop may be adjusted to predetermine the tension in the wire strand after its repair.
It is also to be noted that if a repair device that is longer than two interconnected fasteners is required, a plurality of individual fasteners may be interconnected to provide the longer fastener structure. In such a longer fastening structure either end of a fastener may be interconnected with either end of an adjacent fastener since the configuration of the entry channels of the loops tends to prevent accidental dislodgement when the fastener is not under tension.
It is further to be noted that one or s plurality of my fasteners may be used as an independent tension element, such as an angulated gate support, in fence structures or elsewhere, if desired.
The foregoing description of my invention is necessarily of a detailed nature so that a specific embodiment of its best mode might be set forth as required, but it is to be understood that various modifications of detail, rearrangement and multiplication of parts might be resorted to without departing from its spirit, essence or scope.
Having thusly described my invention, what I desire to protect by Letters Patent, and | A repair device to refasten the ends of a broken strand of wire in a fence structure, especially such as a strand of barbed wire. The repair device provides at least two similar releasably interconnectable portions, each having a first medial interconnecting hook defined at a first end of an elongate wire body and a second wire fastening hook defined at the second end of the wire body. A conic wire nut is movably carried on the wire body to receive the second wire fastening hook therein and fasten upon that second hook and a loop of fence wire carried by the hook to interconnect one end of the fence wire with the second end portion of the repair device. The wire nut defines peripherally extending wings to aid manual manipulation and may be formed with a slot or releasably interconnectable portion to allow placement on the wire body after formation. More than two of the repair devices may be joined to each other to span a greater distance between wire ends to be connected. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is related to U.S. patent application Ser. No. 08/070,710 filed of even date herewith, entitled "HIGH DIFFERENTIAL OUTPUT IMPEDANCE SETTER" by Cary Loren Delano, assigned to the assignee of the present invention, and said application is incorporated herein by reference. U.S. patent application Ser. No. 08/070,710 has been abandoned in favor of file wrapper continuing application Ser. No. 08/282,752.
1. Field of the Invention
The present invention relates to transconductors and, in particular, to low voltage transconductance cells for use in filters.
2. Description of the Prior Art
The heart of a transconductance capacitor filter is the filter's transconductor cells. The filter's performance is determined by the characteristics of each of its transconductor cells. The characteristics of a desirable transconductor cell are extremely high bandwidth, low noise, low power consumption, high output and input impedances, low distortion and good common mode rejection.
Transconductance cells typically include one or more differential pairs. Referring to FIG. 1, a schematic diagram of a prior art differential pair 10 is shown. The differential pair 10 includes a first current source 12, a second current source 14, a first transistor 16, a second transistor 18 and a third transistor 20. A non-inverting input 22 is connected to the gate of the transistor 16, and an inverting input 24 is connected to the gate of the transistor 18. An inverting output 26 is connected to the junction of the current source 12 and the drain of the transistor 16. Similarly, a non-inverting output 28 is connected to the junction of the current source 14 and the drain of the transistor 18. A gate bias input 30 is connected to the gate of a transistor 20. Both of the current sources 12 and 14 are connected in common to a voltage source 32 having a potential V DD .
In operation, the potential at the gate bias input 30 determines the amount of current which flows through the source of the transistor 20 and consequently the amount of Current which flows through the source of each of the transistors 16 and 18. Thus, the potential at the gate bias input 30 sets the gain of the differential pair 10.
Since a transconductor capacitor filter requires good matching between its transconductance cells, in order to compensate for variations in manufacturing, the gate overdrive voltage, V g .o., must be fairly large. With respect to FIG. 1, V g .o. =V gate-source -V threshold .
The differential pair 10, because of its configuration, provides common mode rejection. If the signals provided to the non-inverting input 22 and the inverting input 24 vary in unison, no differential current is produced between the non-inverting output 28 and the inverting output 26.
However, in order for the transistors 16, 18 and 20 to remain within a linear operating region, each transistor must be supplied a drain-source potential at least equal to the gate overdrive voltage V g .o. plus roughly 200 millivolts.
Therefore, when the differential pair of FIG. 1 operates from a supply voltage V DD of 2.7 volts, and actual components are used to generate the currents of the first and second current sources 12 and 14, the differential pair 10 operates on the lower edge of its capabilities, thereby limiting the bandwidth and the headroom of the differential pair 10. "Headroom" refers to the capacity to accommodate input signal swing without driving an amplifier or buffer into saturation or into a non-linear operating region.
Therefore, it would be desirable to provide a transconductance cell that both provides a high level of performance and operates with a lower supply voltage than required with prior art circuits.
SUMMARY OF THE INVENTION
The preferred embodiment of the invention is directed to a filter transconductance cell which operates with a low supply voltage. The filter transconductance cell of the present invention utilizes a differential pair gain stage which operates with a low voltage supply. The filter transconductance cell further utilizes differential pairs to function as a negative impedance converter to thereby achieve a high differential output impedance.
The above features and advantages of the present invention will become apparent from the following description and the appended claims taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a prior art differential pair.
FIG. 2 is a schematic diagram illustrating a low voltage differential amplifier in accordance with the present invention.
FIG. 3 is a simplified schematic diagram illustrating a negative impedance converter in accordance with the present invention.
FIGS. 4A and 4B are a detailed schematic diagram of a low voltage filter transconductance cell in accordance with the present invention.
FIG. 5 is a schematic diagram of a filter which utilizes the low voltage filter transconductance cell of FIGS. 4A and 4B.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 2, a schematic diagram of a low voltage differential pair 100 in accordance with the present invention is shown.
The low voltage differential pair 100 includes a first current source 102 and a second current source 104. An inverting output 106 is connected to the junction of the drain of a transistor 108 and the current source 102. Similarly, a non-inverting output 110 is connected to the junction of the drain of a transistor 112 and the current source 104. The source of each of the transistors 108 and 112 is connected to common. The junction of the current sources 102 and 104 is connected to a supply voltage source 114 having a potential of V DD . A non-inverting input 116 is connected to the gate of the transistor 108 and an inverting input 118 is connected to the gate of the transistor 112.
In contrast to the differential pair 10 of FIG. 1, the required supply voltage V DD for the differential pair 100 is reduced by one gate overdrive voltage plus 200 millivolts since the transistor 20 of FIG. 1 is eliminated. This allows the available supply voltage V DD to be more fully utilized by the transistors 108 and 112.
Thus, in contrast to the differential pair 10 of FIG. 1, for a given supply voltage, the differential pair 100 provides a higher transconductance and a resultant higher bandwidth. Another advantage of the differential pair 100 is the harmonic cancellation provided because the sources of transistors 108 and 112 are grounded.
Ideally, each transconductor-capacitor pair within a transconductance capacitor filter should have a phase shift of exactly 90° in order to prevent oscillations, as detailed further herein. By eliminating all internal nodes within the differential pair, as is the case with the differential pairs 10 and 100, FIGS. 1 and 2, respectively, the phase shift between the input and the output of the differential pair 100 is 90° when the outputs are terminated within a capacitor.
The low voltage filter transconductance cell of the present invention utilizes a negative impedance converter to raise its differential output impedance.
In further detail, referring now to FIG. 3, a simplified representation of a negative impedance converter 200 that is incorporated into the present invention is shown. In general, a negative impedance converter achieves a high differential output impedance by placing a positive feedback in parallel with an output impedance 202. The negative impedance converter 200 includes a pair of cross-connected transconductance cells 204 and 206 each having a transconductance value of g m . For common mode signals, the output impedance is 1/g m . The output impedance for differential signals, however, is equal to the parallel combination of the output impedance 202 and (-1/g m -1/g m ). The value of this parallel combination may be either positive or negative depending upon the value of g m . If the output impedance is negative and no load is connected to the converter 200, the converter 200 will latch.
The transconductance cell 204 operates as a voltage controlled current source having an output current equal to (g m ×V a ) amps, where V a is the voltage across the input 208. Similarly, the transconductance cell 206 operates as a voltage controlled current source having an output current equal to (g m ×V b ) amps, where V b is the voltage across the input 210.
If the magnitude of converter 200, i.e., (-1/g m -1/g m ), is close to the value of the output impedance 202, the differential output impedance exhibited at the output impedance 202 will have a magnitude much greater than the output impedance 202. As detailed in the cross-referenced patent application, using a minimum number of components, the gain of the negative impedance converter 200 is set, by way of a feedback loop, to an optimum value in order to maximize the differential output impedance of a current source.
Referring now to FIGS. 4A and 4B, a detailed schematic diagram of a low voltage filter transconductance cell 300 in accordance with the present invention is shown. In the transconductance cell 300, input signals at a first non-inverting input 302 are sampled by transistors 310, 311, 312 and 313, the transistors having commonly-connected gates. Input signals at a second non-inverting input 304 are sampled by transistors 306, 307, 308, and 309, the transistors having commonly-connected gates.
Similarly, input signals at a first inverting input 314 are sampled by transistors 318, 319, 320 and 321, the transistors having commonly-connected gates. Input signals at a second inverting input 316 are sampled by transistors 322, 323, 324 and 325, the transistors having commonly-connected gates.
Because the transistors 306, 308, 310, 312, 318, 320, 322, and 324 have commonly-connected drains, any common mode currents produced by these transistors are mirrored back to a non-inverting output 326 and an inverting output 328 through transistors 330, 332 and 334. In further detail, the gates of the transistors 332 and 334 are commonly-connected to the junction of the drains of the transistors 306, 308, 310, 312, 318, 320, 322 and 324. The drain of the transistor 332 is connected to the non-inverting output 326, and the drain of the transistor 334 is connected to the inverting output 328.
The transistor 330, through a resistor 336, operates as the input to a current mirror consisting of transistors 330, 332 and 334.
A set of transistors 307, 309, 311, 313, 319, 321, 323, and 325 together operate as a differential pair that provides the gain of the transconductance cell 300.
Although an internal node 338 is present at the drain of the transistor 330, the filter transconductance cell 300 still provides adequate common mode rejection up to high frequencies. This internal node does not affect the bandwidth with respect to differential signals.
A pbias input 340 sets the common mode output level of the filter transconductance cell 300. In further detail, a potential at the pbias input 340 drives a current through source of a transistor 342. A pair of transistors 344 and 346, having commonly-connected gates, samples the potential at the inverting output 328 while a pair of transistors 348 and 350, having commonly-connected gates, samples the potential at the non-inverting output 326.
Since the drains of the transistors 344, 346, 348 and 350 are commonly-connected, the current produced at the junction of the drains represents common mode current. The addition of this common mode current to the current produced by the transistor 342 produces a voltage (potential) which adjusts the commonly-connected gates of a pair of transistors 351 and 353. A capacitor 355 at the junction of the drain of transistor 342 and the gates of transistors 351 and 353 operate to compensate the feedback loop thus preventing oscillations.
In turn, the transistors 351 and 353 produce a current, which through their commonly-connected drains is fed back to a current mirror consisting of the transistors 352, 354 and 356. In further detail, current from the junction of the drain of transistors 351 and 353 produces a voltage at the commonly-connected gates of the transistors 352, 354 and 356.
The transistor 356 in turn produces a current which is summed at the non-inverting output 326, while the transistor 352 produces a current which is summed at the inverting output 328. The transistor 354, having its base connected to its drain, operates as the input to the current mirror consisting of the transistors 352, 354 and 356. Thus, the filter transconductance cell 300 has a complete feedback loop which sets the common mode voltage at the outputs 326 and 328.
Transistors 357, 358, 359, 360, 362, 364, 366 and 368 operate as diodes for common mode signals, thereby lowering the common mode output impedance. By lowering the common mode output impedance, less compensation is required for the common mode feedback loop. For differential signals, however, the currents produced by the transistors 357, 358, 359, 360, 362, 364, 366 and 368 cancel out thereby appearing as if the currents are non-existent.
A pair of transistors 370 and 372 function as a negative impedance converter, as previously described with reference to FIG. 3. The gain of this negative impedance converter is optimally set by an external circuit through a V q input 374.
In particular, the potential at the V q input 374 determines the level of current through the resistors 376 and 378. Such an external circuit is disclosed in the above cross-referenced U.S. patent application entitled, Application Ser. Nos. 08/070,710 and 08/285,757.
In the preferred embodiment of the invention, a first power down terminal 380 and a second power down terminal are both normally connected to ground. However, by coupling only one of the first power down terminal 380 or the second power down terminal 382 to ground, the transconductance of the cell 300 can be reduced by half. Because of the configuration of the transconductance cell 300, linearity of the cell is maintained even at the lower transconductance level.
Referring now to FIG. 5, a filter application of the transconductance cell 300 of FIGS. 4A and 4B is shown. In the preferred embodiment of the invention, the filter 400 includes a set of seven transconductance cells 402, 404, 406, 408, 410, 412, and 414 to form a seven pole filter. Each of these transconductance cells corresponds to the transconductance cell 300 of FIGS. 4A and 4B.
A non-inverting filter input 416 is connected to a first non-inverting input 418 of the transconductance cell 402. An inverting filter input 420 is connected to a first inverting input 422 of the transconductance cell 402.
A second non-inverting input 424 of the cell 402 is connected to an inverting output 426 of the cell 404. A second inverting input 428 is connected to a non-inverting output 430 of the cell 404. A non-inverting output 432 of the cell 402 is connected to a first non-inverting input 434 of the cell 404. An inverting output 436 of the cell 402 is connected to a first inverting input 438 of the cell 404.
The non-inverting output 430 is further connected to a first non-inverting input 440 of the cell 406, and the inverting output 426 is further connected to a first inverting input 442 of the cell 406.
A second non-inverting input 444 of the cell 406 is connected to an inverting output 446 of the cell 408. A second inverting input 448 is connected to a non-inverting output 450 of the cell 408. A non-inverting output 452 of the cell 406 is connected to a first non-inverting input 454 of the cell 408. An inverting output 456 of the cell 406 is connected to a first inverting input 458 of the cell 406.
The non-inverting output 452 is further connected to a second inverting input 460 of the cell 404, and the inverting output 456 is connected to a second non-inverting input 462 of the cell 404.
A second non-inverting input 464 of the cell 408 is connected to an inverting output 466 of the cell 410. A second inverting input 468 is connected to a non-inverting output 470 of the cell 410. A non-inverting output 472 of the cell 412 is connected to a first inverting input 474 of the cell 410. An inverting output 476 of the cell 412 is connected to a first non-inverting input 478 of the cell 410.
The non-inverting output 450 is further connected to a second non-inverting input 480 of the cell 410, and the inverting output 446 is connected to a second inverting input 482 of the cell 410.
The non-inverting output 470 is further connected to a first non-inverting input 484 of the cell 412, and the inverting output 466 is connected to a first inverting input 486 of the cell 412.
A second non-inverting input 488 of the cell 412 is connected to an inverting output 490 of the cell 414. A second inverting input 492 is connected to a non-inverting output 494 of the cell 414. The non-inverting output 472 of the cell 412 is connected to a first non-inverting input 500 of the cell 414. An inverting output 476 of the cell 412 is connected to a first inverting input 498 of the cell 414.
The non-inverting output 494 of the cell 414 is further connected to a second inverting input 496 of the cell 414. The inverting output 490 is further connected to a second non-inverting input 498 of the cell 414.
The non-inverting output 494 is also connected to a non-inverting filter output 504, and the inverting output 490 is also connected to an inverting filter output 506.
Stray and/or placed capacitances at the outputs of each of the cells 402, 404, 406, 408, 410, 412 and 414 are represented by the capacitors 508, 510, 512, 514, 516, 518, 520, 522, 524, 526, 528, 530, 532 and 534.
In the preferred embodiment of the filter 400, each of the cells 402, 404, 406, 408, 410, 412 and 414 is identical, and except for the inputs 418 and 422, each input is driven by an output. This feedback configuration sets the common mode level at the input of each of the cells 404-414. Setting the common mode level in turn sets the gain of each of the cells. In further detail, since each of the cells 404-414 is identical there is a common mode level associated with each cell as well as a differential swing associated with each cell. The zero point of an input signal to the filter inputs 416 and 420 and the common mode level of each cell is the same. The common mode input level of the cell 402, however, is set externally using a feedback loop similar to the one in the cell 300, so that the input level is the same as the filter common mode level.
In order to maintain the bandwidth of the filter 400, if the capacitances 532 and 534 double due to output configurations, as with an integrated circuit layout, the transconductance of the cell 414 can be doubled to thereby maintain the same ratio of transconductance to stray capacitance. In order to double the transconductance of the cell 414, the transistors 362, 364, 366, 368, 357, 359, 358 and 360 of FIG. 4A are placed in parallel with transistors 309, 307, 313, 311, 319, 321, 323 and 325.
While only certain preferred embodiments have been described in detail, as will be apparent to those familiar with the art, certain changes and/or modifications can be made without departing from the scope of the invention as defined by the following claims. | A filter transconductance cell utilizes a differential gain stage which operates with a low voltage supply. The filter transconductance cell also includes a negative impedance converter to provide the cell with a high differential output impedance. The filter transconductance cell further includes an arrangement for sensing of a common-mode signal at the input of the differential gain stage and for generating in response thereto a current which is added to each common-mode current at the output of the differential gain stage to thereby produce common-mode rejection. | 7 |
BACKGROUND OF THE INVENTION
The invention concerns a crosslink hinge for the mounting of a door leaf on the carcass of a cabinet, having two links, each pivoted on the other in a scissor-like manner and one pivotally attached at one end directly to the carcass-related hinge part which can be fastened on a mounting plate on the carcass, and the other joined at one end to the door-related hinge hinge part which is in the form of a cup-like insert which can be set in a recess in the door leaf, the other end of each link pivotally attached to the other hinge part indirectly through a link or a sliding guide means.
Crosslink hinges, which in comparison with other link hinges, such as four-pivot hinges, permit a greater opening angle of as much as 180°, are--like the link hinges used quite generally in modern furniture manufacture for mounting doors on a cabinet carcass--mounted, not directly on the carcass, but releasably and adjustably on a mounting plate attached to the latter. The mounting arrangement is, as a rule, such that the carcass-related part of the hinge is adjustable on the mounting plate in two coordinate directions, namely toward and away from the interior of the cabinet, and at right angles to this direction and to the hinge pivot axis. For the various adjustments, fastening or adjusting screws are provided, which are passed through an adjusting slot in the carcass-related hinge part and driven into a tap in the carcass-related part or they are driven through a tap in the latter and bear against the mounting plate. In the case of crosslink hinges, the carcass-related hinge part, however, is covered over by the section of the link arm that is indirectly coupled to the carcass-related hinge part and points toward the cabinet interior; this link arm is, as a rule, in the form of a metal stamping of U-shaped cross section. The web of this section of the link arm therefore covers over at least a portion of the heads of the fastening or adjustment screws, so that openings must be provided at certain points in this web so that the blade of a screwdriver can be put through them whenever a change of the setting has to be made. Especially in the case of the adjusting screw used in making lateral adjustments in the position of the door on the face of the cabinet, i.e., a change in the overlap of the door, such an opening must be provided because this adjusting screw is, as a rule, situated in an area on the carcass-related hinge part that is close to the door and is covered by the link arm when the door is in the open position, i.e., when the hinge is accessible for adjustment. Such openings, however, detract from the appearance of the hinge. Furthermore, the requirement of accessibility to the adjustment and fastening screws prevents or makes it difficult to provide an over-center mechanism on the carcass-related hinge part in the area covered over by the link arm section, inasmuch as it is not feasible to shift the location of these screws to a point deeper inside the cabinet, not only on account of the resultant greater bulk of the hinge, but also on account of the greater stress it would produce on the fastenings. This is because the weight of the door would then be given a greater mechanical advantage with respect to the mounting and adjusting screws, and this would result in a corresponding increase of the bending stress on the carcass-related hinge part and on the adjusting and fastening screws.
It is therefore the object of the invention to improve the known crosslink hinges such that they will be able to be mounted on a corresponding mounting plate on the carcass in a simple and rapid manner, without increasing their dimensions or the stress applied to them, while preserving simplicity of adjustment, without requiring access to the portion of the carcass-related hinge part that is covered by the link arm for hinge adjustment.
SUMMARY OF THE INVENTION
Setting out from a crosslink hinge of the kind referred to above, this problem is solved in accordance with the invention by causing the door-related hinge part cup to be composed of an attaching means which can be fitted snugly into the door-leaf mortise, and a link holder engaged at least partially in the attaching means, and by making the portion of the link holder that is engaged in the attaching means displaceable within a given range relative to the latter at right angles to the hinge pivot axis and parallel to the back of the door, and enabling it to be fixed in desired positions on the door. In this manner, one of the necessary means of adjustment, namely the adjustment of the carcass-related hinge part to change the amount of the door overlap, is transferred to the door-related part of the hinge, and the formerly required adjusting screw on the carcass-related hinge part is then eliminated.
In a preferred development of the invention, the carcass-related hinge part has on its base a projection of inverted-T-shaped cross section, which can be inserted into an open, complementary T-shaped socket on the mounting plate, and the carcass-related hinge part is provided at its rearward end with an open-ended elongated slot through which a screw is passed and driven into the mounting plate until its head engages the surface of the carcass-related hinge part. In this manner the installation and adjustment of the hinge can be accomplished simply by inserting the projection into the socket and locking it at the desired depth therein by tightening the screw passed through the open-ended elongated slot, the head of the screw being accessible at the inner end of the carcass-related hinge part since the link-arm section of the latter leaves the screw exposed even when the door is only partially open.
The link holder of the door-related hinge part preferably has a flange lying against the back of the door and concealing the attaching means in any of the positions in which the link holder may be fixed, so that, when the hinge is installed, the attaching means is not at all visible.
The flange of the link holder is best made in the form of an over-sized mounting flange in the area opposite the edge of the door, and on it at least one hole elongated in the direction of the adjustment of the link holder is provided for the accommodation of an associated mounting screw.
The flange then has on its underside facing the door leaf a shallow recess in which at least one flat, ear-like projection of the attaching means is accommodated, which is smaller than the recess by the amount of the given displaceability of the link holder relative to the attaching means.
The ear-like projection can have in the portion situated beneath an elongated hole in the fastening flange of the link holder a mounting plug projecting toward the door, this plug being driven into a mating bore in the reverse side of the door and additionally holding the insert on the door.
It is then desirable to make the mounting plug expandable in diameter by means of the mounting screw that is driven into it, in order thus to achieve maximum strength in the mounting of the insert in its mortise in the door.
The attaching means is preferably injection-molded of plastic, the ear or ears along with the (expandable) plugs, if used, being made integral therewith.
The link holder, on the other hand, is made preferably of metal, and it is recommendable that it be made by pressure casting--by die casting from zinc alloy, for example.
In the case of a crosslink hinge in which the link arm pivotally attached directly to the door-related hinge part is coupled by a link to the carcass-related hinge part, the design is preferably such that the link arms and the link indirectly coupling the link arm with the carcass-related hinge part have two cheeks in parallel spaced relationship, between which an over-center mechanism holding the hinge in the closed position is disposed. Since the mounting screws or adjusting screws are no longer situated in the area between the supporting-wall-related hinge part and the link arms, there is no longer any difficulty in providing such an over-center mechanism in this area.
In a preferred further development of the invention, this over-center mechanism has a two-armed cam lever pivoted on the carcass-related hinge part, whose arm adjacent the door is biased toward contact with the carcass-related hinge part, while the upper side of the second lever arm is in the form of a cam which, with in the immediate vicinity of the closed position, cooperates with an actuating means provided between the cheeks of the link such that the lever arm on the door side is held lifted away from the carcass-related hinge part against the bias of the spring.
The lever arm at the door end is best configured and arranged such that, when the closed position is approached, it will overreach the pivot pin joining the crosslink arms together in a scissor-like manner, a roller being preferably mounted on the pivot pin and engaging the cam surface on the bottom side of this lever arm before the other lever arm is released by the actuating means. The actuating means cooperating with the cam surface of the cam lever end remote from the door-related hinge part can be simply a transverse pin whose ends are held in bores in the cheeks of the link.
BRIEF DESCRIPTION OF THE DRAWING
The invention is further explained in the description that follows of an embodiment, in conjunction with the drawing, wherein:
FIGS. 1 and 2 are side views of the hinge of the invention, and of its mounting on the supporting wall of a cabinet carcass, the open position being shown in FIG. 1 and the closed position in FIG. 2;
FIG. 3 is a top view of the hinge shown in FIGS. 1 and 2, in a position wherein the door leaf with the hinge mounted on it is open at 90° from the closed position;
FIG. 4 is a top view of the door-related hinge part in a position turned 180° with respect to FIG. 3;
FIG. 5 is a cross section along line 5--5 of FIG. 4;
FIG. 6 is a bottom view of the door-related hinge part as seen in the direction of the arrow 6 in FIG. 5;
FIG. 7 is a cross section corresponding to that of FIG. 5, through the link holder of the door-related hinge part shown in FIGS. 4 to 6;
FIG. 8 is a cross section through the link holder of FIG. 7 as seen in the direction of arrows 8;
FIG. 9 is a top view of the means for attaching the door-related hinge part, as seen in the direction of the arrow 9 in FIG. 10;
FIG. 10 is a cross section through the fastening portion as seen in the direction of the arrows 10--10 of FIG. 9;
FIG. 11 is a front view, partially in section, of the fastening portion shown in FIGS. 9 and 10, as seen in the direction of the arrows 11--11 of FIG. 9, the expansion plug represented on the right side of the drawing being shown in cross section;
FIG. 12 is a bottom view of the fastening means shown in FIGS. 9 and 11;
FIGS. 13 and 14 are diagrammatic cross sections along the longitudinal center plane of the hinge of the invention in the open and closed positions, respectively, an over-center mechanism provided for catching the hinge in the closed position being represented diagrammatically, FIG. 14 showing the carcass-related hinge part elevated above the mounting plate which is represented partially in cross section in the area of the socket;
FIG. 15 is a view of the mounting plate of the hinge of the invention, as seen in the direction of the arrow 15 of FIG. 14, the carcass-related hinge part that is fastened on the mounting plate being indicated diagrammatically in broken lines.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The hinge shown in FIGS. 1 to 3 and indicated as a whole by the number 10 serves for the pivotal mounting of a door leaf 12 on a supporting wall 14 of a cabinet carcass, the door leaf 12 overlapping the outer edge 18 of the supporting wall 14 by a given amount A which is adjustable within a range a in order that the door may be in proper position when it is in the closed state (FIG. 2).
The door-related part of the hinge, which is in the form of an insert 22 which can be set in a recess 20 in the door 12, and also the carcass-related hinge part 26, which can be fastened on the inside face of the supporting wall 14, are pivotally joined by a crosslink mechanism. This crosslink mechanism consists of two crosslink arms 28 and 30 which are pivoted on one another by a pin 32 in a scissor-like manner. The crosslink arm 28 is pivoted at its left-hand extremity, as seen in the drawing, directly within the insert 22, while its end on the carcass side is pivoted at 34 to a link 36 which in turn is pivoted at 38 on the inside end of the carcass-related hinge part 26. The second crosslink arm 30 is pivoted on the one hand directly at 40 to the carcass-related hinge part 26, while its other end is pivoted at 42 to a link whose other end is pivotally attached at 46 inside of the insert 22. The basic construction of this crosslink mechanism to the extent described above is known. The crosslink arms 28 and 30 as well as the link 36 are stamped from sheet metal and have each two parallel cheeks 28a, 28b, 30a, 30b and 36a, 36b, integral with the webs 28c, 30c and 36c. The carcass-related hinge part 26 is mounted adjustably on its mounting plate 50 by means of a screw 48 in the manner yet to be described in conjunction with FIGS. 13 to 15. The mounting plate 50 is, in turn, fastened to the inside surface of the supporting wall 15 by screws or other conventional means.
The special construction of the door-related hinge part in the form of the insert 22 will be further explained below in conjunction with FIGS. 4 to 12, FIGS. 4 to 6 showing the assembled insert composed of the link holder 54 and the attaching means 56, while in FIGS. 7 and 8 the link holder 54 is shown separately, and in FIGS. 9 to 12 the fastener 56 is shown separately.
The link holder 54, made preferably by die-casting from metal, has a guide piece 58 which can be inserted into the attaching means 56 made of plastic, in which a recess 60 is formed, in which recess the front sections of the crosslink arms 28 and 30, the front or door end of the carcass-related hinge part 26, and a section of the link 44, are contained when the hinge is in the closed state. The guide piece 58 has on its sides planar surfaces 62 (FIG. 8) which lie between likewise planar inner surfaces 64 (FIG. 11) of the attaching means 56. The attaching means consists virtually of two sections 66 of more or less segmental shape in plan (FIGS. 9 and 11) which are joined together integrally in their bottom area by two cross members 68 and 70, the circular outer periphery of the moldings 66 and cross members 68 and 70 being equal to the diameter of the recess 22 in the door 12. The attaching means 56 thus fits into the insert 22 and is therefore held in the insert against any displacement parallel to the surfaces of the door. On the other hand, the guide piece 58 is shorter in the direction parallel to the surfaces 62 and 64, respectively, than the diameter of the insert 22, so that the guide piece--and thus the entire link holder 54--is held between the moldings 66 so as to be displaceable by a certain amount in this direction.
The bore 72 which can be seen in the link holder in FIGS. 5, 7 and 8, serves to accommodate a pivot pin joining the front end of the crosslink arm 27 directly to the link holder, while bore 74 (FIGS. 5 and 7) serves to accommodate a pivot pin holding the link 44 in the link holder at the door end. An elongated hole 76 in molding 66 corresponds to the bore 74, and into it projects the pivot pin of appropriate length for the link 44, and thus secures the link holder also against removal from the attaching means. The guide piece 58 of the link holder 54 is therefore displaceable within the attaching means 56 over a range given by the length of the elongated holes 76, while projections 78 (FIG. 10) provided on the lateral longitudinal surfaces of the elongated holes 76 hold the pivot pin in a central displacement position. Due to the resilience of the plastic material of the attaching means, the pivot pin can nevertheless be pushed with moderate effort over the projections 78.
The link holder 54 has a radial flange 80 which projects radially from the upper margin of the guide piece 58 and overlaps the attaching means 56 in any position of the latter, and which is expanded in the area opposite the edge of the door 12 into an enlarged fastening flange having two wings 82 extending on both sides of and symmetrically with the longitudinal central axis of the link holder and being provided each with an elongated hole 84 aligned with the direction of displacement of the link holder relative to the attaching means (FIGS. 3 and 4). Mounting screws 86 (FIG. 3) screwed through these elongated holes 84 into the door 12 hold the link holder 54 and with it the entire door-related hinge part in the desired position of adjustment on the door 12.
The bottoms of the flange wings 82 facing the door 12 are provided with shallow recesses 88 (FIG. 6 and 8) in which there are situated ear-like, flat projections 90 projecting radially from the upper edge of the attaching means 56 (FIGS. 6, 9 and 12), which are shorter in the direction of displacement than the recesses 88, so that they permit displacement of the link holder relative to the attaching means. Each of the ear-like projections 90 is provided in the area situated beneath the corresponding elongated hole 84 with an expansion plug 92 which can be expanded by the mounting screws 86. The mounting screws 86, therefore, are not directly driven into the material of the door 12 in the example here represented, although it is basically possible for this to be the case; instead, they are driven into the expansion plugs 92 which in turn are forced into associated bores (not shown) in the door. The expansion of the expansion plugs 92 when the mounting screws 86 are driven into them provides on the one hand a means of fastening the door-related hinge part 22 to the door such that it can withstand heavy loads, but on the other hand can be removed at any time and reinstalled. The ear-like projections 90 and the expansion plugs 92 are preferably injection molded integral with the attaching means 56.
FIGS. 13 and 14 diagrammatically represent the manner in which the carcass-related hinge part 26 is fastened on the mounting plate, and the configuration and arrangement of an over-center mechanism holding the hinge 10 in the closed position, which is disposed on the carcass-related hinge part in the space between the cheeks of the crosslink arms 20 and 30 and the link 36. The over-center mechanism consists essentially of a two-armed cam lever 96 pivotally mounted at 94 on the carcass-related hinge part 26. Its first lever arm 98 adjacent the door-related hinge part 22, has on its bottom a cam 100 which, when the hinge approaches the closed state (FIG. 14), cooperates with a roller 102 mounted on a pin 32 which joins the crosslink arms 20 and 30 together in a scissor-like manner. To this end, the inside, second lever arm 104 is biased by a compression spring 106 abutting on the carcass-related hinge part 26 such that the first lever arm 98 is urged toward the upper side of the carcass-related hinge part. In the upper side of the carcass-related hinge part there is provided a recess 108 in which the roller 102 lies when the hinge is in the closed state.
The upper side of the second lever arm 104 is in the form of a cam 110 on which rides a pin 112 disposed transversely between the cheeks 36a and 36b of link 36, thereby holding the first lever arm 98 away from the carcass-related hinge part 26. Not until the instant in which the transverse pin 112 comes free of the cam 110 will the cam lever 96 swing counterclockwise. In accordance with the action of the crosslink mechanism and the length of the second lever arm 104, the release of the cam 110 by the pin 112, however, does not take place until just before the door reaches the closed position, when the roller 102 is already running against the cam 100 on the bottom of the lever arm 98. Upon the release of the cam lever by the pin 112, therefore, the force of spring 106 exercises a component acting in the closing direction between the cam 100 and the roller 102.
The fastening of the carcass-related hinge part on the mounting plate 50 so as to be adjustable longitudinally can be understood with the aid of FIGS. 13 to 15 and FIG. 3. The carcass-related hinge part 26 partially overlapping the mounting plate 50 has in its front area towards the door 12 a downwardly projecting, inverted-T-shaped projection 114 (FIG. 14, and in broken lines in FIG. 15), which can be inserted into a correspondingly T-shaped open socket 116 in a projection 118 of the mounting plate. By means of the projection 114 inserted into the socket 116, the carcass-related hinge part 26 is held securely on the mounting plate against lifting from the latter. To set the depth to which the carcass-related hinge part 26 can be inserted on the mounting plate (it is variable to a certain degree and hence adjustable), there is provided on the rearward end of the carcass-related hinge part 26 pointing toward the carcass interior, a slot 120 open on the inside end, through which the mounting screw 48 can be driven into a threaded bore 122 (FIG. 14) on the rearward end of the mounting plate 50 to such an extent that the bottom of its head presses against the planar bearing surface 124 around the slot 120 and thus clamps the carcass-related hinge part onto the mounting plate. Indentations in the confronting surfaces of the carcass-related hinge part and mounting plate additionally secure the carcass-related hinge part in the selected depth of insertion against undesired displacement.
In order on the one hand to facilitate the introduction of the projection 114 into the socket 116, and on the other hand to reduce to the vanishing point the insertion clearance between the laterally projecting arms of the T-shaped projection 114 and the socket 116, i.e., to assure the rigid fastening of the carcass-related hinge part 26 on the mounting plate 50, the arms of the T of projection 114 are made to slope slightly toward the supporting wall of the carcass, in the manner seen in FIG. 14. | Crosslink hinge for mounting a door on the carcass of a cabinet. The door-related part of the crosslink hinge can be affixed in a recess in the door and is composed of an attaching member and a link holder disposed in the attaching member. To vary the position of the door, the link holder is displaceable at right angles to the pivot axis of the hinge and parallel to the door back and can be fixed in the desired position. The carcass-related part of the hinge has on its bottom an inverted-T-shaped projection which can be inserted into a complementary T-shaped socket in its mounting plate. A set screw is threaded into the mounting plate to fix the carcass-related hinge part thereon. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is the U.S. National Stage of International Application No. PCT/EP2002/012457, filed Nov. 7, 2002 and claims the benefit thereof. The International Application claims the benefits of European Patent application No. 02021499.5 EP filed Sep. 26, 2002, both of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method respectively apparatus for monitoring a technical installation. Another object of the present invention is to provide a qualitative and/or quantitative assessment respectively diagnosis of a technical installation, especially of a power plant including turbines and/or generators.
BACKGROUND OF THE INVENTION
[0003] Known methods of monitoring a plant include maintenance personnel walking around the plant for assessment purposes based on human observations.
[0004] Experienced maintenance staff may detect deviations from normal operating conditions such as unusually loud pumps and drives or unusual vibrations of a plant component and report those observations.
[0005] But usually those observations are not stored for future reference and therefore no long term trend analysis can be applied.
[0006] Furthermore slight deviations cannot be tracked and changes in maintenance staff may lead to conclusion failures since observations of different persons are usually not compared to each other or transferred towards a “neutral” observation, or are simply not comparable and/or transferable.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide an advanced method respectively apparatus for monitoring a technical installation including human observations.
[0008] This and other objects are solved by a method respectively apparatus as laid down in the independent claims. Preferred embodiments are subject to the corresponding dependent claims.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The invention includes utilizing human skills and psychology.
[0010] For example, the galvanic skin reflex or other physiological reactions can be used to determine the state of a maintenance worker when observing a plant component.
[0011] Even if he is not aware of a potential failure of a plant component, even slight deviations from a former operating situation of said component may nevertheless be sensed by him unwillingly and cause a physiological reaction such as a change in blood pressure, pulse rate, galvanic skin reflex, breathing pattern, cardiovascular activity etc. without being aware that a failure might be in progress.
[0012] An instrument such as a polygraph (“lie detector”) and its related sensors can advantageously be used to acquire and store at least part of a.m. human physiological reactions during an inspection tour around the plant.
[0013] To avoid wrong conclusions based on acquired and/or stored human physiological reactions, the person performing the inspection tour should be “calibrated” before performing the inspection tour, because there are factors effecting e.g. the heart-beat such as emotion, exercise, hormones, temperature, pain and stress. Furthermore the normal number of pulse beats per minute in the average adult varies from 60 to 80, with fluctuation occurring with exercise, injury, illness, and emotional reactions. So, in a preferred embodiment of the invention, the “normal state” of said person is acquired and stored before said inspection tour as a reference basis.
[0014] The acquisition of human physiological reactions may include voluntary and/or involuntary reactions of the nervous system.
[0015] The somatic nervous system is also the voluntary nervous system because its motor functions may be consciously controlled. It includes somatic motor nerve cells, which carry impulses from the CNS to the skeletal muscles. The impulses carried by the somatic motor nerves produce contractions of the skeletal muscles. Muscle contractions that are brought about by the somatic nervous system may be reflex responses; those may not be consciously controlled.
[0016] The autonomic nervous system—or involuntary nervous system—in contrast to the somatic nervous system, is composed of visceral motor nerve cells, which transmit impulses to smooth muscles, cardiac muscle, and glands. Visceral motor impulses generally cannot be consciously controlled.
[0017] The autonomic nervous system may be subdivided functionally into sympathetic and parasympathetic divisions which are actually overlapping divisions.
[0018] Generally the parasympathetic nervous system is responsible for regulating the body during periods of low stress, uneventful times, times of calm and relaxation.
[0019] While the parasympathetic nervous system decreases heart rate and promotes digestive functions, the sympathetic nervous system takes charge during times of high stress. The sympathetic nervous system increases heart, and breathing rates. It helps us respond when we are called upon to perform a physical feat such as running to get away from something threatening us or standing and confronting a threat to our welfare, or well being. Many times people refer to this reaction as “fight or flight”.
[0020] Physiological changes caused by any of the a.m. nervous systems can be monitored by physiological recording devices such as a polygraph, an instrument equipped with sensors, which, when attached to the body, can pick up subtle physiological changes.
[0021] These fluctuations, in the form of electrical impulses, are amplified within the polygraph and may activate pens that then record the changes on a continuously moving roll of paper.
[0022] When sensors are attached to the scalp, the result is an EEG, electroencephalogram. When the sensor measures changes in the electrical resistance to the skin, the result is a reading of galvanic skin response (GSR). When the sensor is used to pick up subtle changes in the electrical activity of muscles, the result is an electromyogram (EMG).
[0023] A polygraph can also measure a number of other physiological responses such as heart rate and blood pressure and produce recordings of physiological phenomena such as breathing, galvanic skin resistance and cardio tracing that may be used as the basis for the application of a reliable technique for diagnosing the operational state of a plant component.
[0024] A standard polygraph can be used for recording changes in blood pressure, pulse rate, pulse strength, galvanic skin reflex (sweat gland activity), and upper and lower breathing patterns. It does not matter if the subject is “nervous” during the testing process. The polygraph records significant changes from the subject's “normal state”.
[0025] Furthermore, a polygraph is suitable for recording changes in a person's Sympathetic Nervous System, part of the Autonomic Nervous System, which operates independently of conscious thought.
[0026] For example, the lungs and heart continue to operate even when you are asleep—you don't have to think about it.
[0027] These systems can be consciously controlled only very slightly.
[0028] Summing up the invention, it is stated that it utilises human perception, similar to a polygraph (lie detector).
[0029] Maintenance staff performing inspection tours may be equipped with a head-mounted (e.g. digital) camera to record their sight and changes in direction of sight.
[0030] Simultaneously, neuritic currents, changes in blood pressure, pulse rate, pulse strength, galvanic skin reflex (e.g. sweat gland activity) upper and lower breathing patterns etc. may be recorded.
[0031] Thus the five human senses can be employed. Notes can be added manually (e.g. via PDA, hand held PC etc.).
[0032] The results can be stored, e.g. in a database, and be used for trending and plant assessment purposes.
[0033] The analysis of human perception and sight reveals the condition of any particular plant equipment/plant component, e.g. pumps, engines, turbines, generators and so on.
EXAMPLE
[0034] No unusual observations were made, e.g. by plant walkers/plant workers for months.
[0035] However, one day a belt drive between an electric motor and a pump is louder than usual. The reason for this may be that one of three belts is slightly loose.
[0036] After a brief check, the worker realises that there is no urgent need to tighten or change the belt.
[0037] However, on subsequent tours, the workers' perception concerning the belt drive will yield the condition of the belt drive, e.g. how long is the belt drive observed on subsequent tours, level of change in human perception while observing the belt drive, and so on.
[0038] In general, the five human senses may be efficiently utilised for plant assessment.
[0039] Human senses are very sensitive and can not yet be reproduced and/or simulated i.e. by a computer and appropriate software.
[0040] However, objective assessment from human observation is usually hard to obtain; to overcome that problem the invention neatly combines human sensing with objective recording to a powerful plant assessment tool. | The invention makes use of human perception to derive potential faults of at least one component of the technical installation. A sensor device may be employed for acquiring at least one human physiological reaction whereby said human physiological reaction may include at least one of neuritic currents and changes in neuritic currents and blood pressure and changes in blood pressure and pulse rate and changes in pulse rate and pulse strength and changes in pulse strength and galvanic skin reflex and changes in galvanic skin reflex and breathing patterns. | 6 |
FIELD OF THE INVENTION
The invention concerns an electron beam x-ray computer tomography scanner which is compact in size, tiltable, and in which neither the x-ray source nor the x-ray detector are caused to rotate while scanning.
DESCRIPTION OF THE PRIOR ART
Electron beam x-ray computer tomographs without mechanical motion of the x-ray source or the detectors are known in the art from U.S. Pat. Nos. 4,352,021 and 4,158,142. Further improvements of the system described in U.S. Pat. No. 4,352,021 are described in U.S. Pat. No. 4,521,900 and U.S. Pat. No. 4,521,901.
In conventional computer tomographs, the x-ray source and/or the detector arrangement are mechanically moved around an object. These tomographs are usually limited to scan times of about 1 second for a complete 360 degree scan. When mechanical motion is not necessary, significantly shorter measurement times are possible, that is to say, faster scans which can be utilized for the study of quickly moving objects such as the human heart.
In U.S. Pat. Nos. 4,352,02 and 4,158,142, the moving x-ray source is replaced with an electron beam which collides with an arc-shaped anode from a direction which is largely perpendicular to the scan-slice. U.S. Pat. No. 4,352,021 describes a method whereby two dipole magnets guide the electron beam in such a way that its focus approximately describes an arc of 210 degrees over the anode surface. The x-ray radiation which is emitted from the anode is detected by means of an arc-shaped detector arrangement, situated across from the anode and likewise describing an arc of approximately 210 degrees. Thereby, neither the anode nor the detector arrangement describe a full circle and there is only a relatively small overlap region. The described preferred embodiment does not use one but four anode rings (in the following "ring" also represents a ring segment), the four rings each being slightly displaced with respect to each other in a direction largely perpendicular to the scan slice. By successively guiding the electron beam along each of the four anodes and by measuring, with each anode scan in each of the adjacent detector arcs, the x-ray radiation passing through the object, one obtains data sets which are sufficient for the reconstruction of a total of eight largely adjacent slice images from the object.
In U.S. Pat. No. 4,158,142, the relative geometric arrangement of the electron and x-ray sources is similar to that in U.S. Pat. No. 4,352,021. There are, however, differences with regard to the electromagnetic guiding and focussing of the electron beam and there is a complete 360 degree encompassing anode ring and a complete 360 degree encompassing detector ring. The detector and anode rings are coaxial but not coplanar.
The configurations of the U.S. Pat. No. 4,352,021 and 4,158,142 utilize long evacuated electron beam pipes in order to introduce the electron beam onto the anode, which in turn leads to a substantially larger space requirement than that which is usually associated with tomographs utilizing mechanical motion. Moreover, the connection between the electron beam pipe and the anode region and, thereby, their associated integration into the gantry prevents tilting of the gantry unit in order to change the orientation of the scan slice through the object. In addition, the presence of the large funnel-shaped electron beam pipe behind the anode region interferes with the horizontal travel of the object support system (in general the patient bed) and access to the object being scanned is also reduced. Moreover, the enclosed tunnel-like shape of the electron beam pipe results in patient discomfort and claustrophobia. The use of a partial scan of only 210° as described in U.S. Pat. No. 4,352,021 is associated with reduced image quality compared to that of conventional scanners with mechanical motion.
Further disadvantages of the non-mechanical computer tomography scanners of prior art are associated with the use of ion aided focussing to help focus the electron beam at the anode. Small focal spot sizes are required for good high contrast resolution and good system frequency band pass, i.e. good image quality. In the computer tomography system described in U.S. Pat. No. 4,352,021, 4,521,900, and 4,521,901, the size of the focal spot is inversely related to the size of the electron beam at the location of the focussing magnets, i.e. the electron beam must first expand in order for it to be effectively focussed onto the anode. However, the natural occurrence of ion aided focussing between the electron beam source and the magnetic focussing elements inhibits the electron beam from expanding to the required radius. Therefore, ion aided focussing is required between the focussing magnets and the anode, but must be eliminated between the electron beam source and the focussing magnets. For this reason, the systems according to prior art require the installation of ion traps to sweep the positive ions away from the electron beam in the region between the electron beam source and the focussing magnets. These ion trap electrodes represent an additional design complication and are associated with significant additional expense.
Because of the above mentioned deficiencies in electron beam x-ray computer tomography systems without mechanical motion of the x-ray source or x-ray detector, it is the purpose of the present invention to further improve an electron beam x-ray computer tomography scanner for the production of image slices through an object, with an electron beam source as well as electron beam guiding means, with a stationary anode and an x-ray detector ring, wherein the electrons from the electron beam source form an electron beam which collides with the anode ring at a focal spot which, for its part, emits x-ray radiation, in such a way that there is free access to both sides of the scan region, that the space requirements need not be larger than those for conventional scanners with mechanical motion, and that it is possible to tilt the gantry to change the orientation of the scan slice through the object.
BRIEF SUMMARY OF THE INVENTION
The purpose of the invention is achieved by guiding the electron beam from the electron beam source into collision with the anode along a path which is largely parallel to the plane of the anode.
In this manner, the purpose of the invention is completely accomplished. By guiding the electron beam in a direction which is largely parallel rather than perpendicular to the scan plane, the long large diameter evacuated electron beam pipe of prior art is eliminated. As a result, the scan system according to the invention enjoys compact dimensions compared to those of prior art, and free access to the scan region from both the front and back of the scanner is possible. Furthermore, the complications associated with joining the long evacuated electron beam pipe of prior art in a vacuum sealing fashion onto the anode and scan region which prohibited tilting of the gantry are eliminated. As a consequence, the gantry can be easily tilted to angles comparable to those achieved in conventional scanners with mechanical motion, i.e. to +/-25° from the vertical.
By guiding the electron beam around the anode region using electron beam guiding means, the electron beam envelope is caused to describe an arc which is largely coplanar with the anode, and the large, long, cumbersome conical electron beam envelope and associated conical electron beam pipe oriented perpendicular to the scan plane are eliminated. The electron beam guiding means cause the electron beam to come into collision with the anode in such a way that essentially full 360° scans are allowed.
In a preferred embodiment of the invention, the electron beam source exhibits an electron gun for the generation of the electron beam.
This measure has the advantage that electron guns are compact in size and capable of producing large currents with good electron beam quality.
The compact nature of the electron gun allows the amount of space which is needed for generation of the electron beam to be kept to a minimum thereby reducing the overall size of the apparatus according to the invention. Furthermore, its large current capability and good beam quality are important for good image quality. In particular, for fast scans in which, for example, the entire largely 360° scan is effected in tens of milliseconds, image quality is strongly influenced by the integrated detected x-ray flux. This is due to the fact that the image quality depends on the signal to noise level of the detected signals which is, in turn, determined by the incoherent addition of fluctuations due to photon statistics with uncertainties due to electronic and other sources of noise ( noise floor ). For fast scans, the signals are small and the noise floor limits image quality. Since the x-ray yield is directly proportional to the amount of electron current, it is particularly advantageous, in fast scans, to have as much electron current available as possible. Modern electron guns are, by way of example, capable of producing ampere of 130 kV electrons.
Good electron beam quality is an additional important feature for image quality. In particular, the area and shape of the region of intersection between the electron beam and the anode, i.e. the focal spot, must be small in order to effect good high contrast resolution and broad frequency response for imaging. The low emittance and small cathode sizes of electron guns allow for small, by way of example, 1-3 mm diameter focal spot sizes to be achieved.
In a further preferred embodiment of the invention, there are a plurality of electron beam sources.
This measure has the advantage that the maximum path length traveled by the electron beam is reduced by a factor roughly equal to the number of sources used and, as a result of said reduced maximum path length, problems associated with electron beam divergence and focussing are greatly reduced.
In a further preferred embodiment of the invention, the electron beam source is positioned in such a way that the electron beam is initially injected, over a short distance, largely perpendicular to the direction of the circulating electron beam before being bent into the direction of the circulating electron beam using injection means exhibited by the electron beam source.
This measure has the advantage, that the space required for the electron beam source, i.e. electron gun, can be taken from a region which is somewhat removed from the anode, thereby facilitating electron beam generation with a minimum amount of interference with those portions of the anode, x-ray detector, and electron beam guiding means located in close proximity to the electron beam source, which, in turn, allows easier realization of essentially complete 360° scans.
In a preferred variation of this embodiment, the injection means exhibit means to deflect the electron beam into either clockwise or counter-clockwise orbit about the object being scanned.
This variation of the present embodiment has the advantage that the maximum distance which needs to be traveled by the electron beam is approximately halved resulting in substantially simpler electron beam focussing and steering requirements.
In another preferred variation of this embodiment of the invention, the injection means exhibit an electric field.
This variation has the advantage that a simple injection system can be realized with minimum interference with the injecting electron beam. By way of example, the electric field can be in the form of an electrostatic mirror and made from a highly transparent wire mesh. Such a mirror system could be inserted directly into the path of the electron beam such that, without voltage applied to it, the electron beam would pass largely unaffected through the grid. Such a system allows for increased flexibility in the design of the injection means and electron beam guiding means since the transparent electrostatic mirror can be effectively introduced into or removed from the electron beam focussing, guiding and injection optics in a time dependent fashion simply by regulating the applied voltage.
In a further preferred variation of this measure in accordance with the invention, the injection means exhibit a magnetic field.
This variation has the advantage that a stable injection system is realized without the need for high voltages to steer the electron beam into the scan plane. The magnetic fields can be realized through the use of electromagnets or permanent magnets.
In another preferred embodiment of the invention, the electron beam source is positioned largely in the scan plane, with the electron beam being directly injected along the direction of the circulating electron beam.
This measure has the advantage that the injection means is either eliminated or greatly simplified since there is no longer a need to bend the electron beam through an arc of, by way of example, 90°.
In a further preferred embodiment of the invention, the anode and x-ray detector are in the form of an anode ring and an x-ray detector ring with the radius of the anode ring being larger than that of the x-ray detector ring and the electron beam is guided along a path whose radius is larger than that of the x-ray detector ring and smaller than that of the anode ring.
This measure has the advantage that the x-ray fan beam originating at the focal spot need only pass through a minimum amount of x-ray beam attenuating material before entering the x-ray detector in addition to the material exhibited by the object being scanned. This measure also has the advantage that the geometry specified allows a simple and effective solution to the problems of electron beam transport and guidance into collision with the anode.
In a preferred variation of this embodiment, the x-ray detector and anode rings are largely coplanar, and the x-ray detector ring is split into two closely spaced x-ray detector partial rings of equal radius which are separated by a gap, said gap being large enough to allow x-rays emerging from the focal spot to pass through, but small enough to allow a large fraction of the x-rays transmitted through the object being scanned to be detected. This condition is fulfilled, by way of example, when the relationship Rd/Rf (wd-g)/(wd+g) is approximately satisfied where g is the width of the gap between the two x-ray detector half-rings, wd the width of the x-ray fan beam after penetration of the object being scanned at the location of the x-ray detector ring across from the focal spot, Rd the x-ray detector ring radius, and Rf the radius of the arc described by the focal spot around the anode ring.
This variation of the present embodiment according to the invention has the advantage that the scan slice has a more uniform thickness resulting in improved image quality and reduced partial volume artifacts.
In a further preferred embodiment of the invention, the electron beam guiding means exhibit electron beam steering and focussing means, and electron beam extracting means.
This measure has the advantage that the electron beam is guided from the electron beam source to the focal spot without significant losses in electron beam current, with said focal spot moving continuously around the anode in a predetermined fashion throughout the course of the scan, while maintaining a focal spot size which is sufficiently small for good image quality. The electron beam steering means keep the electron beam in a stable orbit as it travels from the electron beam source to the predetermined position on the anode at which the focal spot is to be located. The electron beam focussing means keep the electron beam from increasing to a size which would prohibit its transport from the electron beam source to the focal spot and maintain an adequately small focal spot size for good image quality. The electron beam extracting means remove the electron beam from its orbit into a collision with the anode at the predetermined focal spot location, said focal spot being moved continuously about the anode during the course of a complete scan.
In a further preferred embodiment of the invention, the electron beam guiding means exhibit ion aided focussing.
This measure has the advantage, particularly for large electron beam currents, that the electron beam and focal spot radii are reduced in a particularly simple and effective fashion since, according to the invention and in contrast to prior art, the electron beam is not required to initially expand before it can be properly focussed, and the need for ion traps is either eliminated or greatly reduced.
In another preferred embodiment of the invention, the electron beam guiding means exhibit magnetic fields.
This measure has the advantage that the required forces on the electron beam are easily achieved either using electromagnets or permanent magnets and, in the event of ion aided focussing, the massive slowly drifting focussing ions remain largely unaffected by said magnetic guiding means.
In another preferred embodiment of the invention, the electron beam guiding means exhibit electric fields.
This measure has the advantage that, by way of example, the required focussing and steering forces on the electron beam are easily achieved without requiring a large amount of material in or near the electron beam. In this connection, said electric fields can be generated using wire mesh electrodes which are essentially transparent to the electron beam when no relative voltage difference is applied.
This measure also has the advantage that, in the event of ion aided focussing, the force acting on both the electrons and the ions can be the same, independent of their greatly differing speeds, thereby providing additional flexibility in focussing, steering, and extracting the combined electron-ion system.
In another preferred embodiment of the invention, the electron beam guiding means exhibit both electric and magnetic fields.
This measure has the advantage that maximum flexibility in system design and adjustment is allowed since the differing advantageous features of both magnetic and electric fields outlined above can be utilized where said respective features are appropriate.
Further advantages can be derived from the description and the accompanying drawings. Clearly, the characterizing features mentioned above and described below are applicable not only in the corresponding combination given but also in other combinations or by themselves without departing from the framework of the current invention.
Embodiments of the invention are represented in the drawings and are described in the following description. Shown are:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1: Overview of an electron beam x-ray computer tomography scanner according to the invention.
FIG. 2: Schematic front view of the scanner according to the invention.
FIG. 3: Expanded cross sectional slice through the gantry.
FIG. 4A: Possible scheme for electron beam extraction,
FIG. 4B: Magnetic field configuration in possible scheme for electron beam extraction,
FIG. 5A: Space charge expansion for a 1 ampere 130 keV electron beam at large distances,
FIG. 5B: Space charge expansion for a 1 ampere 130 keV electron beam at intermediate distances,
FIG. 5C: Space charge expansion for a 1 ampere 130 keV electron beam at small distances,
FIG. 6A: Relationship between the generalized beam perveance and the equilibrium beam radius,
FIG. 6B: Relationship among the generalized beam perveance, the beam current, and the neutralization fraction of the beam.
FIG. 7A: Side view of possible scheme for electron beam injection exhibiting a magnetic field,
FIG. 7B: Top view of possible scheme for electron beam injection, exhibiting a magnetic field,
FIG. 8A: Side view of possible scheme for electron beam injection exhibiting an electric field,
FIG. 8B: Top view of possible scheme for electron beam injection exhibiting an electric field,
FIG. 9A: Side view of possible scheme for electron beam injection in which the electron beam source is positioned along the orbit of the electron beam,
FIG. 9B: Top view of possible scheme for electron beam injection in which the electron beam source is positioned along the orbit of the electron beam.
FIG. 10 is a schematic front view of the scanner illustrating a configuration similar to that shown in FIG. 2 but including plural electron sources to generate the orbiting electron beam.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cross section through a preferred embodiment of an electron beam x-ray computer tomography system (1) according to the invention. An electron beam source (31) introduces an electron beam (32a,32b) into the vacuum vessel (11). The electron beam source (31) exhibits an electron source (33) which can be in the form of an electron gun for the production of the electron beam (32a) and injection means (34) for guiding the injecting electron beam (32a) into the portion of the vacuum vessel designed for the circulating electron beam (32b). The electron beam (32b) is guided around the vacuum vessel (11) with electron beam guiding means (36). Electron beam guiding means (36) exhibit electron beam extracting means (35) to extract the circulating electron beam (32b) into a collision with the anode (4) at the focal spot (41), and electron beam steering and focussing means (38) to maintain the circulating electron beam (32b) along the desired path. As a consequence of the collision between the electron beam (32b) and the anode (4), the electrons in the electron beam (32b) are stopped and emit an x-ray fan beam (42). The x-ray fan beam (42) passes through the object (2) being scanned and the transmitted intensity is detected in an x-ray detector (5). Said object (2) is supported during the scan on an object support (14). The x-ray detector (5) exhibits a gap (51) which is large enough to allow the x-ray fan beam (42) emerging from the focal spot (41) to pass through the x-ray detector (5), but small enough to allow most of the x-ray intensity emerging from the object (2) to be detected in the portion of the x-ray detector (5) located across from the focal spot (41). Signals produced in the x-ray detector (5) are digitized by means of analog to digital converter (8) and passed to computer (9). The computer (9) reconstructs an image slice through the object (2) which can be displayed on screen (13). Computer (9) also controls and monitors the various scan functions of the x-ray computer tomography system (1). The orientation of the slice through the object cut by x-ray fan beam (42) can be adjusted through tilting of the gantry assembly (12) by means of tilt mechanism (10). A vacuum system (15) is connected to vacuum vessel (11) in order to measure, regulate, and change the pressure in vacuum vessel (11), depending on the desired conditions for ion aided focussing and scan operating conditions.
FIG. 2 shows a front view of a preferred embodiment of the invention. The electron beam source (31) introduces the electron beam into the circulating electron beam (32b) region. Through adjustment of the electron beam guiding means (36), the circulating electron beam (32b) can be guided to become an extracted electron beam (32c) and caused to collide with the anode (4) at the focal spot (41) to produce the x-ray fan beam (42). The x-ray fan beam (42) is incident on the object (2) and the transmitted portion of the x-ray fan beam (42) is detected in the x-ray detector (5).
FIG. 3 shows and expanded cross section of the gantry assembly (12) in a preferred embodiment of the invention. The geometry of the system is such that there is sufficient space to guide the circulating electron beam (32b) within the appropriate region of the vacuum vessel (11). Moreover, the x-ray detector (5) exhibits two half-detectors (5a,5b) which are separated by a gap (51) which is large enough to allow the x-ray fan beam (42) emerging from the focal spot (41) on the anode (4) to pass through, but small enough to detect most of the x-ray flux transmitted through to the opposite side of the x-ray detector (5) for detection. X-ray fan beam collimation (43) is provided for in order to define the width of the image slice through the object (2) and to prevent a large fraction of the x-rays emerging from the focal spot (41) from striking the x-ray detector (5) at the x-ray detector (5) location near the focal spot (41). The vacuum vessel (11) exhibits a vacuum window (13) to allow the x-ray fan beam (42) emerging from the focal spot (41) to exit the vacuum vessel (11) without significant attenuation. The vacuum vessel (11) contains the anode (4) and the electron beam (32) and allows for variable partial pressures which include, in particular, the range between 1×10 -7 to 1×10 -5 Torr. Electron beam guiding means (36) exhibit electron beam steering and focussing means (38) in the vicinity of the circulating electron beam (32b), and electron beam extracting means (35) in the vicinity of the anode (4).
FIG. 4A represents a cross section of an embodiment of the invention in the region between the anode (4) and the x-ray detector (5) in which electron beam steering and focussing means (38) are used to generate a magnetic field B 1 in the region of the circulating electron beam (32b) and electron beam extracting means (35) also exhibit electron beam extracting and focussing means (35a) generating magnetic fields B 3 in the vicinity of the anode (4) and B 2 in the region between B 1 and B 3 . Field clamp (37) helps to keep fields B 3 and B 2 from extending too far into the region of B 1 . The direction of the magnetic fields B 1 , B 2 , and B 3 is schematically indicated by the arrows in FIG. 4A.
In FIG. 4B, the magnitude of the magnetic fields in a direction largely transverse to the plane of the circulating electron beam (32b) as a function of the relative location between the x-ray detector (5) and the anode (4) is qualitatively indicated. B 1 and B 3 are of opposite sign and B 3 is much larger than B 1 . There is a point P intermediate between B 1 and B 3 where the field is approximately zero.
In this schematic and simplified example of an embodiment of the invention, the extraction process can be envisioned as occurring between two oppositely directed magnetic fields B 1 and B 3 . The B 1 field directs the circulating electron beam (32b) along the desired path. Extraction occurs when the B 1 fields in the appropriate locations are reduced in strength so that the circulating electron beam (32b) moves radially outward towards the anode (4). After reaching the point P, the electron beam enters the region of fields B 3 and B 2 . Being large and of opposite sign to field B 1 , field B 3 causes the electron beam to sharply deflect into collision with anode (4).
By way of example, for a 130 keV, 1 Ampere electron beam (32b), B 1 could exhibit magnetic field strengths for the purpose of steering the electron beam, which are largely dipole in nature with strengths of 20 gauss. For the purpose of focussing, B 1 could exhibit fields which are largely quadrupole in nature and with strengths of 5 gauss. The B 3 fields generated by electron beam extracting means (35) could be approximately 250 gauss. Clearly gantry (12) can incorporate magnetic shielding to shield the electron beam (32b) from the effects of the earth's magnetic field, or the influence of the earth's field can be taken into account in determining the values of B 1 , B 2 , and B 3 .
FIGS. 5A through 6B give examples of the dependence of the electron beam radius on space charge effects, with and without ion aided focussing. As the electron beam propagates along its path, it expands radially due to its initial divergence, i.e. emittance, its mutual electrostatic repulsion, and due to multiple scattering with residual gas along its path. The electromagnetic self interaction of the electron beam has two terms, an electrostatic repulsion term, and an attractive magnetic term. In the absence of ion aided focussing, the repulsive term is larger than the attractive term and the electron beam expands under the action of self-forces. However, in consequence of the scattering of the electron beam from residual gas along its path, a certain number of gas atoms become positively ionized and are drawn into the negatively charged electron beam, thereby causing its partial neutralization. As a result of this neutralization, the electrostatic repulsive term is reduced. Under certain conditions, the magnetic attraction term can be larger than the reduced electrostatic term, and the beam spontaneously focuses, hence the name ion aided focussing.
The advantages of ion aided focussing according to the invention, and the relationship among space charge expansion of the beam, i.e. the mutual electrostatic repulsion of the electrons in the beam, beam emittance, and ion aided focussing can be best illustrated with the aid of a simple model of the beam envelope. For a uniform cylindrically symmetric beam, the equation of the beam envelope radius r has been given by E. P. Lee and R. K. Cooper, Particle Accelerators 7, 83, 1976 and by J. D. Lawson, "Space Charge Optics", Applied Charged Particle Optics, edited by A. Septier, Academic Press, London, 1983, and U.S. Pat. No. 4,521,901. We have:
r"=ε.sup.2 /r.sup.3 +K/r+gz/3r.sub.o 1.
where z is the longitudinal distance traveled by the beam, r the radius of the beam envelope, ε the beam emittance, K the generalized beam perveance, r o the initial radius of the beam, and g a factor characterizing multiple scattering. r" represents the second derivative of r with respect to z.
Equation 1 describes the radial acceleration of the beam with respect to distance traveled, z. The first term on the right hand side of the equation represents the expansion of the beam due to its finite emittance. The second term represents the effect of space charge on the beam, and the third term is the multiple scattering expansion of the beam due to the residual vacuum along the transport path. We also have:
K=2Nr.sub.c (1=β.sup.2 -f)/(β.sup.2 Γ) 2.
with N the number of electrons per unit length in the laboratory frame, r c the classical radius of the electron, β is the ratio of the electron speed to the speed of light, Γ the ratio of the relativistic mass of the electron to its rest mass, and f the neutralization fraction of the beam. If there are as many positive ions as electrons in the beam, f=1, the beam is neutralized, and K is negative, i.e. attractive. If there are no positive ions in the beam, f=0 and K is positive.
The factor g has a value which is directly proportional to the pressure along the electron beam path. In perfect vacuum, g=0. At a pressure of 1×10 -6 Torr, g is approximately 2×10 -10 cm -1 . It turns out that this term is usually small compared to the first and second terms and can normally be neglected in the cases of interest to us here.
FIG. 5A through 5C show the relationship between the beam radius versus distance for a uniform 1 ampere parallel beam of 130 keV electrons in vacuum according to equation 1, i.e. ε=f=g=0, for large (FIG. 5A), intermediate (FIG. 5B), and small (FIG. 5C) values of the reduced variables plotted. The vertical axis variable is the radius of the electron beam in units of the initial radius and the horizontal axis variable the longitudinal distance traveled by electrons in the beam in units of the initial radius. For example, as can be read from FIG. 5C, the beam expands to twice its initial radius
after traveling a distance of roughly 100 times its initial radius, i.e. a 0.5 mm radius beam expands to 1.0 mm in radius after traveling a distance of 50 mm. It turns out, for this simplified example, that the distance traveled for a given radial expansion scales with the inverse square root of the beam current and therefore, by way of example, a 0.5 mm radius beam of 100 milliamperes of current expands to 1.0 mm radius after traveling a distance of roughly 50√10≈160 mm.
FIGS. 6A and 6B contrast the behaviour illustrated in FIGS. 5A through 5C with an example of the behaviour when ion aided focussing is used under the approximation that the multiple scattering term is negligible, i.e. g=0. As can be seen from equation 1, an equilibrium beam radius can be approximated by the condition r"=0, i.e. K=-ε 2 /r 2 . Taking, by way of example, a beam emittance of 10 π mm-mr, the numerical relationships graphed in FIG. 6A result. For example, an equilibrium beam radius of 1 mm requires a perveance of K=-1×10 -4 .
FIG. 6B shows the relationship between the neutralization fraction f and the perveance K in units of the beam current in amperes for a 130 keV electron beam. For example, for an electron beam current of 1 ampere, a K value of -1×10 -4 requires a neutralization fraction of approximately 87%. In this case, such neutralization fractions can be achieved using partial vacuum pressures of approximately 5.5×10 -6 Torr.(See for example Lee and Cooper, U.S. Pat. No. 4,521,901 and the references contained therein.)
FIGS. 7A through 9B illustrate various means for electron beam injection. FIGS. 7A, 8A and 9A schematically show side views of a cut through the gantry analogous to that in the top portion of FIG. 1. and FIGS. 7B, 8B, and 9B, a top view. For the sake of clarity, only elements relevant to the electron beam injection are labeled in the figures. In FIGS. 7A through 8B, the electron beam source (31) injects the electron beam over a short distance in a direction largely perpendicular to the scan plane, before bending it in a direction from which it can begin its orbit around the gantry. In FIGS. 9A and 9B, the electron beam source (31) is located aligned along the direction of propagation of the circulating electron beam.
In FIGS. 7A and 7B, injection means (34) exhibit a magnetic field B indicated by the array of vertical arrows in FIG. 7A. As the injecting electron beam (32a) enters into the magnetic field B, it is caused to bend in such a way that it becomes aligned with the direction of the circulating electron beam (32b) and begins its orbit about the gantry. By changing the polarity of the magnetic field B, the electron beam (32) can be caused to orbit in a clockwise or counter-clockwise direction as indicated by the oppositely directed arrows at the ends of the lines representing the circulating electron beam (32b) in FIG. 7B.
FIGS. 8A and 8B show an injection geometry similar to that of FIGS. 7A and 7B, however with the injection means (34) exhibiting electric fields E represented by the slanted array of arrows in FIG. 8B. By applying a sufficiently high negative high voltage to injection means (34), the injecting electron beam (32a) can be deflected into the proper orientation for orbiting as indicated by the lines representing the circulating electron beam (32b). By way of example, by applying a negative high voltage to the portions of the injection means labeled (34c) and (34d), an electric field E (qualitatively represented by the arrows in FIG. 8B) can be generated which will deflect the injecting electron beam (32a) to the "right" in the figure. Correspondingly, low voltage values on injection means (34c) and (34d) and high negative voltages on injection means (34a) and (34b) will cause the injecting electron beam (32a) to be deflected to the "left". Clearly, in this manner, the electron beam can be caused to orbit either clockwise or counterclockwise about the gantry depending on the voltages and associated electric fields of injection means (34a-d). Various values of the electric fields associated with injection means (34a-d) can be selected in order to steer and focus the electron beam (32) and the injection means (34a-d) can exhibit highly transmitting wire mesh to allow the electron beam (32) to pass through when so desired.
FIGS. 9A and 9B illustrate a configuration for the electron beam source (31) in which the injection means (34) are either eliminated or greatly simplified in that the electron beam source (31) is positioned along the orbit of the electron beam (32) so that the electron beam (32) emerging from the electron beam source (31) is injected directly into the orbiting path.
FIG. 10 shows a front view of another preferred embodiment of the invention which utilizes plural electron beam sources (61) and (62). Sources (61) and (62) introduce electrons into the circulating electron beam region (32b) in the same manner as single electron source (31) and may each be constructed in the same manner as single source (31). Although only two electron sources are shown in FIG. 10, additional sources may also be used. The use of plural electron sources such as shown in FIG. 10 has the advantage that the maximum distance which the electron beam produced by each source must travel is reduced to the path length between sources. A reduced beam path length diminishes wellknown problems associated with electron beam divergence and focussing which progressively degrade the beam. | An electron beam x-ray computer tomography scanner is improved so that a compact, tiltable configuration without mechanical motion is achieved. By introducing the electron beam in a direction which is largely parallel rather than perpendicular to the scan plane, the long large diameter evacuated electron beam pipe of prior art is eliminated. As a result, the scan system according to the invention enjoys compact dimensions compared to those of prior art, and free access to the scan region from both the front and back of the scanner is possible. | 0 |
FIELD OF THE INVENTION
The present invention generally relates to techniques for monitoring and controlling continuous sheetmaking systems such as a papermaking machine and more specifically to separating the control of the wet end and dry end of the paper machine through estimation of one or more physical properties of the sheet that is formed at the wire. This technique affords papermaking machine direction controls to continue in the event of a sheet break or other disturbance that results in the loss of scanner measurements at the dry end.
BACKGROUND OF THE INVENTION
Various systems are available and used to manufacture sheets of paper and other paper products. The sheets of paper being manufactured often have multiple properties that are monitored and controlled during the manufacturing process. With the standard approach to papermaking machine direction (MD) controls, controlled variables, such as basis weight or dry weight of the paper and the ash content of the paper, are measured at the reel and controlled by adjustment of manipulated variables, such as stock flow to the machine and filler addition to the stock. The control of these or other sheet properties in a sheet-making machine is typically concerned with keeping the sheet properties as close as possible to target or desired values.
In the manufacturing process, if there is a sheet break that prevents the paper sheet from reaching the reel scanner, or if the reel scanner malfunctions, the controller loses measurements and the MD controls can no longer be used. During the interim when measurements are not available and the MD controls are off, process changes may occur that move the controlled variables away from, their desired operating points. Subsequently when the sheet is re-threaded, through the papermaking machine and is put back on the reel and/or scanner measurements resume, production is interrupted. While the controller brings these variables back, to target for a period of time after the rethreading, the paper sheet produced may not be usable or saleable. This is because the break in the paper sheet often disturbs or interferes with the control of the sheet-making machine, so the paper sheet produced after the break typically has sheet properties that are not near the target or desired values. As a result, the sheet-making machine often, needs to be operated until the disturbances earned by the break are eliminated and the sheet properties return to or near the target or desired values. This results in a loss of both time and materials. What is needed is a means of keeping the controlled variables close to target even when they cannot be measured.
SUMMARY Of THE INVENTION
The present invention is based in part on the recognition that separating wet end and dry end paper machine control through estimation of one or more measurable physical variables for the paper that develops at the wire allows for paper machine MD controls to continue even when there is a sheet break or other loss of scanner measurements. A mathematical model is used to estimate the controlled variables, such as dry weight, basis weight, and ash percent at the wire, and these estimated values are then controlled, When scanner measurements are reestablished, parameters in the model are recursively updated to compensate for any model errors and to ensure an accurate model. MD controls preferably consist of a cascade set-up where the estimated wire dry weight or wire basis weight and estimated wire ash percent are controlled by manipulating the stock flow and the addition of filler to stock. When, the scanner measurements are available, they become the downstream variables in the cascade control and are controlled by manipulation of the setpoints for the estimated wire weight and ash. In a preferred application in papermaking, the dry weight and ash percent of the sheet that forms at the wire or web are estimated with a mathematical model The inventive technique can he implemented by estimating other measurable physical properties using different models. Other suitable physical properties include, for instance, brightness, opacity and formation characteristics such as floe size or fiber orientation.
Accordingly, in one aspect, the invention is directed to a control system for a sheet making machine, which has a wet end and a dry end. The wet end has a number of input variables that can be manipulated to affect the properties of the paper sheet being formed. The properties of the paper sheet at the wet end affect the properties of the sheet measured by sensors at the dry end.
The control system for the sheet making machine includes a dry end controller, an estimator and a wet end controller: The dry end controller is responsive to setpoints for the paper sheet properties at the dry end, the measurements of the paper sheet properties at the dry end and develops setpoints for the paper sheet properties at the wet end. Each setpoint establishes a target value for a respective paper sheet property at the wet end. The estimator is responsive to the measurements of the paper sheet properties at the dry end and to further signals which convey quantitative information of present values of the wet end input variables to develop estimated values of paper sheet properties at the wet end. The wet end controller is responsive to the setpoints for the wet end paper sheet properties developed by the dry end controller and to the estimated values of paper sheet properties at the wet end and manipulates the inputs to the wet end.
In another aspect, the invention is directed to a continuous control method for maintaining measurable properties of a sheet being formed in sheet making machine as close as possible to their setpoints as set forth above. The method including the steps of:
developing setpoints for the paper sheet properties at the wet end as a functions of the setpoints for the paper sheet properties at the dry end and the paper sheet properties measured by the sensors at the dry end, each of the setpoints for the paper sheet properties at the wet end quantitatively establishes a target for a respective one of the paper sheet properties at the wet end.
developing estimated values for wet end paper sheet properties as a function of the dry end paper sheet properties measured by the sensors and of further signals which convey quantitative information of present values of the wet end input variables; and
manipulating the wet end input variables as a function of the setpoints and estimated values for the wet end properties.
With the present invention, in the case where the dry weight and ash. percent of the sheet that, develops at the wire or web are estimated, there is no loss of weight and ash control during sheet breakage. In particular, dry weight and ash percent can be controlled based on the wet end estimates while measured dry end values are unavailable. Furthermore, this reduces the likelihood of sheet breakage while threading the machine. The measured values will be closer to target when the sheet is threaded, into the machine thereby reducing scrap and lost time.
Another feature of the invention is that separating the wet end and dry end control variables effectively increases the bandwidth for disturbance rejection since estimated values for dry weight and ash percent of the sheet at the wet end eliminate much of control delay associated with waiting for dry end measurements. Some wet end disturbances will be eliminated more quickly.
While the invention will be illustrated as implemented in papermaking, it is understood that the invention is applicable in other sheet making processes such as, for example, in the manufacturer of rubber sheets, plastic film, metal foil, and the like. For these applications, the “wet end” corresponds to the initial unit operations where the raw material in its molten or pliable state is processed and the “dry end” corresponds to a downstream phase where the final sheet product is formed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a papermaking system;
FIG. 2 is a schematic illustration of the wet end of a papermaking system; and
FIGS. 3 and 4 are block diagrams depicting the process control concept of maintaining paper machine control at the wet end through the use of a basis weight or dry weight estimator and a percent ash estimator; and
FIG. 5 is a flow diagram of a process implemented by the papermaking system.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The process control, system will be illustrated by implementing the technique in a sheetmaking system 10 that includes papermaking machine 2 , control system 4 and network 6 as illustrated in FIG. 1 . The papermaking machine 2 produces a continuous sheet of paper material 12 that is collected in take-up reel 14 . The paper material 12 , having a specific width, is produced from a pulp suspension, comprising of an aqueous mixture of wood fibers and other materials, which undergoes various unit operations that are monitored and controlled by control system 4 . The network 6 facilitates communication between the components of system 10 .
The papermaking machine 2 includes a head box 8 , which distributes a pulp suspension uniformly across the machine onto a continuous moving screen or wire 30 , The pulp suspension entering headbox 8 may contain, for example, 0.2-3% wood fibers and possibly other solids, with the remainder of the suspension being water. Headbox 8 includes any suitable structure for distributing a pulp suspension. Headbox 8 may, for example, include a slice opening through which the pulp suspension is distributed onto screen or wire 30 which comprise a suitable structure such as a mesh for receiving a pulp suspension and allowing water or other materials to drain or leave the pulp suspension. As used herein, the “wet end” forming portion of sheetmaking system 10 comprises headbox 8 and wire 30 and those sections before the wire 30 , and the “dry end” comprises the sections that are downstream from wire 30 .
Sheet 12 then enters a press section 32 , which includes multiple press rolls where sheet 12 travels through the openings (referred to as “nips”) between pairs of counter-rotating rolls in press section 32 , In this way, the rolls in press section 32 compress the pulp material forming sheet 12 . This may help to remove more water from the pulp material and to equalize the characteristics of the sheet 12 on both of its sides.
As sheet 12 travels over a series of heated rolls in dryer section 34 , more water in sheet 12 is evaporated. A calendar 36 processes and finishes sheet 12 , for example, by smoothing and imparting a final finish, thickness, gloss, or other characteristic to sheet 12 , Other materials (such as starch or wax) can also be added to sheet 12 to obtain the desired finish. An array of induction heating actuators 24 applies heat along the cross direction (CD) to one or more of the rollers to control the roll diameters and thereby the size of the nips. Once processing by calendar 36 is complete, sheet 12 is collected onto reel 14 .
Sheetmaking system 10 further includes an array of steam actuators 20 that controls the amount of hot steam that is projected along the CD. The hot steam increases the paper surface temperature and allows for easier cross direction removal of water from the paper sheet. Also, to reduce or prevent over drying of the paper sheet, paper material 14 is sprayed with water in the CD. Similarly, an array of rewet shower actuators 22 controls the amount of water that is applied along the CD.
In order to control the papermaking process, the properties of sheet 12 are continuously measured and the papermaking machine 2 adjusted to ensure sheet quality. This control may be achieved by measuring sheet properties using one or more scanners 26 , 28 that are capable of scanning sheet 12 and measuring one or more characteristics of sheet 12 , For example, scanner 28 could carry sensors for measuring the dry weight, moisture content, ash content, or any other or additional characteristics of sheet 12 . Scanner 28 includes suitable structures for measuring or detecting one or more characteristics of sheet 12 . such as a set or array of sensors. A scanning set of sensors represents one particular embodiment for measuring sheet properties. An array of stationary sensors can be used instead. Scanner 28 is particularly suited for measuring the dry end dry weight and ash content of the paper product.
Measurements from scanner 28 are provided to control, system 4 that adjusts various operations of papermaking machine 2 that affect machine direction characteristics of sheet 12 . A machine direction characteristic of sheet 12 generally refers to an average characteristic of sheet 12 that varies and is controlled in the machine direction. In this example, control system 4 is capable of controlling the dry weight of the paper sheet by adjusting the supply of pulp to the headbox 8 . For example, control system 4 could provide information to a stock flow controller that regulates the flow of stock through valves and to headbox 8 . Control system 4 includes any hardware, software, firmware, or combination thereof for controlling the operation of the sheetmaking machine 2 or other machine. Control system 4 could, for example, include a processor and memory storing instructions and data used, generated, and collected by the processor.
The stock supplied to headbox 8 is produced in a process as shown in FIG. 2 where pulp is introduced into a stock preparation unit 52 , For example, stock preparation unit 52 cleans and refines the pulp fibers so that the pulp fibers meet required standards. Stock preparation unit 52 could also receive and process recycled fibers recovered from the screen or wire 30 that rotates between rollers 70 and 72 , The consistency of the pulp is measured with sensor 54 and signals therefrom can, be employed to control the flow of pulp and/or recycled water into stock preparation unit 52 . Regulating the drive speed of rollers 70 , 72 controls the wire or machine speed. Sensor 74 measures the total and ash consistency of the entering the headbox and sensor 76 measures the same properties of die white water. Readings from sensor 74 , 76 are employed, for instance, in determining the values of, c T ww the total consistency in the white water, c T hb the total consistency in the headbox, c a ww the ash consistency in the white water, c a hb the ash consistency in the headbox, which are further explained here. The fibers in stock preparation unit 52 are mixed with one or more fillers. The resulting mixture represents a thick stock 58 and has a relatively high fiber consistency typically of about 4%. The thick stock 58 is then mixed with white water in a short circulation path 60 to produce a thin stock 62 that has a relatively low fiber consistency typically of about 0.2%. “White water” is the water that is removed from the wet stock on wire 30 . The consistency of the stock exiting the stock preparation unit 52 is measured with sensor 56 and signals therefrom can be employed to control the flow of filler. The thin stock 62 is provided to headbox 8 . A long circulation path 64 provides recycled material to stock preparation unit 52 for recovery.
Fillers including chemical additives can be added at different steps in the process. Wet-end chemical and. mineral additives include, for example, acids and bases, alum, sizing agents, dry-strength adhesives, wet-strength, resins, fillers, coloring materials, retention aids, such as polyacrylamides, fiber flocculants, defoamers, drainage aids, optical brighteners, pitch control chemicals, slimicides, and specialty chemicals. Precipitated calcium carbonate can be used as filler. Paper manufacturers use fillers to enhance printability, color and other physical characteristics of the paper.
The term “dry weight” refers to the weight of a material (excluding any weight due to water) per unit area. Paper is generally made of three constituents: wafer, wood pulp fiber, and ash. “Ash” is defined as that portion of the paper that remains after complete combustion. In particular, ash may include various mineral components such as calcium carbonate, titanium dioxide, and clay (a major component of clay is SiO 2 ). The term “water weight” refers to the mass or weight of water per unit area, of the wet paper stock that is on the wire. The term “basis weight” refers to the total weight of the material per unit area.
During normal operations of the papermaking machine 2 ( FIG. 1 ), scanner measurements control operations of the papermaking machine with both the dry end control and wet end control loops operating. However, in the event of a paper breakage or other disturbance that causes the scanner measurements to be unavailable, the wet end control continues to operate.
In implementing the inventive process, once the physical properties to be estimated are selected, a mathematical model is developed to calculate their values.
For instance, the dry weight and percent wire ash can be estimated with the following formula:
d
^
=
f
d
r
T
c
T
ρ
q
vw
(
dry
weight
estimate
)
r
T
=
1
-
c
T
ww
c
T
hb
a
^
=
r
a
c
a
ρ
q
vw
(
ash
weight
estimate
)
r
a
=
1
-
c
a
ww
c
a
hb
%
a
^
=
f
a
×
100
×
a
^
d
^
(
ash
percent
estimate
)
where {circumflex over (d)} is the estimated dry weight at the wire, r 96 is estimated total retention which is the proportion of solids retained on the wire, c 96 cris total consistency which is the mass of solids in the stocks as a percent of the total mass of the stock, ρ is stock density at the headbox, q is stock flow from the headbox to the wire, ν is machine speed, w is sheet width; â is the estimated ash weight at the wire, r a is estimated ash retention on the wire, C a is ash consistency of the stock flow to the headbox, c τ ww is total consistency in the white water, c τ hb is total consistency in the headbox, C a ww is ash consistency in the white water, c τ hb is ash consistency in the headbox, and f d is a correction factor based on the measured dry weight, d, which is derived by, for example, filtering of
a ^ d ^ ,
and, f a is a correction factor based on the measured ash, %α, which is derived by, for example, filtering of
%
a
^
%
d
^
.
With the control process of the present invention as illustrated in FIG. 3 , control of the paper machine 200 is partitioned between the wet end 202 and dry end 204 by introducing estimates of the dry weight: and percent: ash at the wire 30 ( FIG. 2 ). The process effects control of a set of final quality variables, such as, for example, dry weight, percent ash, moisture, brightness, opacify, and a set of wet end variables, such as, for example, estimated dry weight, estimated percent ash, total retention and ash retention. The clear partition of the wet end and dry end controls of the papermaking machine is easy for operators to understand and implement.
The control system includes a wet end controller 206 , a wire dry weight aid ash estimator 208 and a dry end controller 210 . As described above, scanners at the dry end 204 develop dry end signals that provide an electronic measure of the dry end dry weight (designated “Base Sheet DWT” in FIG. 4 ) and dry end ash weight (“Base Sheet Ash” in FIG. 4 ). The dry end signals are applied to the wire dry weight and ash estimator 208 , which thus becomes cognizant of these parameters. Similarly, wet end signals are also developed at the wet end 202 which provide an electronic measure of the headbox flow, headbox total solids consistency, headbox ash consistency, total solids retention, ash retention, wire speed and slice width. The wet end signals are also applied to the wire dry weight (DWT) and ash estimator 208 which further becomes cognizant of these additional parameters.
The estimator 208 calculates the wire dry weight and wire ash percentage which are supplied to wet end controller 206 . More specifically, with further reference to FIG. 4 , the estimator 208 includes a wire dry weight estimator 212 , a wire ash weight estimator 214 and a percent ash calculator 216 . As best seen in FIG. 4 a first subset of the above-described signals is applied to the wire dry weight estimator 212 to develop an estimated wire dry weight signal. Similarly, a. second subset of the above-described signals is applied to the wire ash weight estimator 212 to develop an estimated wire ash weight signal. Each of the estimated wire dry weight and the estimated wire ash weight signals is applied to the percent ash calculator 216 to develop an estimated percent ash signal. The estimated wire dry weight signal and the estimated percent ash signal developed by the estimator 208 are applied to the wet end controller 206 , as best seen. in. FIG. 3
The dry end controller 210 is responsive to quality variable set points and further responsive to signals developed at the dry end that, provide a measure of final quality variable measurements such as, for example, dry weight, ash content, brightness, opacity and moisture. In response to these signals, the dry end controller 210 develops a machine speed set point. (SP) to the wet end process actuators and dryer steam pressure set point for application to the dry end process actuators, all such actuators being as described above. The dry end controller also in response to the signals applied thereto develops a wire dry weight, set point signal and a wire ash set point signal.
The wet end controller is responsive to the estimated wire dry weight and the estimated percent ash signals developed by the estimator 208 and further responsive to the wire dry weight set point and wire ash set point signals developed by the dry end controller 210 . Total and ash retention set point signals are also applied to the wet end controller 206 . In response to the applied signals, the wet end controller 206 develops a stock, flow set point signal, a filler flow set point signal and a retention aid(s) signal(s) for application to the above described wet end process actuators.
With reference to FIG. 5 , there is shown a flow diagram, of a process implemented by the apparatus described in conjunction with FIGS. 3-4 . The process commences and reiterates with each controller update interval, as indicated at 400 .
The first query, as indicated at 402 , is whether dry end measurements are available. If yes, which is indicative of the dry end signals developed by the scanners being applied to the estimator 208 , the estimated wire dry weight and the estimated percent ash signals developed by the estimator 208 are updated and these updated signals continued to be applied to the wet end controller 206 , as indicated at 404 .
The next query, as indicated at 406 , is whether the wet end controls are on. If no, the process loops back to the update interval, indicated at 400 . Otherwise, if yes, the third inquiry 408 is whether the dry end control is on. If yes, the dry end controller 210 updates the wire dry weight and wire ash setpoints for the wet end controller 206 , as indicated at 410 , Furthermore, as indicated at 416 , the wet end controller 210 updates manipulated variables to process, prior to the process looping back to the update interval indicated at 400 . If the response is no to the third inquiry 408 , the last wet end setpoints from, the dry end controller 210 are held, as indicated at 414 . Alternatively, new wet end setpoints may be entered from an operator of the paper machine 200 . In either event, the process continues to the updating of the manipulated variables to process indicated at 416 .
Returning to the first query indicated at 402 , if the dry end measurements are not available, which is indicative of an interruption, failure or the like in the wet end 202 , the present invention contemplates that the paper machine 200 may continue to operate by holding the last wet end estimator tuning parameters, as indicated at 412 . In a specific embodiment of the present invention, the estimated wire dry weight and the estimated percent ash signals developed by the estimator 208 continue to be applied to the wet end controller 206 .
The foregoing has described the principles, preferred embodiment and modes of operation of the present invention. However, the invention should not be construed as limited to the particular embodiments discussed. Instead, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of present invention as defined by the following claims. | Partitioning control of the wet end and dry end, by introducing estimates of physical properties such as dry weight: and percent ash at the wire, allows for machine direction (MD) controls to continue during loss of scanner measurements. A mathematical model estimates the controlled, variables, such as dry weight, basis weight, and ash percent at the wire, and these estimated values are then controlled. When scanner measurements resume, parameters in the model are recursively updated to compensate for any model errors and ensure an accurate model. MD controls consist of a cascade set-up where the estimated wire-dry weight or wire basis weight and estimated wire ash percent are controlled by manipulating stock flow and addition of filler to stock. When scanner measurements are available, they become the downstream variables in the cascade control and are controlled by manipulation of the setpoints for the estimated wire weight and ash. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application No. 60/664,035, which is incorporated herein by reference.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] Physiological and genetic studies indicate that senescence is a highly regulated process (Nooden, Senescence and Aging in Plants, (L. D. Nooden and A. C. Leopold, Ed.), pp. 391-439, Academic Press, San Diego, Calif., 1988; Thomas, et al., Ann. Rev. Plant Physiol. 31:83-111, 1980). Molecular studies suggest that changes in gene expression are associated with the senescence program. For example, the level of mRNA encoding proteins involved in photosynthesis decrease during senescence (Bate, et al., J. Exp. Bot. 42:801-811, 1991; Hensel, et al., Plant Cell 5:553-564, 1993; Jiang, et al., Plant Physiol. 101:105-112, 1993), while mRNA levels of genes encoding proteins thought to be involved in the senescence program increase (Graham, et al., Plant Cell 4:349-357, 1992, Hensel, et al., Plant Cell 5:553-564, 1993; Kamachi, et al., Plant Physiol. 93:1323-1329, 1992; Taylor, et al., Proc. Natl. Acad. Sci. USA 90:5118-5122, 1993).
[0005] It has been suggested that senescence specific promoters can be used to drive the expression of select genes during senescence. U.S. Pat. No. 5,689,042, for example, utilizes a genetic construct comprising a senescence specific promoter, SAG12, operably linked to a Agrobacterium isopentyl transferase (IPT)-coding DNA sequence not natively connected to the promoter sequence. Transgenic plants comprising this construct retain green leaves longer by driving the expression of IPT by means of the SAG12 promoter. IPT is known to increase the level of cytokinin, a class of plant hormones the concentration of which declines during senescence and thus may play a role in controlling leaf senescence.
[0006] Similarly, Gan and Amasino show that inhibition of leaf senescence can be achieved by autoregulated production of cytokinin (Gao, et al., Science 270:1986-1988, 1995). Other senescence-inducible promoters have been identified. For example, the SARK promoter from Phaseolus vulgaris is described in WO 99/29159 and Hajouj et al. Plant Physiol. 124:1305-1314 (2000).
[0007] A useful and desirable aspect of internally regulating the expression of the gene of interest is in the ability to regulate the expression only in those cells undergoing senescence thus leaving normal cells unaffected and spared from the possibly negative effects of cytokinin overproduction.
[0008] Although the use of SAG12 controlled expression of IPT has been shown to control leaf senescence, other phenotypes of such plants are not well understood. The present invention addresses these and other needs.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention relates to the development of drought-resistant plants. The methods of the invention provide plants with increased drought-resistance and other advantageous characteristics, such as increased yield. In addition, the plants of the invention also have greater water-use efficiency. This invention is directed to the preparation of transgenic plants that express a protein involved in cytokinin synthesis under the control of a senescence-inducible promoter.
[0010] The methods of the invention comprise (a) introducing into a population of plants a recombinant expression cassette comprising a SARK promoter operably linked to a nucleic acid sequence encoding a protein involved in cytokinin synthesis; and (b) selecting a plant that is resistant to drought stress. The step of introducing the expression cassette can be carried out using any known method. For example, the expression cassette can be introduced by a sexual cross or using Agrobacterium.
[0011] The SARK promoter is conveniently prepared from Phaseolus vulgaris and may have a sequence at least 95% identical to SEQ ID NO: 1. In some embodiments, the protein involved in cytokinin synthesis is isopentenyl transferase (IPT) from Agrobacterium . Ali exemplary sequence (IPT) sequence is one that is at least 95% identical to SEQ ID NO: 3.
[0012] The sequence can be introduced into any plant capable of transformation with recombinant expression constructs. The expression in tobacco is exemplified herein. Other plants conveniently used in the invention include turf grasses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows that WT tobacco plants displayed a progressing leaf wilting, whereas two independent transgenic lines did not show wilting symptoms during a drought stress of 5 and 7 days without water.
[0014] FIGS. 2A-2L show 4 month-old tobacco plants subjected to drought stress followed by rehydration. Both wild type ( FIG. 2A ) and transgenic plants ( FIGS. 2B and 2C ) displayed leaf wilting symptoms after 7 days of drought. The leaf wilting symptoms became more pronounced after 18 days of drought, both in WT ( FIG. 2D ) and the two transgenic lines ( FIGS. 2E and 2F ). Rehydration of the plants for 7 days had little effect on wilted WT plants ( FIG. 2G ), but induced partial recovery of the transgenic lines ( FIGS. 2H and 2I ) with transgenic line T4-24 ( FIG. 2I ) showing better recovery than transgenic line T2-36 ( FIG. 2H ). Rehydration of the plants for 14 days did not recovered WT plants ( FIG. 2J ), but fully recovered both transgenic lines ( FIGS. 2K and 2L ).
[0015] FIG. 3 Shows fresh weight of plants shown in FIG. 2 after 14-day rewatering. Values are Mean ±SD (n=40).
[0016] FIG. 4 shows WT Arabisdopsis plants and T1 transgenic plants (pSARK:IPT) after drought stress and 5 days of rehydration.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0017] As used herein, the terms “drought-resistance” or “drought-tolerance” refer to the ability of a plant to recover from periods of drought stress (i.e., little or no water for a period of days). Typically, the drought stress will be at least 5 days and can be as long as 18 to 20 days.
[0018] The term “water-use efficiency” refers to the ability of a plant to grow with substantially no yield penalty under extended periods with less than normal (typically about half) amounts of water.
[0019] The term “senescence” (also referred to as programmed cell death) refers to a genetically controlled, active process by which plant cells and tissues loose organization and function.
[0020] The term “senescence associated gene” refers to a gene involved in senescence. The expression of such a gene may be induced (or altered) during the process of senescence.
[0021] As used herein, the term “promoter” includes all sequences capable of driving transcription of a coding sequence in a plant cell. Thus, promoters used in the constructs of the invention include cis-acting transcriptional control elements and regulatory sequences that are involved in regulating or modulating the timing and/or rate of transcription of a gene. For example, a promoter can be a cis-acting transcriptional control element, including an enhancer, a promoter, a transcription terminator, an origin of replication, a chromosomal integration sequence, 5′ and 3′ untranslated regions, or an intronic sequence, which are involved in transcriptional regulation. These cis-acting sequences typically interact with proteins or other biomolecules to carry out (turn on/off, regulate, modulate, etc.) transcription.
[0022] A “maturation-inducible promoter” is a promoter that confers temporal specificity of an operably linked coding sequence such that expression occurs at the completion of maturation and/or during the process of senescence.
[0023] A “senescence-inducible promoter” is a promoter that confers temporal specificity of an operably linked coding sequence such that expression occurs during the process of senescence.
[0024] The term “plant” includes whole plants, shoot vegetative organs/structures (e.g. leaves, stems and tubers), roots, flowers and floral organs/structures (e.g. bracts, sepals, petals, stamens, carpels, anthers and ovules), seed (including embryo, endosperm, and seed coat) and fruit (the mature ovary), plant tissue (e.g. vascular tissue, ground tissue, and the like) and cells (e.g. guard cells, egg cells, trichomes and the like), and progeny of same. The class of plants that can be used in the method of the invention is generally as broad as the class of higher and lower plants amenable to transformation techniques, including angiosperms (monocotyledonous and dicotyledonous plants), gymnosperms, ferns, and multicellular algae. It includes plants of a variety of ploidy levels, including aneuploid, polyploid, diploid, haploid and hemizygous.
[0025] Two nucleic acid sequences or polypeptides are said to be “identical” if the sequence of nucleotides or amino acid residues, respectively, in the two sequences is the same when aligned for maximum correspondence as described below. The term “complementary to” is used herein to mean that the sequence is complementary to all or a portion of a reference polynucleotide sequence.
[0026] Optimal alignment of sequences for comparison may be conducted by the local homology algorithm of Smith and Waterman Add. APL. Math. 2:482 (1981), by the homology alignment algorithm of Needle man and Wunsch J. Mol. Biol. 48:443 (1970), by the search for similarity method of Pearson and Lipman Proc. Natl. Acad. Sci. (U.S.A.) 85: 2444 (1988), by computerized implementations of these algorithms (GAP, BESTFIT, BLAST, FASTA, and TFASTA in the Wisconsin Genetics Software Package, Genetics Computer Group (GCG), 575 Science Dr., Madison, Wis.), or by inspection.
[0027] “Percentage of sequence identity” is determined by comparing two optimally aligned sequences over a comparison window, wherein the portion of the polynucleotide sequence in the comparison window may comprise additions or deletions (i.e., gaps) as compared to the reference sequence (which does not comprise additions or deletions) for optimal alignment of the two sequences. The percentage is calculated by determining the number of positions at which the identical nucleic acid base or amino acid residue occurs in both sequences to yield the number of matched positions, dividing the number of matched positions by the total number of positions in the window of comparison and multiplying the result by 100 to yield the percentage of sequence identity.
[0028] The term “substantial identity” of polynucleotide sequences means that a polynucleotide comprises a sequence that has at least 70% sequence identity, at least 80% sequence identity, at least 85%, 90%, 93% 95%, or 97% compared to a reference sequence using the programs described herein; preferably BLAST using standard parameters, as described below. One of skill will recognize that these values can be appropriately adjusted to determine corresponding identity of proteins encoded by two nucleotide sequences by taking into account codon degeneracy, amino acid similarity, reading frame positioning and the like. Substantial identity of amino acid sequences for these purposes normally means sequence identity of at least 40%, 60%, 70%, 80%, 90%, 95% or 97% compared to a reference sequence using the programs described herein. Polypeptides which are “substantially similar” share sequences as noted above except that residue positions which are not identical may differ by conservative amino acid changes. Conservative amino acid substitutions refer to the interchangeability of residues having similar side chains. For example, a group of amino acids having aliphatic side chains is glycine, alanine, valine, leucine, and isoleucine; a group of amino acids having aliphatic-hydroxyl side chains is serine and threonine; a group of amino acids having amide-containing side chains is asparagine and glutamine; a group of amino acids having aromatic side chains is phenylalanine, tyrosine, and tryptophan; a group of amino acids having basic side chains is lysine, arginine, and histidine; and a group of amino acids having sulfur-containing side chains is cysteine and methionine. Preferred conservative amino acids substitution groups are: valine-leucine-isoleucine, phenylalanine-tyrosine, lysine-arginine, alanine-valine, aspartic acid-glutamic acid, and asparagine-glutamine.
[0029] Another indication that nucleotide sequences are substantially identical is if two molecules hybridize to each other, or a third nucleic acid, under stringent conditions. Stringent conditions are sequence dependent and will be different in different circumstances. Generally, stringent conditions are selected to be about 5° C. lower than the thermal melting point (Tm) for the specific sequence at a defined ionic strength and pH. The Tm is the temperature (under defined ionic strength and pH) at which 50% of the target sequence hybridizes to a perfectly matched probe. Typically, stringent conditions will be those in which the salt concentration is about 0.02 molar at pH 7 and the temperature is at least about 60° C.
[0030] For the purposes of this disclosure, stringent conditions for hybridizations are those which include at least one wash in 0.2×SSC at 63° C. for 20 minutes, or equivalent conditions. Moderately stringent conditions include at least one wash (usually 2) in 0.2×SSC at a temperature of at least about 50° C., usually about 55° C., for 20 minutes, or equivalent conditions.
[0031] The term “expression cassette” refers to any recombinant expression system for the purpose of expressing a nucleic acid sequence of the invention in vitro or in vivo, constitutively or inducibly, in any cell, including, in addition to plant cells, prokaryotic, yeast, fungal, insect or mammalian cells. The term includes linear or circular expression systems. The term includes all vectors. The cassettes can remain episomal or integrate into the host cell genome. The expression cassettes can have the ability to self-replicate or not, i.e., drive only transient expression in a cell. The term includes recombinant expression cassettes which contain only the minimum elements needed for transcription of the recombinant nucleic acid.
Preparation of Expression Cassettes
[0032] The expression cassettes of the invention comprise senescence inducible promoters. The SARK promoter from Phaseolus vulgaris is exemplified below. The promoter is described in WO 99/29159 and Hajouj et al. Plant Physiol. 124:1305-1314 (2000). Other suitable promoters include the Arabidoposis SAG12 promoter as described in Gan et al., Science, 270:1986-8 (1995). One skill will recognize that the particular promoter used in the constructs of the invention, so long as expression is induced by senescence. Thus, for example, promoters form homologues of the SARK or SAG12 genes from other species can be conveniently used in the expression cassettes of the invention.
[0033] The promoters are used to drive expression of gene encoding a protein that inhibits or slows the senescence process. In some preferred embodiments, the gene encodes a protein involved in cytokinin synthesis. For example, isopentenyl transferase (IPT) catalyzes the synthesis of cytokinin. Examples of IPT sequences are presented in: Crespi et al., EMBO J. 11:795-804 (1992); Goldberg et al., Nucleic Acids. Res. 12:4665-4677 (1984); Heide Kamp et al., Nucleic Acids Res., 11:6211-6223 (1983); Strabala et al., Mol. Gen. Genet. 216:388-394 (1989) GenBank Accession Number: NC — 003308, as well as X14410 (see SEQ ID NOs: 2 and 3)
Production of Transgenic Plants
[0034] DNA constructs of the invention may be introduced into the genome of the desired plant host by a variety of conventional techniques. For example, the DNA construct may be introduced directly into the genomic DNA of the plant cell using techniques such as electroporation and microinjection of plant cell protoplasts, or the DNA constructs can be introduced directly to plant tissue using ballistic methods, such as DNA particle bombardment. Alternatively, the DNA constructs may be combined with suitable T-DNA flanking regions and introduced into a conventional Agrobacterium tumefaciens host vector. The virulence functions of the Agrobacterium tumefaciens host will direct the insertion of the construct and adjacent marker into the plant cell DNA when the cell is infected by the bacteria.
[0035] Microinjection techniques are known in the art and well described in the scientific and patent literature. The introduction of DNA constructs using polyethylene glycol precipitation is described in Paszkowski et al. Embo J. 3:2717-2722 (1984). Electroporation techniques are described in Fromm et al Proc. Natl. Acad. Sci. USA 82:5824 (1985). Ballistic transformation techniques are described in Klein et al. Nature 327:70-73 (1987).
[0036] Agrobacterium tumefaciens -mediated transformation techniques, including disarming and use of binary vectors, are well described in the scientific literature. See, for example Horsch et al. Science 233:496-498 (1984), and Fraley et al. Proc. Natl. Acad. Sci. USA 80:4803 (1983).
[0037] Transformed plant cells which are derived by any of the above transformation techniques can be cultured to regenerate a whole plant which possesses the transformed genotype and thus the desired phenotype such as seedlessness. Such regeneration techniques rely on manipulation of certain phytohormones in a tissue culture growth medium, typically relying on a biocide and/or herbicide marker which has been introduced together with the desired nucleotide sequences. Plant regeneration from cultured protoplasts is described in Evans et al., Protoplasts Isolation and Culture, Handbook of Plant Cell Culture, pp. 124-176, MacMillilan Publishing Company, New York, 1983; and Binding, Regeneration of Plants, Plant Protoplasts, pp. 21-73, CRC Press, Boca Raton, 1985. Regeneration can also be obtained from plant callus, explants, organs, or parts thereof. Such regeneration techniques are described generally in Klee et al. Ann. Rev. of Plant Phys. 38:467-486 (1987).
[0038] One of skill will recognize that after the expression cassette is stably incorporated in transgenic plants and confirmed to be operable, it can be introduced into other plants by sexual crossing. Any of a number of standard breeding techniques can be used, depending upon the species to be crossed.
[0039] The expression cassettes of the invention can be used to confer drought resistance on essentially any plant. Thus, the invention has use over a broad range of plants, including species from the genera Asparagus, Atropa, Aveiza, Brassica, Citrus, Citrullus, Capsicum, Cucuinis, Cucurbita, Daucus, Fragaria, Glycine, Gossypium, Helianthus, Heterocallis, Hordeum, Hyoscyamus, Lactuca, Linum, Lolium, Lycopersicon, Malus, Manihot, Majorana, Medicago, Nicotiana, Oryza, Paniieum, Pannesetum, Persea, Pisum, Pyrus, Prunus, Raphanus, Secale, Senecio, Sinapis, Solanum, Sorghum, Trigonella, Triticum, Vitis, Vigna , and, Zea.
[0040] In some embodiments, the methods of the invention are used to confer drought resistance on turf grasses. A number of turf grasses are known to those of skill in the art. For example, fescue, Festuca spp. (e.g., F. arundinacea, F. rubra, F. ovina var. iduriuscula , and F. ovina ) can be used. Other grasses include Kentucky bluegrass Poa pratensis and creeping bentgrass Agrostis palustris.
[0041] Those of skill will recognize that a number of plant species can be used as models to predict the phenotypic effects of transgene expression in other plants. For example, it is well recognized that both tobacco ( Nicotiania ) and Arabidopsis plants are useful models of transgene expression, particularly in other dicots.
[0042] Drought resistance can assayed according to any of a number of well-know techniques. For example, plants can be grown under conditions in which less than optimum water is provided to the plant. Drought resistance can be determined by any of a number of standard measures including turgor pressure, growth, yield and the like. In some embodiments, the methods described in the Example section, below can be conveniently used.
[0043] All publications and patent applications cited in this specification are herein incorporated by reference as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be readily apparent to one of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.
EXAMPLES
Identification of the SARK (Senescence-Associated Receptor Kinase) Gene
[0044] The cDNA of the SARK gene was isolated from Phaseolus vulgaris by a differential display technique as described in Hajouj et al. (2000). The sequence of the full length cDNA of SARK revealed that it encodes a serine/threonine protein kinase. A hydrophobic transmembrane domain was observed suggesting that the SARK gene encodes a receptor kinase (Hajouj et al. 2000). Northern blot analysis revealed the up-regulation of the SARK gene during early stages of leaf senescence. The initiation of the SARK gene expression preceded any visual sign (yellowing) of the attached bean leaf senescence. Leaf discs, when incubated in the dark, displayed accelerated yellowing.
[0045] Similar to the intact attached leaves, transcripts levels of the SARK gene increased at the onset of the senescence process prior to any visual yellowing of the leaf (Hajouj et al (2000)). Thus, we can define the SARK gene as a senescence-associated gene (SAG). Moreover, the appearance of the SARK transcripts at the very early stages of senescence both in the attached or detached leaves suggests a regulatory role in the senescence process. Antibodies raised against the SARK protein were produced and used for western blot analysis. The temporal pattern of the levels of the SARK protein resembled that of the RNA and further support the notion that the SARK protein is associated with the senescence processes of detached and attached leaves.
Isolation of the SARK Promoter
[0046] The upstream region of 5′-end of the SARK gene was isolated by the inverse PCR approach as described by Maniatis et al. (Molecular cloning, a laboratory manual 2 nd edition. Bean genomic DNA was isolated by plant DNA extraction kit (Scotlab) according the manufacturer's instructions. The DNA was digested with the restriction enzyme XbaI and recirculated by relegation. The following primers were used for the PCR reaction.
[0000]
1)
5′ ACGTCCAACCAAAGACC 3′
2)
5′ TCTGCAGCTAGTGCGATATCC 3′
[0047] The PCR reaction was performed under the following conditions: 30 sec at 94° C., 30 sec at 55° C., 2 min at 72° C. for 40 cycles and then 10 min at 720 C.
[0048] A DNA fragment of 1.4 kb was amplified. DNA sequencing of this fragment revealed that it included 340 bp of the 5′end of the SARK DNA. This sequence revealed the existence of an intron close to the 5′end of the SARK gene.
[0049] To isolate a longer fragment upstream of the 5′ region of the SARK gene, a thermal asymmetric interlaced (TAIL) PCR technique was performed as described by Liu et al (Plant J. 8: 457-463). Three PCR primers were used:
[0000]
1)
5′ TCTGCAGCTAGTGCGATATCC 3′
2)
5′ TTGGTGGATGAATAATGGAG 3′
3)
5′ ACTGTAACTCACAAATTAGA 3′
[0050] Three PCR reactions were carried out to amplify target sequences.
[0051] The PCR products were sequenced. Approximately 800 bp of the 5′end of the cDNA were identified and are shown in SEQ ID NO: 1. The PCR fragment was cloned in pUC57.
[0000] Creation of Transgenic Plants Carrying the pSARK:IPT Construct.
[0052] The Agrobacterium ipt (isopentenyl transferase), the enzyme that catalyzes the rate limiting step in cytokinins biosynthesis was fused to the SARK promoter. Gan and Amasino (Science 270; 1996 (1995) have shown that the promoter of the Arabidopsis SAG12 gene (senescence-associated gene) when linked to the ipt gene induced the synthesis of cytokinins and delayed the process of leaf senescence. The Agrobacterium IPT was operably linked to the 830 nucleotide length promoter of the SARK gene and introduced as a HinII/XbaI fragment into pB101 (ClonTech) to create the pBI p-SARK:IPT. Agrobacterium transformation was performed by electroporation.
Tobacco Transformation
[0053] Plants were transformed via the Agrobacterium -mediated transformation method. Expression of Agrobacterium Isopentyl Transferase (IPY) gene under the regulation of the SARK promoter caused delayed senescence of the tobacco leaves. The transgenic tobacco containing the p-SARK-IPT has shown considerable delay in the regular senescence of both the individual leaves and the whole plants. The WT plants flower usually 3 to 3.5 months after germination and start to exhibit yellowing of the first leaves (at the bottom) after 4 months. However, the transgenic plants displayed a significant delayed senescence and did not show any yellowing of the first leaves until 10 months after germination.
[0054] Detached leaves of the transgenic tobacco showed also a significant delay in yellowing when incubated under dark conditions. Normally, detached tobacco leaves display initial yellowing after 5-6 days of incubation in the dark and complete their yellowing after 10-12 days. The detached leaves of the transgenic plants, however, did not show any sign of yellowing for 20 days and even after 30 days of dark incubation they were still green although initial yellowing was observed. These results demonstrated that in addition to the attached leaves, the autoregulatory mechanism of cytokinins synthesis in detached leaves of the transgenic plants was also functional.
Arabidopsis Transformation
[0055] PCR amplification of the pSARK:IPT using the following primers was performed with the by the Pfu turbo DNA polymerase (Stratagene).
[0000]
SARKIPF
5′T T C C T T A G A T G C T G T C A C A A T C A 3′
SARKIPTR
5′G A A C A T C T T A T C C A G A T G A A G A C A
G 3′
[0056] The template for the PCR amplification was the transgenic tobacco DNA containing the pSARK:IPT
[0057] The PCR product (PSARK:IPT) was cloned with the TOPO cloning kit into Topo competent cells (DH5α-T1) according to the instruction of the manufacturer (Invitrogen).
[0058] DNA plasmid minipreps was performed with the Qiaprep kit (Qiagen).
[0059] The plasmid was digested with BglII and EcoRI and was ligated with the Cambia 1380 vector (CAMBIA, Canberra Australia)
[0060] Electroporation of the Cambia vector carrying the pSARK:IPT was performed into (DH5α) competent cells. DNA plasmid miniprep of the transfected DH5α colonies was carried out with the Qiaprep kit (Qiagen). The Cambia vector containing the pSARK:IPT was electrophoretically introduced into Agrobacterium for plant transformation. Arabidopsis thaliana plants were transformed by the vacuum infiltration technique with Agrobacterium tumefaciens containing the pSARK:IPT and the hygromycin resistance gene (hiptligene) for selection in plants.
[0000] Expression of Isopentyl Transferase (IPT) under the Regulation of SARK Gene Promoter in Tobacco Plants Confers Drought Resistance.
[0061] Transgenic tobacco plants carrying the pSARK:IPT have been grown in the greenhouse for 2-3 months. No morphological differences could be visualized between the transgenic and the WT plants during the first 3-4 months.
[0062] Following the initiation of flowering, 3 month old tobacco plants were subjected to drought stress (no water was added to the pots) for 5-16 days. The WT plants displayed a progressing leaf wilting ( FIG. 1 ). However, the transgenic plants (two independent lines) did not show wilting symptoms ( FIG. 1 ) during a drought stress of 5 and 7 days without water. Long dehydration periods of 16 days caused severe irreversible wilting of the WT plants and less severe, and reversible wilting in plants carrying the pSARK:IPT. Rehydration (re-watering of the dehydrated plants) caused recovery of the transgenic pSARK:IPT plants, whereas the WT plants could not be recovered ( FIG. 1 ) from the drought stress.
[0063] Wild type plants (WT) and two transgenic lines of tobacco plants carrying the pSARK-IPT (T2-36 and T4-24) were grown in the greenhouse for 5 months. No morphological differences could be observed between the transgenic and the wild-type plants during the first 3-4 months of growth under optimal conditions. Following the initiation of flowering, 4 month-old tobacco plants were subjected to drought stress (no water was added to the pots) for a period of 18 consecutive days ( FIG. 2 , A-F). Both wild type ( FIG. 2A ) and transgenic plants ( FIGS. 2B and 2C ) displayed leaf wilting symptoms after 7 days of drought. The leaf wilting symptoms became more pronounced after 18 days of drought, both in WT ( FIG. 2D ) and the two transgenic lines ( FIGS. 2E and 2F ). Rehydration of the plants for 7 days had little effect on wilted WT plants ( FIG. 2G ), but induced partial recovery of the transgenic lines ( FIGS. 2H and 2I ) with transgenic line T4-24 ( FIG. 2I ) showing better recovery than transgenic line T2-36 ( FIG. 2H ). Rehydration of the plants for 14 days did not recovered WT plants ( FIG. 2J ), but fully recovered both transgenic lines ( FIGS. 2K and 2L ). Measurements of the Fresh Weight of the wild-type and transgenic plants at the end of the rehydration period showed that the transgenic lines attained a fresh weight of 250 gram/plant, while the wild-type remained dry with a weight that did not exceed 20% of that of the transgenic lines ( FIG. 2 ). FIG. 3 shows the fresh weight of plants shown in FIG. 2 after 14-day rewatering. Values are Mean ±SD (n=40).
Expression of the IPT Gene Under the Regulation of the SARK Gene Promoter Confers Drought Resistance to Transgenic Arabidopsis Plants.
[0064] Arabidopsis thaliana plants were grown under long day's regime (16/8 h) at 23° C. No morphological and developmental differences could be distinguished between the WT and the transgenic (pSARK:IPT) plants grown under normal conditions. However, when two month-old plants (at the stage of advanced flowering) were subjected to drought stress (no water was added to the pots) they displayed differential stress resistance. The WT plants underwent severe irreversible wilting and leaf yellowing after 12 days of dehydration, whereas 10 different independent lines of the T1 transgenic plants (pSARK:IPT) showed mild wilting and recovered from the drought stress after 5 days of rehydration ( FIG. 4 ). | The present invention relates to the development of drought-resistant plants. This invention is directed to the preparation of transgenic plants that express a protein involved in cytokinin synthesis under the control of a senescence-inducible promoter. | 2 |
BACKGROUND
Test strips for analytical purposes are generally supplied to users in test strip vials from which individual test strips are removed as needed. A variety of test strips are known in the art including, for example, those designed to measure the concentration of an analyte in a fluid sample. With currently available test strip vials, it may be difficult for a user to remove a single test strip without tilting and/or shaking the vial, especially when the test strip vial is filled with test strips. Furthermore, tilting and/or shaking of test strip vials may result in undesired test strip spills and potential contamination of test strips. The present disclosure addresses these and related issues in the art.
SUMMARY OF THE INVENTION
The present disclosure provides test strip carriers for insertion into test strip vials and methods of making the same. Also provided are test strip vials including test strip carriers, and systems including test strip vials, test strip carriers and analytical test strips. The test strip carriers of the present disclosure are capable of engaging with the caps of test strip vials and thereby facilitating the retrieval of one or more test strips from the test strip vials upon opening of the test strip vials. These and other objects, features and advantages of the present disclosure will become more fully apparent from the following detailed description of the embodiments, the appended claims and the accompanying drawings.
In a first aspect, the present disclosure provides a test strip carrier for insertion into a test strip vial, wherein the test strip vial includes a cap hingedly coupled to the test strip vial. The test strip carrier includes a first end configured for insertion into the test strip vial and defining a test strip basket, the test strip basket including a base and a wall. The test strip carrier also includes a second end configured to engage the cap and a flexible connector connecting the first end to the second end, wherein the test strip carrier is configured such that when the first end is inserted into the test strip vial and the second end engages the cap, opening of the cap raises the test strip basket from a first position to a second position within the test strip vial.
In one embodiment of the test strip carrier according to the first aspect the wall is an annular wall.
In one embodiment, the second end of the test strip carrier is configured to snapedly engage the cap.
In one embodiment, the second end of the test strip carrier is at least substantially disk shaped.
The test strip carrier according to the first aspect can be formed from a single piece of flexible material. In one embodiment, the flexible material is a polymer. In one embodiment, the flexible material is a polymer, and the polymer is a plastic.
In one embodiment, the second end of the test strip carrier is attached via an adhesive to the cap.
In a second aspect, the present disclosure provides a system including a test strip vial, wherein the test strip vial comprises a cap hingedly coupled to the test strip vial. The system also includes a test strip carrier, wherein the test strip carrier includes a first end configured for insertion into the test strip vial and defining a test strip basket. The test strip basket includes a base and a wall. The test strip carrier also includes a second end configured to engage the cap and a flexible connector connecting the first end to the second end. The system also includes a plurality of test strips disposed in the test strip basket, wherein the test strip carrier is configured such that when the first end is inserted into the test strip vial and the second end engages the cap, opening of the cap raises the test strip basket from a first position to a second position within the test strip vial.
In one embodiment of the system according to the second aspect the wall is an annular wall.
In another embodiment, the second end of the test strip carrier is configured to snapedly engage the cap.
In another embodiment, the second end of the test strip carrier is at least substantially disk shaped.
In the system according to the second aspect, the test strip carrier can be formed from a single piece of flexible material. In one embodiment, the flexible material is a polymer. In one embodiment, the flexible material is a polymer, and the polymer is a plastic.
In a third aspect, the present disclosure provides a test strip vial including a cap hingedly coupled to the test strip vial. The test strip vial also includes a test strip carrier, wherein the test strip carrier includes a first end inserted into the test strip vial, wherein the first end defines a test strip basket. The test strip basket includes a base and a wall. The test strip carrier also includes a second end engaged with the cap and a flexible connector connecting the first end to the second end. Opening of the cap raises the test strip carrier from a first position to a second position within the test strip vial.
In one embodiment of the test strip vial according to the third aspect the wall is an annular wall.
In another embodiment, the second end of the test strip snapedly engages with the cap.
In another embodiment, the second end of the test strip carrier is at least substantially disk shaped.
In the test strip vial according to the third aspect, the test strip carrier can be formed from a single piece of flexible material. In one embodiment, the flexible material is a polymer. In one embodiment, the flexible material is a polymer, and the polymer is a plastic.
In one embodiment, the test strip vial includes a plurality of analytical test strips disposed in the test strip basket.
In one embodiment, the second end of the test strip carrier is attached via an adhesive to the cap of the test strip vial.
In a fourth aspect, the present disclosure provides a method of making a test strip carrier for insertion into a test strip vial having a cap hingedly coupled thereto. The method includes cutting a test strip carrier pattern from a sheet of flexible material and folding the test strip carrier pattern to form a test strip carrier, wherein the test strip carrier includes a first end configured for insertion into the test strip vial and defining a test strip basket. The test strip basket includes a base and a wall. The test strip carrier also includes a second end configured to engage the cap and a flexible connector connecting the first end to the second end. The test strip carrier is configured such that when the first end is inserted into the test strip vial and the second end engages the cap, opening of the cap raises the test strip carrier from a first position to a second position within the test strip vial.
In one embodiment of the method described in the fourth aspect the wall is an annular wall.
In one embodiment, where the wall is an annular wall, the test strip carrier pattern comprises a first engagement slit and a second engagement slit, and the annular wall is formed by engaging the first engagement slit with the second engagement slit.
In one embodiment, the second end of the test strip carrier is configured to snapedly engage the cap of the test strip vial.
In one embodiment, the second end of the test strip carrier is at least substantially disk shaped.
In one embodiment, the flexible material is a polymer. In one embodiment, the flexible material is a polymer, and the polymer is a plastic.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views:
FIG. 1 shows an embodiment of a test strip carrier according to the present disclosure;
FIG. 2 shows the test strip carrier of FIG. 1 inserted into a test strip vial and engaged with a test strip vial cap;
FIG. 3 shows the test strip carrier of FIG. 2 with analytical test strips disposed therein; and
FIG. 4 shows a cutout pattern which can be folded to form a test strip carrier according to the present disclosure.
Before the present invention is further described, it is to be understood that this invention is not limited to the particular embodiments described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.
As used herein and in the appended claims, the singular forms “a,” “and,” and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
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.
DETAILED DESCRIPTION
Test Strip Carriers
As indicated above, the present disclosure provides test strip carriers for insertion into test strip vials. With reference to FIGS. 1 , 2 and 3 , exemplary embodiments of the test strip carriers of the present disclosure are now described. A test strip carrier 100 includes a first end 101 . The first end 101 defines a test strip basket having a base 103 and a wall 104 . In the embodiment shown in FIGS. 1 , 2 and 3 , the wall 104 is an annular wall, although additional configurations are possible, e.g., a wall having one or more 90° angles. As used herein, the term “annular” refers to a shape which is at least substantially circular or elliptical.
With reference to FIG. 1 , the test strip carrier 100 optionally includes one or more base tabs 106 which extend from the base of wall 104 , and which can be folded during assembly of the test strip carrier such that they engage the base 103 to form the test strip basket. The test strip carrier 100 optionally includes a first engagement slit 107 and a second engagement slit 108 (engagement slits 106 and 107 are visible in the cutout provided in FIG. 4 and are shown in an engaged configuration in FIG. 1 ). In one embodiment, during formation of the test strip carrier 100 , the wall 104 is formed by engaging first engagement slit 107 with second engagement slit 108 or vice versa. The dimensions of the wall 104 may vary. However, the distance from the base 103 to the top of the wall 104 should be less than the length of the test strips 120 held by the test strip basket to facilitate retrieval of the test strips from the test strip basket.
With reference to FIGS. 2 and 3 , the first end 101 is configured for insertion into a test strip vial 109 which includes a cap 110 hingedly coupled to the test strip vial 109 , e.g., via a hinge or flange. When the test strip carrier 100 is inserted into the test strip vial 109 , the first end 101 slidably engages with the inner wall 111 of the test strip vial 109 . In other words, first end 101 engages the inner wall 111 via a sliding action. To allow for such slidable engagement, the dimensions of the first end 101 can be configured based on the dimensions of the test strip vial 109 into which the test strip carrier 100 will be inserted. In another embodiment, the test strip vial 109 is configured based on the dimensions of the test strip carrier 100 to be inserted therein.
In one embodiment, the first end 101 , is configured such that the outer dimensions of the first end 101 , e.g., the circumference of the base including the width of the wall, are sufficiently less than the circumference of the interior wall 111 of test strip vial 109 so as to allow the test strip carrier 100 to slide within the test strip vial 109 with the application of minimal force, e.g., the force applied by a user using one hand to open the test strip vial 109 . It may also be desirable to configure test strip carrier 100 such that it engages the inner wall 111 of the test strip vial 109 with sufficient tightness to prevent test strips 120 from sliding past the test strip carrier 100 to the space below the test strip carrier 100 in the test strip vial 109 .
In one embodiment, the base 103 optionally includes one or more apertures (not shown) extending through the base 103 . These apertures can provide for the exchange of gasses between the area beneath the base 103 and the area above the base 103 . Generally, these apertures are sized such that they are large enough to allow for the exchange of gasses between the area beneath the base 103 and the area above the base 103 but small enough to prevent the passage of test strips 120 through the apertures.
The test strip carrier 100 also includes a second end 102 , which is configured to engage the cap 110 of the test strip vial 109 . Engagement of the cap 110 with the second end 102 may be accomplished in a variety of ways. For example, via application of an adhesive material between the second end 102 and the interior surface 112 of cap 110 .
In one embodiment, the second end 102 is configured to detachably engage the cap 110 of the test strip vial 109 . In other words, in one embodiment, the test strip carrier is not a component of the cap 110 , but is instead a separate component which can detachably engage with the cap 110 . Such a configuration is of substantial benefit to the art because the test strip carrier 100 can be readily configured to work with a variety of preexisting test strip vials. In this manner, substantial costs associated with the design and production of new test strip vials and/or retooling of assembly lines can be avoided.
In one embodiment, the second end 102 is configured to snapedly engage, e.g., via a snap feature, the cap 110 of the test strip vial 109 . In other words, second end 102 and cap 110 can be configured for snap-fit engagement. For example, in one embodiment second end 102 is at least substantially disk shaped. Where second end 102 is at least substantially disk shaped, it may be sized to snap into annular gap 113 of cap 110 .
A flexible connector 105 connects the first end 101 to the second end 102 . The flexible connector may take a variety of shapes, provided that the flexible connector is capable of operating as described herein. As shown in FIGS. 1-3 , in one embodiment the flexible connector 105 has an elongate rectangular shape.
Overall, the test carrier 100 is configured such that when it is inserted into test strip vial 109 , opening of the cap 110 raises the test strip basket from a first position to a second position within the test strip vial 109 . For example, with reference to FIG. 3 , the pivoting motion of cap 110 about flange 115 , moves the cap 110 from a closed position to an open position. Because second end 102 is engaged with the cap 110 , the motion of the cap 110 exerts an upward force on the test strip basket via the flexible connector 105 . The distance between the first position and the interior surface 112 of cap 110 , when the cap 110 is in the closed position, is at least as long as the test strips 120 to be held by the test strip basket. The distance between the second position and the rim 114 of the test strip vial 109 is such that the ends of the test strips 120 will extend beyond the rim 114 of the test strip vial 109 when present. In other words, when a user opens cap 110 of test strip vial 109 , the test strip basket is raised within the test strip vial 109 thereby lifting the test strips 120 from a first position closer to the base of the test strip vial 109 to a second position towards the upper edge or rim 114 of test strip vial 109 .
Test Strip Vials for Use with the Disclosed Test Strip Carriers
The test strip carriers of the present disclosure can be configured for insertion into a variety of test strip vials known in the art. Vials suitable for use with the test strip carriers disclosed herein are described, for example, in U.S. Pat. Nos. 5,723,085, and 5,911,937, the disclosures of each of which are incorporated by reference herein.
In one embodiment, the test strip carriers of the present disclosure are configured for insertion into a test strip vial 109 as shown in FIGS. 2 and 3 . In the embodiment shown in FIGS. 2 and 3 , the test strip vial 109 is cylindrical in shape with an integrally formed bottom. The test strip vial 109 includes an interior wall 111 . A cap 110 is provided which is adapted to seal the vial closed with a substantially hermetic seal. The cap 110 can be integrally connected to the vial 109 with a small flange 115 . In one embodiment, the vial 109 and cap 110 are injection molded from a thermoplastic material.
The cap 110 includes a cap rim 116 . The cap rim 116 is intended to fit over the annular rim 114 of the outer wall 117 of the test strip vial 109 in a sealing manner. A ridge 118 may be formed on the inside of cap 110 to enhance the seal of the cap 110 to the vial 109 . An annular gap 113 extends from the ridge 118 to the outer edge of interior surface 112 of cap 110 .
The test strip vial 109 has an annular ridge 119 extending around the periphery of the test strip vial 109 . The annular ridge 119 and a smooth transition surface at the upper edge or rim 114 of the vial 109 form an annular region for interlocking with the cap 110 .
The inside of the cap 110 , including the ridge 118 and the annular gap 113 , combine to form an annular region for interlocking with the interlocking annular region on the vial 109 . The inner surface of cap 110 extending from cap rim 116 to ridge 118 is angled so as to guide the upper edge or rim 114 of the vial wall into the annular gap 113 . The annular rim 114 of the vial 109 is designed to fit within the annular gap 113 .
Analyte Test Strips for Use with the Disclosed Test Strip Carriers
The test strip carriers of the present disclosure can be configured to work with any of a wide variety of analyte test strips. In some embodiments, the test strip carriers of the present disclosure are configured to hold FreeStyle® test strips for use in blood glucose monitoring or Precision® brand test strips for use in monitoring glucose and ketones. FreeStyle® and Precision® brand analyte test strips are available from Abbott Diabetes Care Inc., Alameda, Calif. Exemplary analyte test strips are also described in U.S. Pat. Nos. 6,071,391; 6,120,676; 6,143,164; 6,299,757; 6,338,790; 6,377,894; 6,600,997; 6,773,671; 6,592,745; 5,628,890; 5,820,551; 6,736,957; 4,545,382; 4,711,245; 5,509,410; 6,540,891; 6,730,200; 6,764,581; 6,299,757; 6,338,790; 6,461,496; 6,503,381; 6,591,125; 6,616,819; 6,618,934; 6,676,816; 6,749,740; 6,893,545; 6,942,518; 6,175,752; and 6,514,718, the disclosures of each of which are incorporated by reference herein.
Test strips suitable for use with the test strip carriers described herein include optical and electrochemical test strips configured for use in testing for any of a wide variety of analytes, including, but not limited to, glucose, lactate, acetyl choline, amylase, bilirubin, cholesterol, chorionic gonadotropin, creatine kinase (e.g., CK-MB), creatine, DNA, fructosamine, glucose, glutamine, growth hormones, hormones, ketones, lactate, peroxide, prostate-specific antigen, prothrombin, RNA, thyroid stimulating hormone, and troponin.
Test strips suitable for use with the test strip carriers described herein also include test strips configured for use in testing for drugs, such as, for example, antibiotics (e.g., gentamicin, vancomycin, and the like), digitoxin, digoxin, drugs of abuse, theophylline, and warfarin, may also be determined and the like.
Materials for Construction
Test strip carriers according to the present disclosure may be formed and/or constructed from a variety of suitable materials, provided that the materials are sufficiently flexible to operate as described herein. In one embodiment, the test strip carrier is formed from single piece of flexible material, as shown in FIG. 4 , which is folded to achieve the final configuration. In another embodiment, the test strip carrier is molded, e.g., injection molded, to achieve the final configuration. Suitable flexible materials include polymers, e.g., plastics. In one embodiment, the flexible material is a thermoplastic polymer, e.g., polycarbonate, polystyrene, polyethylene, polysulfone or polypropylene.
Desiccants
It may be desirable to keep the test strips stored in the test strip vials disclosed herein as moisture free as possible. As such, the test strip vials disclosed herein can include one or more desiccants, e.g., silica gel. The desiccant can be located in the test strip vial or included as a component of the test strip vial itself. The desiccant can also be located on and/or in the material used to form the test strip carrier. In one embodiment the desiccant is included in a moisture absorbing desiccant entrained polymer. This polymer can be used as a component of the test strip vial and/or the test strip carrier. It can also be used to coat one or more surfaces of the test strip vial and/or the test strip carrier. Processes and resulting structures for producing moisture absorbing desiccant entrained polymers are described, for example, in U.S. Pat. No. 5,911,937, the disclosure of which is incorporated by reference herein.
Method of Making
In one embodiment, the test strip carrier 100 is formed from a single piece of flexible material which is folded into the final configuration to be inserted into a test strip vial 109 . The single piece of flexible material can be cut from a sheet of flexible material, e.g., a flexible polymer. A variety of methods are known in the art for cutting a predetermined pattern from a sheet of flexible material. Such methods include, but are not limited to, die cutting and laser cutting. These methods can be readily adapted to large scale, high throughput applications as needed.
In one embodiment, the cutout pattern has the configuration shown in FIG. 4 . The numeric identifiers in FIG. 4 refer to the structures of the test strip carrier 100 that can be formed from the identified portions of the cutout pattern. The test strip carrier 100 shown in FIGS. 1 , 2 and 3 can be formed from the cutout shown in FIG. 4 as follows. The portion of the flexible material forming base 103 is folded at position (A) at an approximately 90° angle relative to the portion of the flexible material which will form the wall 104 . The portion of the flexible material which will form the wall 104 is folded such that first engagement slit 107 engages second engagement slit 108 to form wall 104 . In another embodiment, the flexible material which will form the wall 104 is folded and engaged with itself via application of an adhesive.
Optional base tabs 106 can be folded at an approximately 90° angle relative to wall 104 such that they engage and/or provide support for base 103 . In one embodiment, a plurality of slits (not shown) is provided in base 103 . The base tabs 106 can be inserted into these slits in an interlocking manner to provide engagement of the base tabs 106 with the base 103 . In another embodiment, the base tabs 106 can engage with base 103 via application of an adhesive. The wall 104 together with base 103 and optional base tabs 108 form the test strip basket in which analytical test strips 120 can be disposed.
Second end 102 is folded at position (B) at one end of flexible connector 105 to form a disk shaped engagement element having a cutout which forms a portion of flexible connector 105 as shown in FIGS. 1 , 2 and 3 . The fold at position (B) allows the disk shaped engagement element to pivot about the fold axis while engaged with the cap 110 of test strip vial 109 .
As indicated above, the test strip carrier can also be molded, e.g., injection molded, to achieve the final configuration.
While the present invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process step or steps, to the objective, spirit and scope of the present invention. All such modifications are intended to be within the scope of the claims appended hereto. | The present disclosure provides test strip carriers for insertion into test strip vials and methods of making the same. Also provided are test strip vials including test strip carriers, and systems including test strip vials, test strip carriers and analytical test strips. The test strip carriers of the present disclosure are capable of engaging with the caps of test strip vials and thereby facilitating the retrieval of one or more test strips from the test strip vials upon opening of the test strip vials. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention involves the field of electronic air purification and, more specifically, a miniature device that generates and circulates ionized and ozonated air around an individual's face.
2. Description of Related Art
Ever since humans first began to live in enclosures instead of outdoors like wild animals, they have been faced with problems of indoor air pollution. At the very least, a building impedes fresh air flow and traps various potentially noxious substances and airborne disease organisms. Originally, a major source of noxious airborne substances was smoke from indoor fires intended to heat the dwelling and cook food. Eventually, chimneys and similar devices were developed to conduct most of the smoke safely to the outdoors.
Over time various other heating and cooling technologies were perfected to further improve the quality of indoor air. It seems that today we have almost come full circle. The outdoor air, at least in most major cities, is saturated with pollutants resulting from automobile exhaust and manufacturing activities. At the same time, escalating energy costs have resulted in "energy efficient" buildings which reduce heating and cooling costs by reducing the amount of outdoor air allowed to enter the building. To make matters worse, many modern materials used in building materials and furniture outgas toxic or irritating vapors. With less outdoor air entering to dilute these outgassed toxins, the building air can become extremely unpleasant or even unhealthful to breath.
There have been a wide variety of attempts to deal with problems of "indoor air pollution" or the "sick building syndrome," as this problem is sometimes called. Specialized air filters have been applied to central air systems in an effort to cleanse the air. Smaller room-sized filtering systems have also been employed. Elaborate heat exchangers have been added to air intakes so that more air can be exchanged with the outside without a great loss of energy. Unfortunately, such solutions are expensive to employ and are often not undertaken until air quality problems become critical.
Ultimately the solution to indoor air pollution lies in improved building designs, improved construction materials, and improved control of outdoor air pollution. But in the meantime, many people are stuck in buildings that have inadequate air quality. Sensitive individuals are especially impacted by poor air quality and may need to employ special devices to ameliorate indoor air quality.
One popular approach has been the use of negative ion or ozone generators. The basis for such devices is relatively simple. Generally, they employ a high voltage electrical source to produce a corona discharge which negatively charges air molecules and particulates suspended in the air. At the same time, some of the oxygen molecules (O 2 ) in the air are converted into a more reactive compound, ozone (O 3 ). The negatively charged particulates generally interact with neutral or positively charged surfaces and "precipitate" from the air, thus resulting in a reduction in the number of particulates. Ozone tends to react with various airborne organic molecules, often destroying them or rendering them less toxic. Ozone may also destroy airborne disease organisms. Finally, there is some evidence that negative ions in the air may promote psychological and/or physical well being. Certainly, the clean smell and feel of the air following an electrical storm is at least partly due to the presence of ozone and negative ions.
One problem with many negative ion generating systems is that they are fairly large and require a source of electrical power such as a wall plug. Thus, the units are not portable and, while such a unit may cause a localized region of improved air quality, it does little for a sensitive individual who must frequently move from room to room. In addition, it is somewhat difficult to direct the ionized air. In most systems the ionized air simply diffuses into the room. A few systems contain fans to direct the ionized air, but fans tend to increase the bulk and complexity of the devices. There have also been some efforts to produce "portable" units that can be carried about by an individual, but these "portable" units have actually weighed in the neighborhood of five pounds.
OBJECTS AND SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a truly portable negative ion/ozone generator that an individual can easily move from room to room;
It is an additional object of the present invention to provide a portable negative ion/ozone generator that is sufficiently small to be worn as an unobtrusive portion of one's apparel;
It is yet another object of the present invention to provide a portable negative ion/ozone generator that is very energy efficient and gives a long period of operation from a battery or other direct current power source; and
It is a further object of the present invention to provide a portable negative ion/ozone generator that is capable of producing a sufficient air flow to distribute the ionized air and can, thereby, act to prevent particulates and contaminants from reaching the face of a user wearing the device.
These and other objects are met by a small, battery-powered device that can be clipped to a wearer's front shirt pocket or worn suspended from a cord about the wearer's neck. The device comprises a housing containing a compact circuit that transforms direct current provided by the battery into a negative high voltage pulsating current connected to a sharp metal point enclosed within the hollow body of the housing. A corona discharge forms on the metal point, ionizing air molecules and any particulates, and generating ozone. An opening into the hollow body of the device is covered by a metal grid connected to the positive terminal of the battery. The negative ions are attracted to this grid to complete an electrical circuit. Movement of the ions results in mass movement of air causing a stream of air to emerge through the grid. As the air passes the grid, negatively charged particulates are deposited on the grid. The cleansed air stream, containing traces of ozone and negative ions, can be directed to flow across the face of the user, thereby limiting the contact of contaminated ambient air with the eyes and nasal passages of the user.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
FIG. 1 shows a perspective drawing of the device of the present invention;
FIG. 1a shows the device with a removably attached small filter pad;
FIGS. 2a, and 2b illustrate the device of the present invention in use being worn by an individual;
FIG. 3 is a diagram of the electronic circuitry of the preferred embodiment of the present invention; and
FIG. 4 shows the device with the housing opened to reveal inner components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a portable personal negative ion/ozone generator.
A difficulty in creating a personal negative ion/ozone generator is to produce a unit that is small enough to be conveniently carried or worn on a user's person. Such a device must have a self-contained power source, such as a battery, and be capable of operating for a reasonably long time on that battery. The notion behind negative ion/ozone generators is that the air will be purified by electrostatic dust precipitation (electrically charged particulates in the air become attracted to neutral or positively charged objects) and by destruction of pollutants and airborne disease organisms through reaction with ozone.
One method of ionizing air and producing ozone is to establish a corona discharge. Corona discharges occur when a surface contains an excess of electrons at a sufficiently high negative potential that surrounding air molecules take up electrons and become ionized. As the ionized atoms undergo changes in energy level, the gas emits light so the discharge is frequently visible as a faint blue glow. Although any surface may be used to create a corona discharge, pointed surfaces are most effective. Natural corona discharges are often visible during electrical storms when pointed objects such as lightning rods can be seen to glow. In the days of sailing ships corona discharges from the tips of masks were known as St. Elmo's Fire, and the eerie blue "flames" were regarded with superstitious dread by sailors.
An ionizing source large enough to produce an effective concentration of ozone and negative ions is necessary. At the same time, excessive ozone can be irritating to one's lungs and mucus membranes. Furthermore, voltages sufficiently high to support a corona discharge can impart an unpleasant static electrical shock. Therefore, the discharge must be kept away from the user's touch. Finally, means must be provided to move the purified air into the vicinity of the user's nose. The present invention provides a unique solution to these and related problems.
A miniature electronic circuit is used to transform battery voltage into a sufficiently high negative potential to effect a corona discharge. The negative potential is conducted to a metallic needle point where a corona discharge occurs. This emitter point is contained within a chamber in the device so that a user can never come into contact with the high voltage. As the corona discharge occurs, electrons, originally generated by the electrochemical reaction of the battery, are transferred to air molecules. An electric circuit is completed by placing a conductive grid placed near the emitter point and connected to the battery.
The conductive grid has several important purposes. First, the grid captures many of the negative ions and provides a surface on which charged particulates can precipitate. Because the grid should be easily cleaned of precipitated particulates and because ozone is reactive, the grid should be constructed of, or plated with a conductive and nonreactive metal such as nickel, gold, silver, chromium, rhodium or platinum. Currently the preferred choice is a steel grid with a nickel plating.
Second, the migration of negative ions moving from the emitter point to the grid causes a mass flow of air molecules. This flow exits through the grid and blows in whatever direction the grid is aimed. As elaborated below, grid structure and placement is critical to produce maximum air flow. In a unit with proper grid structure and placement air flow rates of 100 ft/min have been measured with a Dwyer vanometer.
The unit creates a significant net flow of air without any moving mechanical parts. This air flow can deliver purified air to the face of the user, thereby shunting away contaminants in the ambient air. Furthermore, this constant flow of air dilutes the ozone so that there can be an effective concentration of ozone in the vicinity of the emitter point within the device, while the ozone concentration six inches from the device has been diluted to about 0.04 ppm, a level which OSHA considers as safe.
FIG. 1 shows a perspective view of the entire device 10. The unit comprises a rectangular shaped housing 11 about the size of an average shirt pocket. The exact size and shape is unimportant. The unit should be small enough and light enough to be conveniently attached to a user's clothing. A clip 12 is provided for this purpose. Alternatively, a cord 22 can be looped through the clip 12 so the device can be worn around the user's neck (see FIG. 2b).
A small slide switch 14 controls the power from a 9-volt battery 42 that is contained within a battery compartment 16 at one end of the device. The battery can be easily replaced by opening a battery compartment door. A connector 18 for an AC adaptor is also provided. This adaptor allows the device to be operated from house current, and also recharges a nickel cadmium battery if such a battery is installed.
A conductive grid 1.9 is located at the opposite end of the unit 10 from the battery compartment 16. This grid 19 forms the top of an ionization chamber 44 located within the device 10. As shown in FIG. 4, this chamber 44 is formed by the walls of the housing 11, the grid 19, and a membrane barrier 46 which lies between the chamber 44 and an electronics board 45. A point emitter 48, comprising a metallic needle, penetrates the membrane barrier 46 to connect to the electronics board 45. A neon gas-discharge lamp 49 is located at one edge of the membrane barrier 46 and is visible by looking through the grid 19 from the grid end of the device 10.
When the device 10 is operational, a corona discharge occurs at the emitter point 48, thereby ionizing the air and forming ozone. The negative ions so formed are attracted to the conductive grid 19, which is also connected to the battery 42, causing a mass flow of air (arrows, FIGS. 2a and 2b) towards and through the grid 19. FIGS. 2a and 2b show the device 10 in use being worn clipped to a front shirt pocket 24 or hung about the neck of a user 22. The mass flow of ionized air propels a stream of air upward and towards the face of the user 22. At the same time, replacement air is drawn into the ionization chamber 44 through the edges of the grid. 19, where it, too, becomes ionized and accelerated towards the grid 19 and out of the unit 10.
The structure of the grid 19 and its placement relative to the emitter point 48 is critical for attaining a maximum air flow. It has been discovered that the grid 19 must have adequate open areas so that air circulation is not impeded. At the same time there must be sufficient surface area for adequate ion interaction and particulate precipitation. Grids with about 80% open space are preferred. Grids with a considerably larger percentage of open space would tend to have inadequate charged area and would also be excessively fragile. Similarly grids with a considerably smaller percentage of open space tend to excessively impeded the mass air flow.
The grid opening geometry is also important. The preferred grid 19 has hexagonal openings with a diameter of about one quarter inch. Screens with similarly-sized circular or square openings should also work effectively. Grids with considerably smaller openings excessively impede the air flow and are fragile. Grids with .much larger openings do not effectively present charged surfaces for attracting ionized air and charged particulates.
Finally, there is an important interaction between grid geometry and opening and distance from the emitter point 48. If the grid 48 is too close to or too far from the emitter point 48, the velocity of the accelerated air is considerably slowed. Each different grid configuration has a somewhat different ideal distance from the grid 19 to the emitter point 48. With the preferred grid geometry, as described above, the emitter point 48 produces a maximal air flow when it is about 0.3 inches from the grid 19.
In the ionization chamber 44 a relatively high concentration of ozone inactivates pollutants and microbes, many of which are drawn to and captured by the grid 19. The flow of purified air past the face of the user 22 prevents many contaminants in the ambient air from ever reaching the nasal passages of the user.
A small filter pad 17, trapezoidal in outline, as shown in FIG. 1a, which contains activated charcoal can be removably attached to the unit 10 by mating of a hook-and-loop system (VELCRO™) 15, 13. When installed, the filter pad 17 forms approximately a 45-degree angle with the metal grid 19. Because the filter pad 17 is trapezoidal, it does not interact with the air stream near the edges of the grid 19. This allows the replacement air to enter the ionization chamber 44 unimpeded. However, the ionized air exiting the center of grid 19 strikes the filter pad 17. The filter pad absorbs ozone, as well as organic pollutants, from the air. The filter pad 17 directs the purified air stream somewhat away from the user's face in case the user is especially sensitive to even residual levels of ozone. The filter pad 17 can be easily flipped over, exposing a fresh surface to the ionized air stream. After both surfaces are exhausted, a fresh filter pad is installed.
FIG. 3 shows miniature electronic circuitry located on the electronics board 45. The purpose of the circuitry is to transform the low voltage, relatively high current source of the 9-volt battery 42 into high voltage (about 15,000 volts) at a low current to effect ionization at the emitter point 48. Essentially, the circuit is a switching step-up power supply. The slide switch 14 switches the power on and off. If an optional AC adaptor 32 is installed, a connector switch 28 that is part of the connector 18 interposes a first resistor 30 (R 1 ) between the AC adaptor 32 and the battery 42 to provide a trickle charge. The position of the connector switch 28 with the adapter 32 attached is shown dotted in FIG. 3.
When the slide switch 14 is closed, current from the positive pole of a current source, either the battery 42 or an optional AC adaptor 32, if it is attached to the device, flows through a first coil 33 (L 1 ), through a depletion mode metal oxide field effect transistor (MOSFET) 34 (Q 3 ), and through a second resistor 40 (R 2 ), with a preferred value of 10 ohms, to return to the current source. A high voltage (600 V) MOSFET such as BSS135 is preferentially employed for Q 1 , which acts as a switch.
The coil 33 (L 1 ) has an inductance of about 10 mH. As the current flows through the coil 33, a magnetic field forms and expands. The magnetic field intersects the windings of a second coil 35 (L 2 ) which surrounds the first coil 33. This changing magnetic field induces a voltage in the second coil 35. One leg of the second coil 35 is attached to the negative pole of the current source through a third resistor 31 (R 3 , 1.2 k ohm), while the other leg is attached directly to a gate 36 of the MOSFET 34. The third resistor 31 protects the gate 36 from excessive current flows.
The third resistor 31 normally holds the gate 36 negative. The MOSFET 34 conducts slightly operating in a constant current mode in a "pinched off" region. The second resistor 40 maintains the MOSFET in the "pinched off" region, thereby improving the sharpness of the switching and reducing the overall current drain of the circuit. However, the slight current flow in the first coil 33 induces a voltage in the second coil 35 temporarily overcoming the negative gate voltage. The gate 36 becomes briefly positive, causing the MOSFET 34 to conduct significantly. The magnetic field in the first coil 33 then increases, until it reaches a plateau, at this point the induced voltage disappears allowing the gate 36 to go negative, and causing the MOSFET 34 to return to conducting minimally, the magnetic field surrounding the first coil 33 collapses and the entire process starts over. Thus, the MOSFET/coil arrangement acts as an oscillator, known in the art as a blocking oscillator with a flyback transformer, which rapidly turns the current flow in the first coil 33 on and off.
Each time the magnetic field surrounding the first coil 33 collapses, the magnetic lines of force of the collapsing field interact with the coil's windings to induce a voltage pulse therein. Because the first coil has many windings, the induced voltage pulse has a much higher voltage-about 600 V--than does the battery 42. A first diode 37 (D 1 ) and a first capacitor 38 (C 1 ) form a path between the first coil and the positive pole of the current source.
In a preferred embodiment the first capacitor 38 (C 1 ) has a value of about 0.05 μF, and a diode such as IN4948 or a high efficiency diode such as HER 108 is used as the first diode 37. A third coil 39 (L 3 ) is connected between a first terminal of the first capacitor 38 and the positive pole of the current source. When the MOSFET 34 stops conducting, the high voltage pulse from the first coil 33 passes through the first diode 37 to a second terminal of the first capacitor 38, thereby charging it. As successive voltage pulses reach the first capacitor 38, the voltage potential difference between the second terminal of the capacitor 38 and the positive pole of the current source gradually increases.
A K3000 breakdown diode 50 (D 2 ) with a breakdown voltage of 350 V is connected between the second terminal of the first capacitor 38 and the positive pole of the current source. When the first capacitor 38 has charged to 350 V, the breakdown diode 50 suddenly begins to conduct discharging the first capacitor 38, thereby causing a voltage pulse through the third coil 39. The third coil 39 is actually the primary winding of an auto step-up trigger coil whose secondary coil comprises a fourth coil 51 (L 4 ).
As the 350 V pulses pass through the third coil 39, they induce high voltage pulses of about 15,000 V in the fourth coil 51. Actually, the high voltage pulses are induced with one polarity as the third coil 39 is energized (expanding magnetic field), and with an opposite polarity when the current flow through the third coil 39 ends (collapsing magnetic field).
The fourth coil 51 is connected to two 200 pF, 15 kV capacitors 52 (C 2 ) and 53 (C 3 ) through two high voltage diodes 55 (D 3 ) and 54 (D 4 ) arranged so that the reversing high voltage pulses alternately charge one and then the other of the two capacitors. This results in a negative potential of about 15,000 V in an emitter leg 56 of the circuit. The conductive needle comprising the emitter point 48 is connected to the emitter leg 56 through a fourth resistor 58 (R 4 ) which, in turn, is connected to a neon gas-discharge lamp 49 and a fourth capacitor 57 (C 4 ) connected in parallel to constitute a relaxation oscillator. The fourth resistor 58 preferably has a value of 22 megaohms and acts as an ion current limiting resistor both to protect the user from shock and to protect the MOSFET 34 from an excessive current flow should a conductive object be inserted through the grid 19. This configuration results in the neon lamp 49 visibly pulsating to give an indication of the high voltage corona discharge occurring on the emitter point 48. The pulse rate of the neon lamp 49 is a direct monitor of the rate of negative ion production. A weakening of the battery 42 can be detected as a lowering of the pulse rate.
As mentioned above, the emitter point 48 is located within the housing 11 of the device 10 in the ionization chamber 44. The opening to this chamber is covered by the metal grid 19 which is connected to the positive pole of the current source. Thus, ionized air molecules and ionized particulates are attracted to the grid 19 where they give up electrons to complete the circuit. The particulates remain attached to the grid 19 thus creating a need to occasionally clean off the grid 19. At the same time, this flow of ions creates a mass flow of air which propels a stream of purified, ozonated air in whichever direction the device is pointed.
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | A small, battery-powered air purifier can be clipped to a wearer's front shirt pocket or worn suspended from a cord about the wearer's neck. The device includes a housing containing a compact circuit that transforms direct current provided by the battery into a negative high voltage pulsating current which is connected to a sharp metal point contained within a chamber inside the hollow housing. A corona discharge forms on the sharp point, ionizing air molecules and any particulates, and generating ozone. An opening into the chamber is covered by a noncorrosive metal grid connected to the positive terminal of the battery. The negative ions are attracted to this grid, thereby completing an electrical circuit. Movement of the ions to the grid results in mass movement of air which causes a stream of air to emerge through the grid. As the air passes the grid, negatively charged particulates are deposited on the grid. The cleansed air stream, containing traces of ozone and negative ions, can be directed to flow across the face of the user, thereby limiting the contact of contaminated ambient air with the eyes and nasal passages of the user. An activated charcoal filter pad can be attached to the device to interact with the cleansed air stream to reduce the ozone level. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to the preparation of fiber suspensions for use in the making of paper, and while it was developed in connection with the preparation of waste paper products for recycling, it is also applicable to the treatment of wood pulp chips and other cellulosic fibrous materials.
The recycling of waste paper products in significant volume is much older than any patent now in force, but the most significant increase in its practice followed World War II when a major increase in the use of corrugated board containers made comparatively large amounts of used cartons available for recycling. Prior to that development, the waste paper products primarily subject to recycling were newspapers and other printed paper, which required deinking as a major stage in their preparation for reuse.
Large quantities of used corrugated cartons which became available for recycling following World War II posed a different preparation problem in that a great many had been assembled with the aid of asphaltic adhesives that were impossible to remove by any commercially feasible process. Further, the asphaltic adhesives tended to appear as substantial globs or smears on the surface of paper products made therefrom, and their use was therefore limited to low grade products such as low grade boxboard.
These problems were relatively successfully avoided by a technique which became known as "asphalt dispersion" by which the asphaltic materials were reduced to such small particle size and were so thoroughly dispersed in the stock that it could be used successfully in a wider variety of boxboard-type products, especially when provided with a cover layer of better grade stock. United States patents disclosing asphalt dispersion technology include Hollis U.S. Pat. Nos. 2,697,661 of 1954, and 2,977,274 of 1961, and Sandberg U.S. Pat. No. 3,057,769 of 1962.
Each of those patents taught that a preliminary step according to its technique was pulping the waste paper products in a conventional manner, followed by digestion under steam pressure to soften the thermoplastic asphaltic materials, and then by subjecting the digested pulp to a refining action, and all three patents show this action being carried out in a disk-type refiner. Each of these patents also taught that the system should include a cyclone for separating the steam from the digested pulp.
A somewhat different approach was proposed in another patent contemporaneous with Sandberg and the second Hollis patent, namely Durant U.S. Pat. No. 2,910,298 of 1959. In the system and method disclosed by Durant, the initial pulping operation was replaced by steps of shredding the waste paper material, cleaning the shredded material to the extent of removing tramp metal and other foreign objects by air-float cleaner apparatus, and then moistening the cleaned waste paper pieces before feeding them into a steam pressure digester. At the discharge end of the digester, Durant provided a different form of refining apparatus where in effect the digested waste paper was subjected to a combing action under steam pressure. The ultimate object was the same as in the Hollis and Sandberg patents, namely to reduce asphaltic contaminants into particles of minimal size and to distribute those particles throughout the fibers.
More recently, a joint development by Wisconsin Tissue Mills and Stake Technology Ltd. was described in a paper entitled "Steam Explosion Technology and Fiber Recycling" presented at a TAPPI conference in March of 1991. The system described in that paper and related literature includes a digesting chamber where high temperature and pressure are maintained throughout the dwell time, following which the cooked waste paper materials are discharged into air at atmospheric pressure and room temperature. The paper lists three runs in which the temperature range was 190° to 203° C., the dwell time was four minutes, and the pressure was approximately 400 psi. The process is described as resulting in particle sizes of residual contaminants of from 1/2 to 1/10 that of the contaminants in waste paper furnish produced by repulping without steam treatment.
SUMMARY OF THE INVENTION
According to the present invention, it has been discovered that important practical advantages can be achieved if waste paper products to be recycled are shredded, cleaned and moistened, but not pulped, and then after treatment with steam under moderate pressure and temperature conditions for a relatively short time interval, are discharged directly from the steam chamber into a vessel containing a substantial volume of aqueous liquid through an orifice which directs the resulting mixture of cellulosic fibers and steam against or below the surface of that liquid.
In particular, it has been discovered that the use of this technique not only results in a high degree of defibering of the paper materials without requiring preliminary pulping, but also the fibers thus treated show distinctively improved strength characteristics as compared with recycled waste paper products which have been defibered by the process described in the above TAPPI paper. Further, tests indicate that these results are obtained utilizing substantially lower temperature and pressure conditions than in the process described in the TAPPI paper.
The technology provided by the invention is also at least as effective as the process described in the TAPPI paper in that contaminant materials, such particularly as printing inks and adhesives, are reduced to very small particle sizes and also are physically separated from the paper fibers so that they can be readily washed out of the fiber suspension which results from the discharge of the cooked materials directly into a large volume of liquid. Indeed, tests indicate that the separation of such contaminants from the paper fibers is so complete that they can be effectively removed from the fiber suspension by washing and often without the necessity of froth flotation treatments such as have been found necessary in deinking processes according to conventional technology.
Further, while this invention was conceived and initially developed for application to the recycling of waste paper products, it is also applicable to the defibering of cooked wood pulp, and it offers the same advantage of increased fiber strength with such pulps as with waste paper pulps.
Other objects and advantages of the invention will be pointed out in or apparent from the description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view illustrating a continuous system embodying and for practicing the invention in the preparation of waste paper materials for reuse in the making of paper; and
FIG. 2 is a fragmentary section on a larger scale showing the connection between two components of the system in FIG. 1;
FIG. 3 is a diagrammatic view illustrating a modification of the system shown in FIG. 1; and
FIG. 4 is a diagrammatic view illustrating a system for practicing the process of the invention on a batch basis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the operation of the system shown in FIG. 1, waste paper materials from a supply source 10 are fed first to a shredder 11 of any suitable commercial type which will reduce the paper materials to pieces of a desired size such for example, as approximately 6 to 10 inches square. The shredded materials are then transmitted to a cleaner 12 of any suitable commercially available type which will effect reasonably complete separation of the paper and plastic materials from heavy contaminant pieces or particles such particularly as paper clips, staples and heavy trash of all kinds. Generally, this can be readily done by the use of a cleaner wherein air jets blow the paper and other light materials free of heavy trash.
At the next station 13, the shredded and cleaned waste paper materials are moistened by spraying before being dumped into a hopper 15. In the preferred practice of the invention, the moistening will be only enough to wet the paper materials but not to disintegrate them, e.g. to provide moistened materials with a solids content of the order of 50% or more as they are dumped into the hopper 15.
The chute 16 at the bottom of hopper 15 delivers the shredded, cleaned and moistened but still relatively dry paper materials into the inlet end of a feeder 20 capable of feeding the waste paper material into a pressure digesting chamber 22 without the loss of steam pressure from within the chamber 22. The precise nature of the feeder 20 is not material to the present invention. It is shown as a pressure feeder of the type disclosed in Beveridge U.S. Pat. No. 2,323,194 of 1947 and Kehoe U.S. Pat. No. 2,616,802 of 1952. A feed screw 23 having a drive 24 compresses the paper materials into plug form in the outlet pipe 24 to minimize loss of steam pressure from the tubular digester chamber 22. Alternatively, the feeder 20 could be a rotary valve such as is shown and described in Messing U.S. Pat. No. 3,130,879 of 1964. Steam at super-atmospheric pressure is continuously supplied to the digester 22 by a pipe 26.
The steam treatment chamber 22 is an elongated cylindrical tube wherein a conveyor screw 30 includes a shaft 31 which extends through one end of the tube and is provided with a drive indicated generally at 33. In the practice of the invention for recycling waste paper materials, the dwell time of material in the tube 22 may range from 15 seconds to 5 minutes, depending upon the temperature, which may also vary from as low as 180° F. to as high as 450° F., as further discussed hereinafter. The pitch and speed of screw 30 should be correspondingly designed and controlled.
At its downstream end, the tube 22 is connected by an open pipe 35 with a discharger 40, which is shown as of essentially the construction and mode of operation disclosed in the above Kehoe patent and Surino U.S. Pat. No. 2,882,967 of 1959. This discharger includes a valve assembly 41 mounted on the outside of the discharger housing 42 by a flange 43, and which includes a short tube 44 enclosing a replaceable wear sleeve 45 and having a flange 46 on its outer end. A pipe 47 connects the tube 44 with a tank 50 or other vessel of sufficiently large size to contain a substantial volume of aqueous liquid L, which can be fresh water or white water from elsewhere in the system, and which during operation of the system will comprise an aqueous suspension of the fibers and other solid constituents of the original feed materials.
It is essential to optimum use of the invention that the pipe 47 either connect with the tank 50 at a level sufficiently close to the bottom of the tank to be readily maintained below the liquid level within the container, or that it deliver the discharge therethrough directly against the surface of the liquid L from above, so that the mixture delivered through the pipe 47 impacts the liquid in tank 50. If, therefore, the pipe 47 connects with tank 50 above the level of the liquid L, it should be inclined downwardly so that the material discharged therefrom will directly impact the surface of the liquid.
The end of valve assembly 41 inside housing 42 includes a plate 51 which covers the end of tube 44 and has an orifice 52 therethrough aligned with tube 44. The effective size of orifice 52 can be adjusted by a shutter plate 53 which is fixed on one end of a shaft 54 journalled in the flanges 43 and 46. Adjusting movement of shutter plate 53 is effected by a worm 55 which meshes with gear 56 on shaft 54 and is itself mounted on flange 45 and provided with an operating handle 57. A vaned rotor 58 inside discharge 40 is driven by a motor 59 as described in the Kehoe and Surino patents to wipe the inlet end of orifice 52 periodically and thereby to keep it free of obstructing solids.
When the system shown in FIG. 1 is being operated continuously in the practice of the invention, a mixture of cooked paper materials and steam will be blown at high speed through the orifice 52 and wear sleeve 45. When this high speed jet strikes the liquid in the tank 50, its rate of travel will be so abruptly reduced that the bits, pieces and clumps of paper materials will be explosively disintegrated and distributed in the liquid in the tank 50 to form a suspension of essentially individual fibers. It is important that the pipe 47 be as short as possible, e.g. 12 inches, in order to minimize the distance that the jet travels before impacting liquid, and thereby to minimize the size of the gas bubble which forms before the steam component of the jet is absorbed in the liquid in tank 50.
The disintegrating action on the cooked materials which is produced as just described appears to be due not only to the shock effect of the deceleration of the solid materials as they strike the relatively stagnant liquid in tank 50, but also to mechanical effects created by their passage at high speed through the orifice 52. It appears that if this orifice is sufficiently restricted in flow area, as for example if it is of a square or diamond shape not more than about 1 inch on the side, skin friction will have a combing effect on the solids passing through the orifice which will initiate the disintegration that is completed by their deceleration in the liquid.
It is important for the purposes of the invention that the disintegration of the cooked materials as they are discharged through the orifice 52 and into the liquid in tank 50 is not limited to defibering, but is also highly effective in disintegrating contaminant materials such particularly as inks which comprise pigment material and an organic binder. More specifically, such inks are sometimes present as relatively large particles or "blobs" on the surface of waste paper material. The process of the invention is effective not only in separating such ink deposits from the paper fibers, but also in disintegrating ink particles of significant size into specks which are of such small size that they can readily be eliminated from the suspension of fibers by washing steps which are conventional in deinking processes.
Similar results have been noted in testing of the invention with respect to contaminant materials other than inks, such as organic adhesives which are commonly present on waste paper materials, and which also are separated from the paper fibers and so reduced in particle size that they can be readily eliminated by washing. In particular, hard contaminant particles, such as thermoset inks, are shattered into such small particles that they are readily removed in a subsequent washing step.
It is desirable that the suspension which is formed in the tank 50 not exceed a consistency range wherein it is freely pumpable. This objective is readily accomplished by continually adding fresh liquid, as indicated by a supply pipe 60 in FIG. 1, preferably at a rate which substantially balances in volume the amount of suspension which is continuously taken away by discharge pipe 61. It is another advantage of the invention that the steam which leaves the discharger 40 with the cooked paper materials is absorbed in the liquid in tank 50, it correspondingly heats the suspension taken away by pipe 61, which is desirable in the further treatment of the suspension, while the replacement liquid from pipe 60 need not be heated.
Since as noted above, the suspension produced in the tank 50 includes substantial quantity of small contaminant particles along with the fibers, it is desirable that the next stage of its treatment be at a screening station 65 where any large contaminant particles are separated from the fiber suspension, including pieces of sheet plastic which have been shriveled by the steam treatment so that they are easily removed by a screen of a type conventionally used in the treatment of paper making stock. The screening station 65 will normally be followed by a washing station 66, such as washing apparatus as described in Seifert U.S. Pat. No. 4,722,793 where the ink and other small contaminant particles are removed.
As noted above, the temperature, pressure and time of treatment in the digesting chamber 22 can vary over substantial ranges, depending upon the identity of the materials being subjected to the process. It is desirable, however, that the pressure and temperature conditions be kept well below those described in the above TAPPI paper, both to minimize cost and especially to minimize degradation of the paper fibers.
For example, comparative testing has been carried out wherein waste paper materials were treated in accordance with the invention for three minutes at 100 psi and 170° C. and were compared with similar waste paper products processed in accordance with the TAPPI paper for from two to five minutes at a temperature of 220° and pressure of 322 psi. Sample sheets made from the fibers produced by each of these processes indicated that the product of the process of the invention was distinctly superior in strength and also lighter in color, while the production cost was necessarily lower in view of the significantly lower pressure and temperature conditions.
For preferred results in the practice of the invention, it is important that the difference in pressures in the discharger 40 and the tank 50 be more than the critical value, i.e. the absolute pressure drop across the orifice 52 should be greater than 2 to 1. For example, if the tank 50 is vented to atmosphere, as indicated at 67, the pressure within the digester tube 22 and discharger 40 should be greater than approximately 30 psi. Under these conditions, the mixed steam and solid particles passing through the orifice 52 will constitute a jet traveling at the speed of sound when it impacts on or below the surface of the liquid in tank 50. It has been determined that under these operating conditions, the process is highly effective in defibering and otherwise disintegrating the solid materials is at an optimum.
It is also believed to be important to obtaining maximum advantages from the technology of the invention that the length of the passage from the orifice 52 to the liquid bath in tank 50 be as short as possible. More specifically, it is believed that if the cooked materials are discharged into a cyclone, as in the prior art systems and processes described hereinabove, the resulting comparatively prolonged exposure of defibered material to the heat of the steam carrying them to the cyclone is detrimental to fiber strength, as well as to color.
These undesirable results are believed to be accentuated if the length of the passage from the point where the cooked materials are released from cooking pressure to the point where they are separated from the steam is relatively long. In contrast, the preferred operating conditions for the process of the invention call for virtually instantaneous transfer of the mixture of solids and steam from the orifice 52 into the liquid in tank 50, and since that liquid can be kept relatively cool, by constant replacement of suspension with water at room temperature or less, there is virtually instantaneous cooling of all solids discharged from the digester.
Further, in addition to the shock of sudden deceleration of which the cooked materials are subjected when they are discharged into the large volume of liquid in the tank 50, the simultaneous release of the pressure thereon creates conditions of explosive decompression, which further contribute to the desired essentially complete defibering and dispersion. At the same time, another factor contributing to effective defibering is the mechanical action on the cooked materials as they are driven at high speed through the orifice 52. This mechanical effect can be multiplied by the modified system as shown in FIG. 3 as now described.
In FIG. 3 the tank 70 corresponds to the tank 50 in FIGS. 1 and 2, but instead of being vented to the atmosphere, provision is made for maintaining the liquid in tank 70 under positive pressure lower than is maintained within the cooking chamber 22. For example, if the steam pressure in chamber 22 is 300 psi, an air pressure pad may be maintained at 130 psi in the top of the tank 70, by a controlled pressure source 72. Since the pressure drop from discharger 40 to tank 70 will be more than critical, the solid materials passing through valve assembly 41 will be subjected to the same mechanical and shock forces described in connection with FIG. 1.
Then instead of discharging the contents of tank 70 directly to a washing station as in FIG. 1, the tank 70 may be connected by another valve assembly 41 and a pipe 74 to a second tank 75, the interior of which is maintained under positive pressure lower than that in tank 70, e.g. 45 psi, by a controlled pressure source 77. The flow of suspension from tank 70 is replaced by liquid, which can be water, as indicated at 78.
In passing from the tank 70 to the tank 75, the solid materials are again subjected to both the mechanical action of passing through an orifice and the shock of striking the relatively stagnant liquid in the tank 75, and these actions are repeated in passing through a third valve assembly 41 and a pipe 79 into a third tank 80, which may be vented to atmosphere at 81 and from which he suspension is withdrawn by a line 82 for further processing. These operations of repeated passage through an orifice at high speed into a relatively stagnant body of liquid cause repetition of the explosive decompression of the fibers if the particular mix of raw materials is found to be inadequately defibered in a system having a single tank 50 as described in connection with FIG. 1. As with tanks 50 and 70, the flow of suspension from each of tanks 75 and 80 is replaced by a liquid (water) supply line 83 and 84 respectively.
As previously noted, while the process of the invention was initially developed in connection with the preparation of paper making stock from waste paper materials, it is applicable to other fiber-containing materials such particularly as wood chips and other fibrous materials which are convertible into paper making fibers. When the process is to be practiced with wood chips, the shredding, cleaning and moistening stations 11-13 are not used, and the chips are delivered directly into the hopper 15 for passage into the feeder 20.
The treatment of chips in the digester tube 22 would require the addition of chemicals as well as steam, and the cooked chips would be supplied to the discharger 40 where they would be sufficiently broken up by the rotor 58, as described in the Kehoe patent, for discharge through the orifice 52 into the tank 50. The combined effect of high speed passage through the orifice 52 followed by impact on the relatively stationary pool of liquid in tank 50 will cause substantial defibering of the chips, although normally not as complete defibering as with waste paper materials as already described. The resulting suspension will then pass through a rough screening station 65 to the washing station 66 where the defibered chips are washed free of cooking liquor, for example in pulp washing apparatus such as is shown in Ericsson U.S. Pat. No. 4,154,644, followed by other processing stations conventional in converting cooked chips to paper making stock.
FIG. 4 illustrates diagrammatically a system for carrying out the process of the invention on a batch basis. The digester chamber 80 is provided at its upper end with a charging valve 82 through which a charge 83 of shredded, air classified and moistened waste paper material is delivered by a conveyor 84. Steam, and any necessary chemicals, are introduced to the top of chamber 80 by a supply line 85. At its lower end, the chamber 80 is provided with a discharge valve 88 having an orifice passage 90 therethrough, and an outlet pipe 92 leads from the valve 90 into the top of a vessel 93, which may be a pipe of substantial diameter, e.g. 12 inches, and which is connected at one end with a large tank 95 filled with liquid L to a level above its connection with the vessel 93.
With this system as shown in FIG. 4, after the charge in chamber 80 has been adequately stream-treated, for example from 2 to 4 minutes at 50 psi, the valve 88 can be shifted to its open position, or it can be oscillated so that the charge within chamber 80 will be discharged through the orifice passage 90 in periodic bursts. In either case, the mixture of steam and solid materials will be forced at high speed through the orifice passage 90 into the vessel 93, which is kept continuously filled with circulating liquid by a pump 96 that draws liquid from the tank 94 and recirculates some of that liquid to the upstream end of the vessel 93, as indicated by the line 97, to carry any uncondensed steam from valve outlet pipe 92 into the tank 95 while the remainder of the resulting suspension from the tank 95 is forwarded at 99 to the next station in the system.
While the processes herein described, and the forms of apparatus for carrying these processes into effect, constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise processes and forms of apparatus, and that changes may be made in either without departing from the scope of the invention, which is defined in the appended claims. | A process of preparing a suspension of paper making fibers in water for use in the making of paper includes the steps of treating a mass of fibrous materials, such as shredded waste paper materials, with steam under pressure in a closed vessel, and transferring the resulting mixture of treated materials and steam to a second vessel containing a substantial volume of aqueous liquid in such manner that the mixture impacts directly the liquid in the second vessel at very high velocity causing disintegration of the solid materials into essentially separate fibers and contaminant particles accompanied by dispersion of these solids in the liquid in the second vessel. Systems are described for carrying out these process steps on either a continuous or a batch basis. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to pharmaceutical compositions for treatment of acne. In particular, the present invention relates to stable pharmaceutical compositions for treatment of acne along with other pharmaceutically acceptable excipients. These compositions exhibit excellent stability, greater permeability, and enhanced therapeutic efficacy. The invention also relates to processes for the preparation of such compositions.
BACKGROUND OF THE INVENTION
[0002] Acne vulgaris is a skin condition that affects over 85% of all people. Acne is a term for a medical condition of plugged pores typically occurring on the face, neck, and upper torso. Following are four primary factors that lead to the formation of acne vulgaris; (1) increased sebum output resulting in oily, greasy skin; (2) increased bacterial activity normally due to an overabundance of Propionibacterium acnes bacteria; (3) plugging (hypercornification) of the follicle or pilosebaceous duct; and (4) production of inflammation by substances leaking into the dermis which cause inflammatory reactions. The plugged pores result in blackheads, whiteheads, pimples or deeper lumps such as cysts or nodules. Severe cases of acne can result in permanent scarring or disfiguring.
[0003] Acne occurs when the oil glands of the skin called sebaceous glands produce an increased amount of oil. The sebaceous glands are connected to canals in the skin called hair follicles that terminate in openings in the skin called pores. The increased amount of oil secreted by the sebaceous glands is caused by an increase in androgen hormones in both males and females during adolescence or puberty. Accompanying the increase in the amount of oil secreted by the sebaceous glands is an increase in the shedding of the skin lining the hair follicles. The increase in the amount of secreted oil in combination with the increase in the shedding of the skin lining the hair follicles increases the likelihood of the pores being clogged by the shedding skin. A pore clogged by the shedding skin is referred to as a comedo.
[0004] The Propionibacterium acnes ( P. acnes ) normally reside on the skin. The propionibacterium acnes invade the clogged follicles and grow in the mixture of oil and cells in the hair follicle. It produces chemicals that stimulate inflammation resulting in acne. Acne lesions range in severity from blackheads, whiteheads and pimples to more serious lesions such as deeper lumps, cysts and nodules.
[0005] In many instances, the inflammation within the acne lesion provides an opportunity for secondary infections to invade and grow in the inflamed hair follicle. Some of these secondary infections can be more serious and more resistant to treatment than the primary Propionibacterium acnes infection.
[0006] Various products and methods are currently available for treatment of acne. The only products that have anti-sebum activity are estrogens and 13 cis-retinoic acid (isotretinoin) and these must be used systemically to be effective. Isotretinoin is used to treat only severe cystic or conglobate acne (Anja Thielitz et al., JDDG, 6, 2008, Pp: 1023-1031). Because of its teratogenic properties, birth defects can occur. Isotretinoin is a powerful drug and can elevate triglycerides, total cholesterol and decrease high-density lipoproteins (HDL). Other side effects include dry skin, dry eyes, itching, headaches, nosebleed, and photosensitivity. It is generally taken for 4-5 months to see improvement. However, all topical retinoic acid preparations may be irritating, and this may contribute to underutilization in clinical practices (Cynthia E Irby et al., J. of Adolescent Health, 43, 2008, Pp-421-424). Recently, one brand of oral contraceptive has been approved for the treatment of acne for patients who request birth control.
[0007] A number of topical and systemic agents are used to lower the number of bacteria that colonize the follicular duct. These include benzoyl peroxide (BP), and BP (5%), erythromycin (3%) combination (Benzamycin®). BP has antibacterial activity and drying effects and is available over the counter or by prescription. BP is applied once or twice daily for 1-2 months. BP can produce erythema and peeling of skin. BP is often tried first for both non-inflammatory and mild inflammatory acne. Other topical antibiotics include clindamycin and erythromycin. It is known that the combination of topical antibiotic such as clindamycin with other topical agents is more therapeutically effective than either drug used alone (James Q. Del Rosso et al., Drug therapy Topics , Volume 85; January 2010, Pp: 15-24). These topical antibiotics are used as solutions, lotions or gels by prescription only. Usually they are applied once or twice daily and results are seen in 1-2 months. Another topical agent, azelaic acid 20% (Azelex®) also has mild antibacterial effects.
[0008] Systemic antibiotics include tetracycline and its analogs, which are used in low doses for years or until the end of the acne prone years. Most patients with mild inflammatory acne receive a combination of topical antibiotics and tretinoin or other retinoid. Application of topical antibiotic such as clindamycin gel after the pretreatment of skin with topical retinoid such as adapalene gel may contribute significantly to the increased efficacy of therapy (Gaurav K. Jain et al., Indian J Dermatol Venereol Leprol , September-October 2007, Vol-73(5), Pp: 326-329). Several clinical studies have also been performed earlier which demonstrates improved efficacy and tolerability of topical antibiotics and topical retinoids (John E. Wolf E. et al., J Am Acad Dermatol, 2009, Vol-49(3), Pp—S211-S217, and J. Z. Jhang et al., J of Derm Treat, 2004, Vol-15, Pp-372-378). Bacterial resistance does occur so antibiotics may be changed or BP is substituted since resistance does not occur with BP. More severe acne requires systemic antibiotics and topical retinoid. The most severe must receive oral isotretinoin for 4-5 months.
[0009] Various topical products containing combination of clindamycin phosphate and adapalene are available in market. For example, Deriva-CMS® Gel [marketed by Glenmark Pharmaceuticals Ltd.], Achilles®-C Gel [marketed by Sandoz Ltd.], Adaple®-C Gel [marketed by Wallace Pharmaceuticals Ltd.], Zudenina®-Plus Gel [marketed by Roemmers SAICF], Medapine®-AC Gel [marketed by Daiichi-Sankyo Co. Ltd.], and Faceclin®-A Gel [marketed by Piramal].
[0010] There are no drugs that directly affect the inflammatory acne. The retinoids do have some anti-inflammatory properties, but these are poorly described. Topical steroid and even systemic steroids have been used to abort a severe flare of fulminant acne, but these are limited uses because of the side effects. Benzoyl peroxide gels are sometimes used as first aid on acne lesions. These function as a “drawing poultice”, but data supporting this use is not available.
[0011] The treatment for acne centers around opening the pore, killing P. acnes , reducing sebum production and regulating inflammatory responses. Retinoids are the agents to reduce sebum production and open the pore. As a topical agent, adapalene (Differin®) or tretinoin (Retin-A®) is used for mild and moderate acne.
[0012] It is often advantageous to be able to deliver the drug over a period of time, such that a desired level of the drug in the target tissue is achieved for a period of time sufficient to achieve the desired result, e.g., killing most of a population of infectious bacterial. Dermatological conditions, such as acne, require multiple delivery strategies because they have multiple delivery requirements, such as killing skin surface bacteria while also penetrating deep into inflamed sebaceous glands to kill bacteria in that locus.
[0013] U.S. Patent Publication No. 2010/0015216 discloses composition for the treatment of acne comprising: a first therapeutic agent selected from the group consisting of salicylic acid, azelaic acid, adapalene, benzoyl peroxide, antibiotics and combinations thereof; and a second therapeutic agent which comprises a taurine species.
[0014] U.S. Pat. No. 5,962,571 discloses a pharmaceutical composition for the treatment of acne having an acne reduction component in an amount sufficient to reduce the redness and blemishes associated with acne.
[0015] U.S. Patent Publication No. 2010/0029781 discloses a method of preparing a solvent-microparticle (SMP) topical gel formulation comprising a bioactive drug wherein the formulation comprises the drug dissolved in a liquid and the drug in a microparticulate solid form dispersed in the liquid.
[0016] U.S. Patent Publication No. 2010/0068284 discloses a stable fixed dose topical formulation comprising therapeutically effective amounts of adapalene-containing microparticles and clindamycin. However, such formulation may not significantly reduce the incident and severity of acne lesions.
[0017] U.S. Pat. No. 5,629,021 discloses micellar nanoparticles and methods of their production.
[0018] U.S. Pat. No. 5,894,019 discloses topical compositions comprising lipid and essentially free of emulsifiers and surfactants.
[0019] European Patent No. EP 0671903 B discloses topical compositions in the form of submicron oil spheres.
[0020] Most of the topical preparations contain vehicles comprising permeation enhancers, solvents, and high amount of surfactants to achieve topical compositions for acne treatment. But use of these agents is harmful, especially in chronic application, as many of them cause undesirable effects such as irritation and dryness and resulting in poor patient tolerability.
[0021] In general, current products are effective in reducing the clinical observation of acne but it does not completely eliminate the condition, hence the consumer is not completely satisfied with results of these products.
[0022] Although various over-the-counter products are commercially available to counteract acne condition, such as anti-acne agents for topical use, including salicylic acid, sulfur, lactic acid, glycolic acid, pyruvic acid, urea, resorcinol, N-acetylcysteine, retinoic acid, isotretinoin, tretinoin, adapalene, tazoretene, antibacterials such as clindamycin and erythromycin, vitamins such as zinc, folic acid and nicotinamide, benzoyl peroxide, octopirox, triclosan, azelaic acid, phenoxyethanol, phenoxypropanol, and flavinoids, however, these agents tend to lack in potential to mitigate the acne condition and may have negative side effects when devised in conventional topical formulations.
[0023] Therefore, despite of the wide availability of products for acne, there exists a need to develop suitable topical preparations which facilitate drug permeation through the skin, exhibiting enhanced therapeutic activity and mitigating instance and severity of adverse events resulting from topical use of anti-acne agents. The topical preparation also ought to render improved tolerability to ensure successful acne therapy.
SUMMARY OF THE INVENTION
[0024] In one general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of one or more anti-acne agent/s or salts thereof.
[0025] In one general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of clindamycin or salts thereof.
[0026] In one general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of clindamycin and one or more anti-acne agent/s or salts thereof.
[0027] In another general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of clindamycin and adapalene or salts thereof.
[0028] In another general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of clindamycin and adapalene or salts thereof, wherein the amount of adapalene or salt thereof in the composition ranges from about 0.01% to about 0.3% w/w of and the amount of clindamycin or salt thereof in the composition ranges from about 0.5% to about 5.0% w/w of the composition.
[0029] In another general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of one or more anti-acne agent/s or salts thereof, wherein said composition comprises oil in amount ranging from about 5 to about 25% w/w of the composition.
[0030] In another general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of one or more anti-acne agent/s or salts thereof, wherein said composition comprises one or more emulsifier/s in amount ranging from about 0.1 to about 10% w/w of the composition.
[0031] In another general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of one or more anti-acne agents or salts thereof, wherein said composition comprises one or more emulsifier/s and oil in the weight ratio ranging from about 0.1:20 to about 0.1:1.
[0032] Embodiments of the pharmaceutical composition may include one or more of the following features. The pharmaceutical composition further may include one or more pharmaceutically acceptable excipients. For example, the pharmaceutically acceptable excipients may include one or more of lipids, oils, emulsifiers or surfactants, pH adjusting agents, emollients, humectants, preservatives, chelating agents, thickening agent, and the like.
[0033] In another general aspect there is provided a stable topical pharmaceutical composition comprising nano size droplets of one or more anti-acne agents or salts thereof, wherein the composition retains at least 80% potency of said ant-acne agent or salt thereof after storage for 3 months at 40° C. and 75% relative humidity.
[0034] D 90 particle size of droplets of anti-acne agent or salts thereof in the composition of the invention is less than about 500 nm, preferably about 250 nm, and more preferably about 100 nm.
[0035] Embodiments of the pharmaceutical composition may include one or more of the following features. The pharmaceutical composition further may include one or more pharmaceutically acceptable excipients. For example, the pharmaceutically acceptable excipients may include one or more of lipids, oils, emulsifiers or surfactants, pH adjusting agents, emollients, humectants, preservatives, chelating agents, thickening agent, and the like.
[0036] In another general aspect there is provided a stable topical pharmaceutical composition prepared by the process comprising:
[0000] a) combining an oily phase comprising one or more anti-acne agents or salts thereof along with other pharmaceutically acceptable excipients with an aqueous phase to form an emulsion;
b) reducing the particle size of emulsion of step a) to a droplet size having D 90 particle size of less than about 500 nm; and
c) mixing other pharmaceutically acceptable excipients to emulsion obtained in step b) and converting it into a suitable finished dosage form.
[0037] Embodiments of the pharmaceutical composition may include one or more of the following features. The pharmaceutical composition further may include one or more pharmaceutically acceptable excipients. For example, the pharmaceutically acceptable excipients may include one or more of lipids, oils, emulsifiers or surfactants, pH adjusting agents, emollients, humectants, preservatives, chelating agents, thickening agent, and the like.
[0038] In another general aspect there is provided a method for improving the local and systemic tolerability of anti-acne agents comprising administering a stable topical pharmaceutical composition comprising nano size droplets of one or more anti-acne agents or salts thereof.
[0039] The details of one or more embodiments of the invention are set forth in the description below. Other features, objects and advantages of the invention will be apparent from the description and claims.
BRIEF DESCRIPTION OF DRAWINGS
[0040] FIG. 1 : Overall assessment of tolerability at the end of the study.
[0041] FIG. 2( a ): Electron micrograph of Sample 1
[0042] FIG. 2( b ): Electron micrograph of Sample 2
[0043] FIG. 2( c ): Electron micrograph of Sample 3
[0044] FIG. 2( d ): Electron micrograph of Sample 4
[0045] FIG. 2( e ): Electron micrograph of Sample 5
[0046] FIG. 2( f ): Electron micrograph of Sample 6
DETAILED DESCRIPTION OF THE INVENTION
[0047] The inventors of the invention have surprisingly found that when anti-acne agents or salts thereof are formulated into nano size droplets in pharmaceutically acceptable emulgel (emulsion gel) system which includes optimized ratios of oils and/or emulsifiers, the composition exhibits enhanced therapeutic efficacy and also the composition is well tolerated (both locally and systemically) for the treatment of acne vulgaris.
[0048] Further, the inventors have found that advantageously the composition possess stable thermodynamic properties and do not have the problems of creaming, flocculation, coalescence or sedimentation, which are commonly associated with macro-emulsion, thus ensuring better stability and longer shelf-life of the resulting product.
[0049] Moreover, the composition of the invention results in immediate and sustained action, covering large surface area with less quantity and posses good spreadability. The composition is also non-irritant to skin and mucous membranes, requires reduced frequency of application, thus leading to improved patient compliance and offers cosmetic benefits like non-stickiness, and non-greasy feel.
[0050] The term “acne” includes inflammatory diseases of the pilosebaceous follicles and/or skin glands, and commonly is characterized by papules, pustules, cysts, nodules, comedones, other blemishes or skin lesions. The term “acne” as used herein includes all known types of acne. Some types of acne which can be treated with the composition of the present invention are, for example, acne vulgaris, acne comedo, papular acne, premenstrual acne, preadolescent acne, acne venenata, acne cosmetica, pomade acne, acne detergicans, acne excoriee, gram negative acne, pseudofolliculitis barbae, folliculitis, perioral dermatitis, hiddradenitis suppurativa, cystic acne, acne atrophica, bromide acne, chlorine acne, acne conglobata, acne detergicans, epidemic acne, acne estivalis, acne fulminans, halogen acne, acne indurata, iodide acne, acne keloid, acne mechanica, acne papulosa, pomade acne, premenstral acne, acne pustulosa, acne scorbutica, acne scrofulosorum, acne urticata, acne varioliformis, acne venenata, propionic acne, acne excoriee, gram negative acne, steroid acne, nodulocystic acne and acne rosacea.
[0051] The embodiments of the present invention relate to a topical pharmaceutical composition which comprises one or more anti-acne agents or salts thereof in the form of nano size droplets, such as a non-gel emulsion.
[0052] In a preferred embodiment, the nano size droplets of anti-acne agents or salts thereof posses a D 90 particle size of less than about 500 nm.
[0053] In a further embodiment, the nano size droplets of anti-acne agents or salts thereof posses a D 90 particle size of less than or equal to about 250 nm, and more preferably less than or equal to about 100 nm.
[0054] In a further embodiment, the composition of the present invention is stable and retains at least 80% potency of anti-acne agent when stored for at least three months at 40° C. and 75% relative humidity.
[0055] In a yet another embodiment, the topical pharmaceutical composition exhibits excellent local and systemic tolerability to anti-acne agents when administered in the form of nano sized droplets.
[0056] Anti-acne agent for the purpose of the present invention may be selected from, but not limited to one or more of adapalene, azelaic acid, benzoyl peroxide, salicylic acid, sulfur, lactic acid, glycolic acid, pyruvic acid, urea, resorcinol, N-acetylcystein, retinoic acid, octopirox, triclosan, phenoxyethanol, phenoxypropanol, clindamycin, erythromycin, tretinoin, isotretinoin, sodium sulfacetamide, tazarotene, spirinolacton, or salts thereof.
[0057] In a preferred embodiment, the composition comprises nano size droplets of clindamycin or salts thereof.
[0058] In a further preferred embodiment, the composition comprises a combination of at least two anti-acne agents or salts thereof.
[0059] In an embodiment the composition comprises a combination of clindamycin and adapalene or salts thereof.
[0060] In another embodiment, the weight ratio of adapalene to clindamycin in the composition ranges from about 1:5 to about 1:15.
[0061] In a further embodiment, the composition comprises about 0.5% to about 5.0% w/w, and preferably about 1.0% w/w of clindamycin or salt thereof (based on 100% total weight of the composition).
[0062] In a further embodiment, the composition comprises about 0.01% to about 0.3% w/w, and preferably about 0.1% w/w of adapalene or salt thereof (based on 100% total weight of the composition).
[0063] The composition of the present invention further comprises one or more pharmaceutically acceptable excipients selected from, but not limited to lipids, oils, emulsifiers/surfactants, initiators, pH adjusting agents, emollients, humectants, preservatives, and chelating agents.
[0064] The pH of the composition of the invention ranges from about 4.5 to about 7.0, and preferably from 5.0 to about 6.5.
[0065] Suitable lipids which can be used include one or more of hydrocarbons, fatty alcohols, fatty acids, glycerides or esters of fatty acids with C 1 -C 36 alkanols. Hydrocarbons may include paraffin or petroleum jelly. Fatty alcohols may include decanol, dodecanol, tetradecanol, hexadecanol or octadecanol. Fatty acids may include C 6 -C 24 alkanoic acids such as hexanoic acid, octanoic acid, decanoic acid, dodecanoic acid, tetradecanoic acid, hexadecanoic acid, octadecanoic acid, unsaturated fatty acids such as oleic acid and linoleic acid. Glycerides may include olive oil, castor oil, sesame oil, caprylic/capric acid triglyceride or glycerol mono-, di- and tri-esters with palmitic and/or stearic acid. Esters of fatty acids may include C 1 -C 36 alkanols such as beeswax, carnauba wax, cetyl palmitate, lanolin, isopropyl myristate, isopropyl stearate, oleic acid decyl ester, ethyl oleate and C 6 -C 12 alkanoic acid esters and the like.
[0066] Suitable oils may include one or more of almond oil, apricot seed oil, borage oil, canola oil, coconut oil, corn oil, cotton seed oil, fish oil, jojoba bean oil, lard oil, linseed oil, boiled macadamia nut oil, mineral oil, olive oil, peanut oil, safflower oil, sesame oil, soybean oil, squalane, sunflower seed oil, tricaprylin (1,2,3 trioctanoyl glycerol), wheat germ oil and the like. The preferred quantity of oil used is in the range of about 5 to about 25% w/w, and more preferably in the range of about 5% to about 20% w/w of the composition.
[0067] Suitable emulsifiers/surfactant may include one or more of ionic polysorbate surfactant, Tween® 20, Tween® 40, Tween® 60, Tween® 80, Nonylphenol Polyethylene Glycol Ethers, (alkylphenol-hydroxypolyoxyethylene), Poly(oxy-1,2-ethanediyl), alpha-(4-nonylphenol)-omega-hydroxy-, branched (i.e. Tergitol® NP-40 Surfactant), Nonylphenol Polyethylene Glycol Ether mixtures (i.e. Tergitol® NP-70 (70% AQ) Surfactant), phenoxypolyethoxyethanols and polymers thereof such as Triton®, Poloxamer®, Spans®, Tyloxapol®, different grades of Brij, sodium dodecyl sulfate and the like. The preferred quantity of the emulsifiers/surfactant used is in the range of about 0.1% to about 10% w/w of the composition.
[0068] In a preferred embodiment, the ratio of emulsifier or surfactant to oil in the pharmaceutical composition of the present invention ranges from about 0.1:20 to about 0.1:1, preferably about 0.1:10 to about 0.1:1.
[0069] Suitable pH adjusting agents which can be used include one or more of organic or inorganic acids and bases including sodium hydroxide, potassium hydroxide, ammonium hydroxide, phosphate buffers, citric acid, acetic acid, fumaric acid, hydrochloric acid, malic acid, nitric acid, phosphoric acid, propionic acid, sulfuric acid, tartaric acid and the like.
[0070] Suitable emollients which can be used include one or more of caprylic/capric triglycerides, castor oil, ceteareth-20, ceteareth-30, cetearyl alcohol, ceteth 20, cetostearyl alcohol, cetyl alcohol, cetyl stearyl alcohol, cocoa butter, diisopropyl adipate, glycerin, glyceryl monooleate, glyceryl monostearate, glyceryl stearate, isopropyl myristate, isopropyl palmitate, lanolin, lanolin alcohol, hydrogenated lanolin, liquid paraffins, linoleic acid, mineral oil, oleic acid, white petrolatum, polyethylene glycol, polyoxyethylene glycol fatty alcohol ethers, polyoxypropylene 15-stearyl ether, propylene glycol stearate, squalane, steareth-2 or -100, stearic acid, stearyl alcohol, urea and the like.
[0071] Suitable preservatives which can be used include one or more of phenoxyethanol, parabens (such as methylparaben and propylparaben), propylene glycols, sorbates, urea derivatives (such as diazolindinyl urea), and the like.
[0072] Suitable humectants which can be used include one or more of propylene glycol, glycerin, butylene glycol, sorbitol, triacetin and the like.
[0073] Suitable chelating agents which can be used include one or more of disodium EDTA, edetate trisodium, edetate tetrasodium, diethyleneamine pentaacetate and the like.
[0074] Suitable initiators which can be used include one or more of alcohols like C 1 -C 12 alcohols, diols and triols, glycerol, methanol, ethanol, propanol, octanol and the like.
[0075] In one embodiment, composition of the invention may be prepared by a) combining an oily phase comprising one or more anti-acne agents or salts thereof along with other pharmaceutically acceptable excipients with an aqueous phase to form an emulsion; b) reducing the particle size of emulsion of step a) to a droplet size having D 90 particle size of less than about 500 nm; and c) mixing other pharmaceutically acceptable excipients to emulsion obtained in step b) and converting it into a suitable finished dosage form.
[0076] The nano size droplets may be produced with reciprocating syringe instrumentation, continuous flow instrumentation, high speed mixing or high pressure homogenization. However, it will be appreciated to the person skilled in the art any known method of reducing the size of droplet may be adopted to serve the purpose of the present invention.
[0077] Small droplets of the nano emulsion may be formed by passing the emulsion through a homogeniser under different pressures ranging from 3,500-21,500 psi. The emulsion may be passed between 4-5 times under the same conditions to get a final D 90 droplet size of less than about 500 nm. The nano droplets formed may be filtered through 0.2 to 0.4 micron filter.
[0078] The gel base may be used in the present invention to form a gel matrix for the preparation of nanogel from nanoemulsion. The gel base comprises of one or more of thickening agents.
[0079] Suitable thickening agents which can be used include one or more of cellulose polymer, a carbomer polymer, a carbomer derivative, a cellulose derivative, polyvinyl alcohol, poloxamers, polysaccharides and the like.
[0080] Suitable dosage form of the invention may include cream, gel, ointment, lotion, liniment, paste, and emulsion.
[0081] In a preferred embodiment, the composition of the invention is in the form of gel.
[0082] The present invention further provides use of a pharmaceutical composition comprising one or more anti-acne agents or salts thereof in the form of nano size droplets for improving the tolerability to anti-acne agents for the treatment of acne vulgaris.
[0083] The efficacy and safety of the composition of the present invention was evaluated vis-à-vis other conventional gel formulation.
[0084] In one study, efficacy and safety of the composition of the present invention (containing 0.1% adapalene and 1% clindamycin) was evaluated vis-à-vis other marketed gel formulation (Deriva-CMS® Gel [marketed by Glenmark Pharmaceuticals Ltd.] containing 0.1% adapalene micro-spheres and 1% clindamycin). Significantly better reductions in total (79.7 vs. 62.7%), inflammatory (88.7 vs. 71.4%) and non-inflammatory (74.9 vs. 58.4%) lesions were reported with the composition of the present invention as compared to the marketed formulation (P<0.001 for all). Mean acne severity score also reduced significantly more with the nano-emulsion formulation (1.9±0.9 vs. 1.4±1.0; P<0.001) than the comparator. Significantly lower incidence and lesser intensity of adverse events like local irriation (4.2% vs. 19.8%; P<0.05) & erythema (0.8% vs. 9.9%; P<0.05) were recorded with the composition of the present invention. FIG. 1 shows the overall assessment of the tolerability.
[0085] In another study, efficacy and safety of the composition of the present invention (containing 1% clindamycin phosphate) was evaluated vis-à-vis other marketed gel formulation (Clindac-A® Gel [marketed by Galderma International] containing 1% clindamycin phosphate). Reductions in inflammatory (73.4 vs. 60.6%; P<0.005) and total (69.3 vs. 51.9%; P<0.001) acne lesions were reported to be significantly greater with the composition of the present invention as compared to the marketed formulation. Significantly more reduction in the mean acne severity score was noticeable with the composition of the present invention (1.6±0.9 vs. 1.0±0.8; P<0.001) than the comparator. A comparable or slightly better safety profile of the composition of the present invention was reported.
[0086] Thus, it is concluded that the composition of the present invention is more effective in reducing total number and severity of lesions including inflammatory and non-inflammatory lesions and is better tolerated (both locally and systemically) than the marketed formulation. The composition of the present invention was also found to reduce the incidence and severity of adverse events resulting from its application when compared with the adverse events resulting from application of the marketed formulation.
[0087] The invention is further illustrated by the following examples which are provided to be exemplary of the invention and do not limit the scope of the invention. While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention.
Example 1
Clindamycin Phosphate Nano Emulsion
[0088]
[0000]
TABLE 1
Sr. No.
Ingredients
% w/w
1
Clindamycin Phosphate
1.00-4.00
2
Polysorbate 80
4.00-8.00
3
Glycerol
7.00-13.00
4
Soyabean oil
14.00-20.00
5
Disodium EDTA
0.05-1.50
6
Vitamin E Acetate
0.05-0.50
7
Water
Q.S.
Procedure:
[0089] Clindamycin phosphate was dissolved in water, polysorbate 80, glycerol, vitamin E acetate and soyabean oil. The resulting blend was homogenized to reduce the droplet size to D 90 particle size of about 250 nm with the help of high pressure homogenization to get the nano emulsion.
Example 2
Clindamycin Phosphate Nanogel
[0090]
[0000]
TABLE 2
Sr. No.
Ingredients
% w/w
1
Clindamycin Phosphate
1.2
2
Adapalene
0.1
3
Polysorbate 80
3.0
4
Glycerol
5.0
5
Soyabean oil
9.0
6
Carbopol 974P
1.0
7
Sodium Hydroxide
Q.S.
8
Water
Q.S.
Procedure:
[0091] Clindamycin phosphate was dissolved in water, alcohol, polysorbate 80, glycerol and soyabean oil. The resulting blend was homogenized to reduce the droplet size to D 90 particle size of about 250 nm by high pressure homogenization to get the nano emulsion. Adapalene was dispersed in alcohol and aqueous dispersion of carbopol 974P followed by suitable pH adjustment using Sodium hydroxide solution. The aqueous dispersion of carbopol 974P was mixed with nano emulsion to get nanogel.
Example 3
Clindamycin Phosphate Nanogel
[0092]
[0000]
TABLE 3
Sr. No.
Ingredients
% w/w
1
Clindamycin Phosphate
0.50-3.00
2
Alcohol
3.00-7.00
3
Polysorbate 80
1.00-5.00
4
Glycerol
3.00-7.00
5
Soyabean oil
7.00-11.00
6
Disodium EDTA
0.05-0.50
7
Vitamin E Acetate
0.05-0.50
8
Carbopol 974P
0.50-3.00
9
Water
Q.S.
Procedure:
[0093] Clindamycin phosphate was dissolved in water, alcohol, polysorbate 80, glycerol, soyabean oil, vitamin E acetate and disodium EDTA. The resulting blend was homogenized to reduce the droplet size to D 90 particle size of about 250 nm with the help of high pressure homogenization to get the nano emulsion. Sodium hydroxide solution was added to aqueous dispersion of Carbopol 974P to adjust the pH and finally it was mixed with nano emulsion to get nanogel.
Example 4
Clindamycin Phosphate Nano Emulsion
[0094]
[0000]
TABLE 4
Quantity
Sr. No.
Ingredients
% w/w
1
Clindamycin Phosphate
1.200
2
Polysorbate 80
3.000
3
Glycerol
5.000
4
Soybean oil
9.000
5
Disodium EDTA
0.250
6
Vitamin E Acetate
0.100
7
Carbopol 974P
1.500
8
Sodium Hydroxide
0.332
7
Water
Q.S.
Procedure:
[0095] Clindamycin phosphate was dissolved in water, polysorbate 80, glycerol, soybean oil, vitamin E acetate and disodium EDTA. The resulting blend was homogenized to reduce the droplet size to D 90 particle size of about 250 nm with the help of high pressure homogenization to get the nano emulsion. Sodium hydroxide solution was added to aqueous dispersion of Carbopol 974P to adjust the pH and finally it was mixed with nano emulsion to get nanogel.
Example 5
Freeze-Fracture Electron Microscopy of the Nanogel Composition
Preparation Procedure—
[0096] For freeze-fracture electron microscopy, the samples (total 6) of nanogel composition were quenched using sandwich technique and liquid nitrogen-cooled propane. Using this technique a cooling rate of 10,000 Kelvin per second is reached avoiding ice crystal formation and artifacts possibly caused by the cryofixation process. The cryo-fixed sample was stored in liquid nitrogen for less than 2 hours before processing. The fracturing process was carried out in JEOL JED-9000 freeze-etching equipment and the exposed fracture planes were shadowed with Pt for 30 sec in an angle of 25-35 degree and with carbon for 35 sec (2 kV/60-70 mA, 1×10 −5 Torr). The replicas produced this way were cleaned with concentrated, fuming HNO 3 for 24 hours followed by repeating agitation with fresh chloroform/methanol (1:1 by vol.) at least 5 times. The replicas cleaned this way were examined at a JEOL 1200 EX transmission electron microscope.
[0000] Size distribution of nanogel droplets is summarized in Table 5.
[0000]
TABLE 5
ORIGINAL
Sr.
MAG.
100 nm = X
No.
NEGATIVE #
[K]
FINAL MAG.
[mm]
1
Sample 1
13.1
39.150
3.9
2
Sample 2
13.1
37.845
3.8
3
Sample 3
13.1
44.370
4.4
4
Sample 4
19.3
69.480
6.9
5
Sample 5
19.3
57.900
5.8
6
Sample 6
19.3
54.040
5.4
[0097] As visible from the electron micrographs of Sample 1 to 6 [ FIG. 2( a ) to 2 ( f ) respectively) taken from several freeze-fracture preparations, the sample contains high concentration of fine substructures (below 20 nm in diameter). They appear frequently singular but also form larger superstructures (between 20 and 150 nm in diameter).
Example 6
Stability Study on Clindamycin Phosphate Nanogel Composition
[0098]
[0000]
TABLE 6
% Drug in the formulation
Sr. No.
Initial
1 Month
2 Month
3 Month
1
100.6%
101.80%
100.60%
93.1%
2
102.7%
101.6%
96.8%
98.5%
3
108.2%
105.5%
100.7%
99.2%
[0099] Table 6 provides stability data of Clindamycin phosphate nanogel composition when stored at 40° C. and 75% relative humidity for three months and indicates that the composition remains stable and retains at least 80% potency of clindamycin phosphate over the storage period.
Example 7
Stability Study on Clindamycin Phosphate and Adapalene Nanogel Composition
[0100]
[0000]
TABLE 7
% drug in the formulation
9
3
6 Month
Month
Sr. No.
Initial
1 Month
2 Month
Month
CRT
CRT
1
Clindamycin
100.5%
96.70%
98.6%
96.0%
ND
ND
Adapalene
102.7%
97.50%
93.9%
95.6%
ND
ND
2
Clindamycin
101.8%
100.40%
96.4%
95%
98.90%
95.35
Adapalene
95.8%
97.70%
93.2%
93.60%
95.30%
95.05
3
Clindamycin
100.2%
97.70%
98.5%
95.8
97.60%
96.85
Adapalene
101.3%
98.50%
98.9%
98.30%
100.80%
99.5
[0101] Table 7 provides stability data of Clindamycin phosphate and Adapalene nanogel composition when stored at 40° C. and 75% relative humidity for three months and at 20° C. and 60% relative humidity from sixth to nine months. The data indicates that the composition remains stable and retains at least 80% potency of clindamycin phosphate and adapalene over the storage period.
[0102] While the invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the invention. | The present invention relates to pharmaceutical compositions for treatment of acne. In particular, the present invention relates to stable pharmaceutical compositions for treatment of acne along with other pharmaceutically acceptable excipients. These compositions exhibit excellent stability, greater permeability, and enhanced therapeutic efficacy. The invention also relates to processes for the preparation of such compositions. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation Application to U.S. Ser. No. 10/427,716, filed on Apr. 30, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a method of making polymer packages, for example, plastic bags. In particular, the present invention relates to a methods and apparatuses relating to closure mechanisms for a resealable bag.
BACKGROUND OF THE INVENTION
[0003] Many packaging applications use resealable containers to store various types of articles and materials. These packages may be used to store and ship food products, non-food consumer goods, medical supplies, waste materials, and many other articles. Resealable packages are convenient in that they can be closed and resealed after the initial opening to preserve the enclosed contents. The need to locate a storage container for the unused portion of the products in the package is thus avoided. As such, providing products in resealable packages appreciably enhances the marketability of those products.
[0004] Resealable packages typically utilize a closure mechanism that is positioned along the mouth of the package. The closure mechanism often comprises profile elements or closure profiles that engage one another when pressed together. Typically a slider device used for opening the closure mechanism is attached to the closure mechanism while the closure profiles are disengaged. This facilitates filling of the package with product after the slider is attached. However, attaching the slider to a closure mechanism in an open state results in difficulty in handling and aligning the pair of closure profiles during manufacturing. If the slider device is attached to the closure mechanism while the closure mechanism is closed, the closure mechanism must be opened before the package can be filled. Prior methods of opening the closure mechanism, including manually opening the closure mechanism, have proved to be inefficient from a manufacturing standpoint.
[0005] It is therefore desirable to attach the slider device to the closure mechanism while the closure mechanism is in a closed state, and to provide a method and apparatus for automatically opening the closure mechanism after the slider device has been attached. Alternately, the slider device may be attached after the closure mechanism has been opened. Further, the opening methods and apparatus of the present invention can be applied to a closure mechanism without a slider, such as a traditional “press-to-close” zipper.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, a method of making a resealable package is provided. The method comprises providing a closure mechanism, the closure mechanism comprising first and second closure profiles, the first and second closure profiles constructed and arranged to selectively engage, and wherein the first and second closure profiles are engaged. The method further comprises providing a pair of panels comprising a flexible polymeric material, providing a means to open the closure profiles, such as inserting a wedge between the closure profiles, to disengage the closure profiles; and attaching the closure mechanism to the pair of side panels. The opening of the closure profiles and attachment of the closure mechanism to the side panels may occur substantially simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For the present invention to be clearly understood and readily practiced, the present invention will be described in conjunction with the following figures, wherein like reference characters designate the same or similar elements, which figures are incorporated into and constitute a part of the specification, wherein:
[0008] The various features and benefits of the present invention are apparent in light of the following detailed description and the accompanying drawings, in which:
[0009] FIG. 1 is a perspective view of a flexible, resealable package manufactured in accordance with an embodiment of the present invention.
[0010] FIG. 2 is a schematic view of a process of manufacturing a resealable package in accordance with an embodiment of the present invention.
[0011] FIG. 3 is a perspective view of a slider attachment device and a device for opening a closure mechanism used in accordance with an embodiment of the present invention.
[0012] FIG. 4 a is a top view of the device for opening a closure mechanism illustrated in FIG. 3 .
[0013] FIG. 4 b is an elevated, side view of the device for opening a closure mechanism illustrated in FIG. 3 .
[0014] FIG. 4 c is an alternate perspective view of the device for opening a closure mechanism illustrated in FIG. 3 .
[0015] FIG. 4 d is an cross-sectional view of the device for opening a closure mechanism illustrated in FIG. 3 taken along line 4 d - 4 d (shown in FIG. 4 b ).
[0016] FIG. 5 is an elevated, side view of a alternate device for opening a closure mechanism used in accordance with an embodiment of the present invention.
[0017] FIG. 6 a is an elevated, side view of a wedge used as part of the device for opening a closure mechanism illustrated in FIG. 5 .
[0018] FIG. 6 b is an elevated, end view of a wedge used as part of the device for opening a closure mechanism illustrated in FIG. 5 .
[0019] FIG. 6 c is a perspective view with a cross-sectional view insert showing an alternate embodiment of a wedge that can be used in conjunction with the apparatus and methods described herein.
[0020] FIG. 6 d is a schematic frontal view of the plow and guide legs of the wedge shown in FIG. 6 c.
[0021] FIG. 6 e is a perspective view showing the relational position between the wedge of FIG. 6 c and a closure mechanism prior to opening the closure mechanism.
[0022] FIG. 6 f is a perspective view showing the wedge of FIG. 6 c passing into a closure mechanism to separate the closure profiles thereby opening the closure mechanism.
[0023] FIG. 7 is an elevated, side view of the device for opening a closure mechanism illustrated in FIG. 5 , illustrating its operation.
[0024] FIG. 8 is an elevated, side view of a alternate device for opening a closure mechanism used in accordance with an embodiment of the present invention.
[0025] FIG. 9 is a top view of the device for opening a closure mechanism illustrated in FIG. 8 .
[0026] FIG. 10 a is an end view of the device for opening a closure mechanism illustrated in FIG. 8 .
[0027] FIG. 10 b is an end view of the device for opening a closure mechanism illustrated in FIG. 8 , illustrating the use of sealing bars in accordance with an embodiment of the present invention.
[0028] FIGS. 11 a - c are cross-sectional views of an opening device and method that employ a perpendicular external force to open a closure mechanism.
[0029] FIG. 12 is a cross-sectional view of an opening device and method that use a channel wedge to open a closure mechanism.
DETAILED DESCRIPTION OF THE INVENTION
[0030] FIG. 1 illustrates an example of a resealable, flexible package 20 having a closure mechanism 41 with first and second closure profiles 23 , 25 and a slider device 11 to open and close the profiles 23 , 25 .
[0031] The resealable package 20 includes first and second opposed panel sections 31 , 33 made from a flexible, polymeric film. For some manufacturing applications, the first and second panel sections 31 , 33 are heat-sealed together along two edges 35 , 37 and meet at a fold line 39 in order to form a three-edged containment section for a product within the interior of the package 20 . The fold line comprises the bottom edge 39 . Alternatively, two separate panel sections 31 , 33 of polymeric film may be used and heat-sealed together along the two edges 35 , 37 and at the bottom 39 .
[0032] The resealable package 20 also includes a closure mechanism 41 made in accordance with an embodiment of the present invention. The closure mechanism 41 includes first and second closure profiles 23 , 25 . The first and second closure profiles 23 , 25 may be of any appropriate design known in the art. Example closure profiles are disclosed in U.S. Pat. Nos. 5,983,466, 5,947,603, and 6,217,215.
[0033] In certain embodiments, a slider device 11 is mounted on the closure mechanism 41 to facilitate the opening and closing of the closure mechanism 41 . Slider devices and how they function to open and close such mechanisms, in general, are taught, for example, in U.S. Pat. Nos. 5,063,644, 5,301,394, 5,442,837 and 5,664,229, each of which is incorporated by reference herein, in its entirety. A preferred slider device is taught in U.S. Pat. Nos. 6,293,701 and D434,345 each of which is incorporated by reference herein, in its entirety.
[0034] In embodiments that include a slider device, a notch 52 is preferably disposed within the closure mechanism 41 . The notch 52 is designed to provide a “park place” into which the slider 11 settles when the closure mechanism 41 is sealed. The notch 52 decreases the chances of an incomplete interlock between the first and second closure profiles 23 , 25 . Example notches are disclosed, for example, in U.S. Pat. Nos. 5,067,208 and 5,301,395, each of which is incorporated by reference herein, in its entirety.
[0035] FIG. 2 illustrates a schematic example of a horizontal form, fill and seal (“HFFS”) process for manufacturing a resealable package 20 in accordance with the present invention. The HFFS process described in U.S. Pat. No. 6,293,896, which is incorporated by reference herein, in its entirety, is substantially similar to that described and shown herein with the obvious variation that the package of the present invention is inverted (i.e. the formation and filling in the present invention is from the top) whereas the formation and filling in the '896 patent occurs from the bottom. The first and second closure profiles 23 , 25 (not shown individually in FIG. 2 ) are provided in an engaged configuration as a continuous length of closure profile material 50 . Preferably, the closure mechanism material 50 is provided on a roll (not shown). The closure mechanism material 50 is unwound and fed to the HFFS process.
[0036] The slider 11 is attached to the closure mechanism material 50 by a slider application station 60 . The slider application station 60 applies the slider 11 to the closure mechanism material 50 through the use of any appropriate means known in the art, for example, the apparatuses as described in U.S. Pat. Nos. 6,199,256 and 6,293,896, each of which are hereby incorporated by reference herein, in its entirety. The slider application station 60 may also be used to notch the closure profile material in order to provide the notch 52 (as shown in FIG. 1 ), as disclosed in U.S. Pat. No. 6,199,256.
[0037] After the slider 11 is applied to the closure mechanism material 50 , the closure mechanism material 50 passes to the HFFS machine 250 . The material that comprises the side panels 31 , 33 of resealable package 20 (as shown in FIG. 1 ) is provided on a roll 220 . The material is unwound and may optionally pass to perforators 230 that score the material to facilitate later removal of a header section 101 . The material then passes over a folding board 245 (as is known in the art) to form the two side panels 31 , 33 . The folding board 245 may include a slitter (not shown), if e.g. the HFFS machine is operated in a different orientation.
[0038] In the embodiments of the invention illustrated in FIGS. 3-8 , the first and second closure profiles 23 , 25 are disengaged by the closure mechanism opening apparatus 70 prior to the closure mechanism material 50 being attached to the first and second side panels 31 , 33 . Alternately, the closure mechanism may be disengaged substantially simultaneously with the closure mechanism being attached to the side panels (i.e. disengagement and attachment as a single step), or disengagement may even occur after attachment to the side panels.
[0039] An example closure mechanism opening apparatus 70 is illustrated in FIGS. 4 a - 4 d . The closure mechanism opening apparatus 70 comprises a rod 76 and a piston 72 that causes selective reciprocating movement of the rod 76 . A preferred rod 76 and piston 72 are manufactured by DE-STA-CO Industries, 31791 Sherman Drive, Madison Heights, Mich. 48071, Model 816, made of steel and aluminum. The rod 76 and piston 72 are preferably mounted on a stand-off base 74 .
[0040] The rod 76 is operably connected to a wedge 80 such that as rod 76 moves, the wedge 80 moves. For example, if the piston is activated to move the rod in a reciprocating manner, the wedge would move in a similar manner. As best shown in FIG. 4 d , the wedge 80 is preferably tapered along its bottom edge to allow it to penetrate between the closure profiles 23 , 25 . A set of guide members 82 are attached at both ends of the wedge 80 . The guide members 82 act to align the closure mechanism material 50 as it passes through the closure mechanism opening apparatus 70 . The guide members 82 are preferably designed and arranged to allow the closure mechanism material 50 to pass between them and align the closure mechanism material 50 beneath the wedge 80 or in similar proximity to the wedge, depending on the spatial orientation of apparatus 70 . The guide members 82 are attached to the wedge 80 by any means known in the art, for example, by machined screws or by welding. Alternatively, the wedge 80 and guide members 82 may be formed integrally.
[0041] The closure mechanism opening apparatus 70 further comprises a three-sided guide channel 78 . The guide channel 78 preferably has a support blade 84 attached to one of its sides as best seen in FIG. 4 d . The stand-off base 74 is attached to the top of guide channel 78 , which has an aperture 81 through its top side as shown in FIG. 4 a . In this way, the selective reciprocating movement of the rod 76 causes the wedge 80 and guide members 82 to move up and down through the aperture 81 in the top of the guide channel 78 .
[0042] Preferably, the closure mechanism opening device 70 further includes a support blade 84 that is designed and arranged such that when the closure mechanism material 50 passes through the guide channel 78 , the closure mechanism material 50 straddles or rides on the blade 84 , which supports the closure mechanism material 50 . As stated previously, the blade 84 preferably assists in aligning the closure mechanism material 50 beneath the wedge 80 .
[0043] In operation, a length of the closure mechanism material 50 that corresponds to the length of a resealable package 20 passes into the guide channel 78 , on top of blade 84 . The progress of the closure mechanism material 50 is stopped. The piston 72 is then actuated whereby the rod 76 is extended. This causes the wedge 80 and guide members 82 to be moved through the aperture 81 of the top of the guide channel 78 . The guide members 82 are forced along the outside of the closure mechanism material 50 , and the wedge 80 is disposed between the closure profiles 23 , 25 . As the wedge 80 is moved downward by the rod 76 , the wedge 80 forces closure profiles 23 , 25 to disengage along the length of the wedge 80 . The wedge 80 is then withdrawn from the closure mechanism material 50 . The opened closure mechanism material 50 is then advanced in an opened state for further processing, as is described below.
[0044] An alternate example embodiment of a closure mechanism opening apparatus 70 is illustrated in FIGS. 5-7 . In this embodiment, the guide channel 78 and the blade 84 are designed and function in a similar manner as in the embodiment illustrated in FIGS. 3-4 d . The closure mechanism opening apparatus 70 further comprises a piston 92 , a brace 98 , and a wedge 100 . The piston 92 includes a rod 96 that may move in a selective reciprocating manner. In this embodiment, the wedge 100 is generally shaped as a sector of a circle as shown in FIG. 6 a . The wedge 100 includes an arm 106 that extends from the corner of the sector that would otherwise correspond with the center of the circle from which the sector would be taken. The arm 106 includes an opening 108 through which a pin or rod may be inserted in such a way as to allow the wedge 100 to rotate around such a pin or rod. The arm 106 is operably connected to the rod 96 such that when the rod 96 is extended from the piston 92 , the wedge 100 rotates, preferably in the direction of the arrow R shown in FIG. 7 . Likewise, when the rod 96 is withdrawn, the wedge 100 will rotate in a direction opposite that in which it rotates when the rod 96 is extended. The wedge 100 is preferably attached to the channel 78 by a brace 98 . In the embodiment illustrated in FIG. 5 , the brace 98 includes an opening that may be aligned with the opening 108 through the wedge 100 . In this way, a pin or rod that is inserted through the opening 108 also serves to attach the wedge 100 to the brace 98 . The brace 98 is also preferably attached to the piston 92 by way of brackets 94 , 95 .
[0045] As best shown in FIG. 6 b , the curved edge 102 of the wedge 100 is tapered so that its leading edge 101 narrows to a point. The curved edge 102 also includes a pair of guide members 104 that are adjacent the leading edge 101 . Similar to the embodiment described above, and as shown in FIG. 7 , a length of the closure mechanism material 50 that corresponds to the length of a resealable package 20 passes into the guide channel 78 , on top of blade 84 . The progress of the closure mechanism material 50 is stopped. The piston 92 is then actuated whereby the rod 96 is extended. This causes the wedge 100 , including guide members 104 , to rotate through an aperture (not shown) in the top of the guide channel 78 . The guide members 104 are forced along the outside of the closure mechanism material 50 , and the curved edge 102 of the wedge 100 is disposed between a portion of the length of the closure profiles. As the wedge 100 rotates, the curved edge 102 of the wedge 100 forces closure profiles to disengage. After the closure profiles disengage, the wedge 100 rotates in the opposite direction, thereby withdrawing from the closure mechanism material 50 . As one skilled in the art will recognize, an alternate embodiment to that illustrated in FIGS. 5-7 would be a blade designed to rotate in a complete 360° arc as it passes through the closure mechanism to disengage the closure profiles. The opened closure mechanism material 50 is then advanced in an opened state for further processing, as is described below.
[0046] FIGS. 6 c - f illustrate an alternate embodiment of a wedge 200 for use with the opening apparatus 70 , for example, as shown in FIG. 5 . As described above, the various methods of opening a closure mechanism with the embodiment illustrated in FIGS. 5-7 may include both reciprocal and rotational movement of the wedge ( 100 , 200 ). For example, reciprocal movement is such that the wedge enters the closure mechanism in one direction (e.g. “R” in FIG. 7 ) and, after opening the closure mechanism, is removed from the closure mechanism in the opposite direction. Rotational movement of the wedge ( 100 , 200 ) occurs by rotating the wedge ( 100 , 200 ) with a controlled mechanical rotating device (not shown) such that the wedge moves in circular direction and passes into and out of the closure mechanism as the wedge ( 100 , 200 ) scribes an arc at some aspect of circle “C” as depicted in FIG. 6 e - f.
[0047] With reference to FIG. 6 c , wedge 200 is shown consisting of a body 210 , an opening plow 220 and guide legs 230 , 232 . As shown FIG. 6 d , the plow 220 is preferably centered along a travel path “P” passing between guide legs 230 , 232 . This arrangement of the plow 220 with the guide legs 230 , 232 facilitates the cooperation of these structures such that during operation the guide legs 230 , 232 capture the closure mechanism and align the plow 220 to pass into the closure mechanism thereby opening the closure mechanism. It is preferable if the plow 220 has a tapered leading edge to facilitate its entry into the closed closure mechanism.
[0048] As further illustrated in FIGS. 6 d - 6 f , the wedge 200 is preferably rotated into the closure mechanism material 50 to thereby separate (open) closure profiles 23 , 25 . After opening, the opened closure mechanism can be advanced for further processing (e.g. attachment, filling, etc.).
[0049] A further preferred embodiment of the invention is illustrated in FIGS. 8-10 b . In this embodiment, the guide channel 78 and the blade 84 are designed and function in a similar manner as in the embodiments described above. In this embodiment, the channel 78 may also include an opening 79 (e.g. shown in FIGS. 10 a - 10 b ) through which a pair of sealing bars, 130 , 132 may pass, as described below. In this embodiment, the closure mechanism opening apparatus 120 comprises a rod 124 and a piston 122 that causes selective reciprocating movement of the rod 124 . A preferred rod 124 and piston 122 are manufactured again, by DE-STA-CO Industries.
[0050] In the embodiment illustrated in FIGS. 8-10 b , the wedge 126 is generally cylindrical in shape, although one end may be tapered to facilitate opening of the closure mechanism material 50 . The piston 122 and rod 124 are held in place above the guide channel 78 by brace 134 .
[0051] This embodiment may take advantage of the fact that, when certain types of sliders 11 are attached to the closure mechanism material 50 , a small opening 51 (as shown in FIG. 9 ) is created between the closure profiles 23 , 25 immediately adjacent to the slider 11 .
[0052] In operation, a length of the closure mechanism material 50 that preferably corresponds to the length of a resealable package 20 passes into the guide channel 78 , on top of blade 84 . The progress of the closure mechanism material 50 is stopped at a point when the opening 51 is directly beneath the wedge 126 . The piston 122 is then actuated whereby the rod 124 is extended. This causes the wedge 126 to be moved through the top of the guide channel 78 . The wedge 126 is disposed in the opening 51 between the closure profiles [ 23 , 25 ].
[0053] Preferably, the guide channel 78 is aligned with sealing bars 130 , 132 that are used to seal the side panels 31 , 33 to the closure profiles 23 , 25 such that the sealing bars 130 , 132 may pass through the opening 79 in the guide channel 78 . In this embodiment, it is preferred to have the sealing bars 130 , 132 move together to seal the side panels 31 , 33 to the closure profiles 23 , 25 at substantially the same time that the wedge 126 is inserted into the opening 51 . The sealing bars 130 , 132 are then withdrawn from the guide channel 78 . The closure mechanism material 50 is then advanced the length of one package 20 with the wedge 126 still inserted between the closure profiles 23 , 25 . As will be understood by one of ordinary skill in the art, this movement will cause the engaged portion of the closure mechanism material 50 to disengage. After the closure mechanism material 50 has been advanced, and thus disengaged along the length of one package 20 , the wedge 126 is withdrawn from the closure mechanism material 50 . The opened closure mechanism material 50 continues in an opened state for further processing, as is described below.
[0054] In the embodiments illustrated in FIGS. 3-7 , the closure mechanism material 50 is opened, but not yet sealed to the side panels 31 , 33 . In the embodiment illustrated in FIGS. 8-10 b , the closure mechanism material 50 is positioned between the side panels 31 , 33 . The side panels 31 , 33 are then heat sealed to the closure profiles 23 , 25 by sealing bars 130 , 132 . The various embodiments of this invention contemplate that opening of the closure mechanism 41 and sealing of the closure profiles 23 , 25 to the side panels 31 , 33 can occur either sequentially (e.g. opening followed by sealing or sealing followed by opening) or simultaneously (i.e. opening and sealing at the same station and substantially at the same time).
[0055] Two additional embodiments are schematically illustrated in FIGS. 11-12 , each of which incorporates a force that is external to the closure mechanism 41 to open the closure profiles 23 , 25 . With reference to FIG. 11 a , a cross-sectional view of an alternate closure mechanism 41 is shown in a closed or engaged position. The engaged mechanism 41 is positioned between two opposing flat surfaces 140 , 141 , on moveable wedges 150 , 151 . Upon activating the opening apparatus 70 illustrated in FIG. 11 a , the moveable wedges 150 , 151 move towards each other, as best shown in FIG. 11 b , with sufficient force to “pinch” the closure profiles 23 , 25 of closure mechanism 41 into an open position. The pinching occurs as surfaces 140 , 141 come in contact with closure profiles 23 , 25 . Following this “pinch-open” action, the wedges 150 , 151 move apart, as shown in FIG. 11 c , and reset for admission of the next closure mechanism to be opened.
[0056] One of skill in the art will recognize many variations of practicing the invention illustrated in FIGS. 11 a - 11 c . For example, one of the moveable wedges ( 150 ) could be replaced with an immovable surface such that only one moveable wedge ( 151 ) would have to move and pinch the closure mechanism against the immovable surface to open these closure profiles.
[0057] A further embodiment utilizing a force external to the closure mechanism to open the closure profiles is illustrated in cross-section in FIGS. 12 a - b . In this embodiment, a channel wedge 160 is placed over closure profile 50 ( FIG. 12 a ), such that said action of placement forces open the closure profiles 23 , 25 ( FIG. 12 b ). Preferably, the interior dimension 162 of the channel wedge 160 is proportioned appropriately to accomplish the opening of the closure profiles 23 , 25 without disrupting the integrity of the package (not shown).
[0058] It is contemplated that the channel wedge embodiment operates in a substantially similar manner the method as previously described for the wedge illustrated in FIGS. 4 a - 4 d . The main difference between these distinct embodiments is that the closure mechanism illustrated in FIGS. 4 a - 4 d lends itself to being split-open by inserting a wedge between the closure profiles, while the closure mechanism of FIG. 12 is opened by a force applied externally to the closure profiles.
[0059] Referring back to FIG. 2 , after opening the closure mechanism in accordance with the invention disclosed herein, the continuous line of packages continues to sealing bars 112 that seal the sides 31 , 33 of the package 20 . The continuous line of packages then pass under hopper 114 that contains the product to be placed in package 20 . As the packages pass under the hopper 114 , product 241 passes through the mouth of the header section 101 and into the interior of the package 20 . In certain embodiments, the mouth of the header section 101 is then sealed by sealing bars 116 to form a tamper-evident structure. Finally, the continuous line of packages is separated into individual packages by cutting knife 118 .
[0060] While specific embodiments and methods for practicing this invention have been described in detail, those skilled in the art will recognize various manifestations and details that could be developed in light of the overall teachings herein. Accordingly, the particular mechanisms disclosed are meant to be illustrative only and not to limit the scope of the invention which is to be given the full breadth of the following claims and any and all embodiments thereof. | A method of making a resealable package is provided. The method comprises providing a closure mechanism, the closure mechanism comprising first and second closure profiles, the first and second closure profiles constructed and arranged to selectively engage, and wherein the first and second closure profiles are engaged. The method further comprises providing a pair of panels comprising a flexible polymeric material, inserting a wedge between the closure profiles, disengaging the closure profiles; and attaching the closure mechanism to the pair of side panels. Various embodiments of opening devices are also presented. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for the production of substrates with a uniform dispersion of extremely fine granules.
2. Description of the Prior Art
A gas-evaporation technique, in which a metal semiconductor or a dielectric is heated causing evaporation of extremely fine granules onto a supporter in an inert gas atmosphere at low pressure (e.g., from 0.1 to 10 Torrs), resulting in a substrate on which extremely fine granules are dispersed, is well known. The substrate formed by the above-mentioned method is used as a base for the production of a medium for magnetic recording in the field of information processing, the production of catalysts in chemistry, the production of various kinds of sensor materials, and the production of electric circuit devices such as switch devices, memory devices, diodes, etc.
However, when this method is used, generally speaking, several or several tens of extremely fine granules are recovered in a coupled form, and it is not possible to obtain uniform dispersion with minute spaces between the granules on the supporter. The reason for this phenomenon is as follows: In this method, the extremely fine granules, which are formed in the gas with diameters ranging from tens to thousands of Angstroms, collide repeatedly with gas molecules, so that the kinetic energy of the initial stage is rapidly lost, and the granules are carried by a convection stream of gas, which is caused by the heat of a heat source for the evaporation, and accumulated on the supporter. Thus, the distance in which the granules are in motion in the gas before arriving at the supporter becomes very long. This process of transportation seems to be the cause of the successive aggregations of granules touching each other. When the extremely fine granules are coupled with each other on the supporter, the regions of coupled fine granules become, in effect, regions of large granules, and the physical and chemical characteristics of the extremely fine granules are lost. For that reason, if such a dispersed substrate of extremely fine granules is used, for example, for sensor materials or materials for electronic circuits, the proportion of unsatisfactory production increases, and it is not possible to ensure the production reliability of the electronic parts, etc., constructed using this substrate.
SUMMARY OF THE INVENTION
The method for the production of substrates with a uniform dispersion of extremely fine granules according to this invention which overcomes the above-discussed and numerous other disadvantages and deficiencies of the prior art, comprises forming extremely fine granules in a granule-formation chamber under a reduced pressure by a gas-evaporation technique, introducing said extremely fine granules into a granule-recovering chamber under high vacuum, which is adjacent to said granule-formation chamber, through a slit formed in the partition between said granule-formation chamber and said granule-recovering chamber, and allowing said extremely fine granules to be dispersed on and attached to a supporter disposed in said granule-recovering chamber.
The partition is, in a preferred embodiment, provided with a throttling mechanism which attains a variable control of the diameter of said slit to thereby adjust the pressure difference between said granule-formation chamber and said granule-recovering chamber.
The supporter is, in a preferred embodiment, cooled by a cooling means while said extremely fine granules are being dispersed on and attached to said supporter.
The method of this invention which overcomes the above-discussed and numerous other disadvantages and deficiencies of the prior art, further comprises evaporating a dispersion medium composed of evaporable materials contained in said granule-recovering chamber, and allowing said extremely fine granules to be dispersed on and attached to said supporter, together with said evaporated dispersion medium.
Thus, the invention described therein makes possible the objects of (1) providing a method for the production of substrates with a uniform dispersion of extremely fine granules being achieved without coupling with each other; and (2) providing a method for the production of substrates in which extremely fine granules formed by a gas-evaporation technique are uniformly dispersed on a supporter without the successive aggregation of granules, thereby producing an extremely fine granule-dispersed substrate which is useful in fields where the characteristics of extremely fine granules are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings as follows:
FIG. 1 is a schematic diagram showing an apparatus for the production of substrates of this invention.
FIG. 2(A) is a microphotograph showing the dispersion structure of extremely fine granules of Cu on a supporter, which was produced by a conventional gas-evaporation technique.
FIG. 2(B) is a microphotograph showing the dispersion structure of extremely fine granules of Cu on a supporter, which was produced according to this invention.
FIG. 2(C) is a microphotograph showing the dispersion structure of extremely fine granules of Cu on a supporter, which was produced, using a dispersion medium, according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
FIG. 1 shows an apparatus for producing a substrate on which extremely fine granules are uniformly dispersed according to this invention. The apparatus has a double structure consisting of an outer verger 8 and an inner verger 9. The chamber 10 between the vergers 8 and 9 is under a reduced pressure and the chamber 11 inside of the verger 9 is under high vacuum. In the chamber 11, a supporter 1 to allow extremely fine granules to be accumulated thereon is held by a holder 2, which is cooled by a cooling medium recycling through a pouring conduit 3 and a discharging conduit 4. A boat 5, which contains an evaporable material generating extremely fine granules when heated, is disposed in the chamber 10.
Alternatively, the boat 5 can be disposed in the chamber 11 and the supporter 1 can be disposed in the chamber 10, if the chamber 10 is under high vacuum and the chamber 11 is under a reduced pressure.
The gas for the maintenance of the reduced pressure in the chamber 10 or 11 comes from a gas cylinder 22 via valve 12 or 13 (e.g., valve 12) to the chamber 10 or 11 (e.g., chamber 10). Removal of the gas from the chambers 10 and 11 is carried out by operation of valves 14, 15, 16, 17 and 18 connected to and oil-sealed rotary pump 6 and an oil diffusion pump 7. After removal of the gas from the chambers 10 and 11 is carried out to attain high vacuum therein, the valve 16 alone is kept open to continue removal from the chamber 11 while the valve 12 is left slightly open to introduce the gas from the cylinder 22 into the chamber 10. The amount of gas to be introduced into the chamber 10 is being monitored using a flow meter 21. Thus, the pressure in chamber 10 is reduced, whereas the chamber 11 is maintained under high vacuum. The pressure ratio of the chamber 10 to the chamber 11 depends upon the diameter of the slit 20 formed on the upper wall of the inner verger 9. For example, when the slit 20 is formed with a diameter of 300 μm and argon gas is introduced into the chamber 10, the pressure ratio is in the range of 10 2 to 10 4 .
Using the above-mentioned apparatus, a substrate on which extremely fine granules are uniformly dispersed is produced as follows: The pressure of the chamber 10 is set in the range of around 0.01 to 10 Torrs and that of the chamber 11 is set in the range of around 10 -5 to 10 -6 Torrs. Then, the boat 5 which is positioned above the slit 20 of the inner verger 9 is heated, resulting in evaporation of the evaporable materials contained in the boat 5. As the evaporation method, a resistance heating method, an electron beam irradiation method, a laser light irradiation method, a plasma- or ion-sputtering method, etc., can be used. The evaporated atoms from the evaporable materials collide repeatedly with each other in the atmosphere under a reduced pressure, resulting in extremely fine granules, which are then drawn into the vacuum chamber 11 via the slit 20 to be dispersed and accumulated on the supporter 1. The start and termination of the arrival of granules at the supporter 1 depend upon the opening and closing of a shielding board 19, which is disposed above the supporter 1. Since the extremely fine granules which are formed in the chamber 10 are instantly drawn into the chamber 11 through the slit 20, they maintain their exist in a granule form without coupling with each other. As the evaporable materials generating the extremely fine granules, metals such as Cu, Zn, Au, Pt, Al, Ha, Ti, V, Cr, Mn, Fe, Co, Ni, Sn, Pb, etc.; semiconductors such as Si, Ge, GaAs, Te, SnO 2 , CdS, CdTe, etc.; or dielectrics such as VO 2 , TiOx, BaTiOx, etc., can be used. As the supporter 1 on which the extremely fine granules from these materials are recovered, a silicon wafer, a plastic film, and other organic and inorganic materials depending upon the purpose of use thereof can be employed.
In order to set a proper difference in the pressure between the chambers 10 and 11, a throttling mechanism which allows variable control of the diameter of the slit 20 can be added to an appropriate portion (e.g., the partition near the slit 20) of the above-mentioned apparatus. Alternatively, variable control of the amount of exhaust gas from the chambers 10 and 11 can be made by the adjustment of the valves 14, 15, 16, 17 and/or 18 which allow the adjustment of the pressure difference between the chambers 10 and 11.
The reason why the supporter 1 is preferably cooled by a cooling medium through the holder 2, is that when the supporter 1 is cooled, the extremely fine granules which have arrived at the supporter 1 rapidly lose their kinetic energy so that correction of extremely fine granules on the supporter 1 can be attained with high efficiency.
EXAMPLE 2
In order to attain a more effective dispersion of the extremely fine granules on the supporter 1, it is preferable to allow materials, which function as a dispersion medium for the extremely fine granules, to be evaporated within the chamber 11. For this purpose, as shown in FIG. 1, a boat 23 containing such materials therein (e.g., SiO 2 or any other evaporable substances) as a dispersion medium is disposed within the chamber 23. The production of substrates on which extremely fine granules are uniformly dispersed, using this dispersion medium, according to this invention is as follows: The pressure of each of the chambers 10 and 11 is, first, set at a given level in the same manner as in Example 1. Then, the materials in the boat 5 are allowed to evaporate in the heat, resulting in extremely fine granules, which are then introduced into the chamber 11 through the slit 20. Also, the boat 23 disposed within the chamber 11 is heated, and the dispersion medium in the boat 23 allow to be evaporated. The extremely fine granules which have been introduced into the chamber 11 are accumulated on the supporter 1, together with the evaporated dispersion medium, and uniformly dispersed on the supporter 1. The dispersion medium is located among the extremely fine granules in such a manner that the extremely fine granules can be uniformly dispersed with minute spaces between the granules on the supporter 1, and thus the uniform dispersion effect of the extremely fine granules increases.
FIG. 2(A) shows a microphotograph showing a conventional dispersion structure of extremely fine granules of Cu on a supporter, which was produced according to a conventional gas-evaporation technique (argon atmosphere under 5 Torrs). FIG 2(A) indicates that a number of the extremely fine granules are aggregated in a chain fashion.
FIG. 2(B) shows a microphotograph showing a dispersion structure of extremely fine granules of Cu on a supporter, which was produced according to Example 1 of this invention, wherein the chamber 10 was charged with an argon atmosphere under 5 Torrs and the chamber 11 with an argon atmosphere under 0.05 Torrs. FIG. 2(B) indicates that the extremely fine granules are uniformly dispersed on the supporter without coupling with each other, as compared with those in FIG. 2(A).
FIG. 2(C) shows another microphotograph showing a dispersion structure of extremely fine granules of Cu on a supporter, which was produced, using SiO 2 as the above-mentioned dispersion medium, according to Example 2 of this invention, wherein the chamber 10 was charged with an argon atmosphere under 3 Torrs and the chamber 11 with an argon atmosphere under 0.05 Torrs. FIG. 2(C) indicates that each of the extremely fine granules of Cu nucleates and the SiO phase surrounds the nucleus, resulting in a uniform dispersion of the extremely fine granules in the SiO phase on the supporter.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | A method for the production of substrates with a uniform dispersion of extremely fine granules comprising: forming extremely fine granules in a granule-formation chamber under a reduced pressure by a gas-evaporation technique, introducing said extremely fine granules into a granule-recovering chamber under high vacuum, which is adjacent to said granule-formation chamber, through a slit formed in the partition between said granule-formation chamber and said granule-recovering chamber, and allowing said extremely fine granules to be dispersed on and attached to a supporter disposed in said granule-recovering chamber. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present invention is based upon U.S. provisional application No. 60/201432, filed May 3, 2000 by the present inventor, full Paris Convention priority is claimed, and said priority document is expressly incorporated by reference as if the same was fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to novel enhanced shaving means for grooming specific areas of animals, and preferably humans. In particular, the present invention relates to scaled down razor means for shaving pubic areas having heightened angular and spatial constraints, preferably of women.
[0003] Attention is called to United States Letters Patents:
4,379,219; 4,488,357; 4,492,024; 4,498,235; 4,551,916; 4,573,266; 4,586,255; 4,587,729; 4,621,424; 4,709,476; 4,742,909; 4,756,082; 4,807,401; 4,916,817; 5,063,667; 5,113,585; 5,157,835; 5,192,712; 5,249,361; 5,399,204; 5,578,114; 5,687,485; 5,800,627; D306,216; D312,568; D316,962; D349,242; D363,142; D370,844; D373,444;
[0004] and D381,121; each of which was examined and found to be different from the instant teachings.
SETTING OF THE INVENTION
[0005] Many women wish to sport undergarments and swimware in a fashion that displays or shows no visible signs of hair growth within the zone defined by the intersection of the boundaries of these undergarments or swimware and their own growth of pubic hair, often referred to as the “bikini line.”
[0006] Likewise, those who desire a smooth, stubble free, and unblemished surface within the pubic area itself have had little resort to possible solutions outside of dilapitory ( for example, NAIR® brand of hair removal products) or trimming based attempts ( eg. LADIBIKINI® by EPILADY)both of which are sorely lacking, in terms of efficacy, result and convenience.
[0007] In short, the problem of shaving the ‘bikini line’ (defined for the purposes of the instant application for U.S. Letters Patent as areas of pubic hair within that region extending at least about from the dual vertices of the inverted triangular zone beginning proximate to each of the respective pubic bones, which demarcate the groin area, through and in between the legs until the distal edge or apex of the triangular zone within an individually predetermined space location in the fold of skin defined by the buttocks) has never been squarely addressed and remains a longstanding need for those who wish to prevent visibility of pubic hair outside of clothing or from existing at all on the ‘mons pubis’, or related areas on men.
[0008] It is well known that certain areas of humans are susceptible to the development of hair. Razor blades and handles for the same were first developed for the facial areas and heads of men. Conventional or standard razor blades are at least about 1.5 inches long, with only width values being varied to date. It is understood that the instant teachings apply equally to single, double, treble or any conventional variation on the number of blades stored in a blade head, as the same is known.
[0009] Traditionally, hair growth in females has been treated by methods varying from wax to radical allopathic laser based or even more extreme treatment regimens or radical medical intervention. This approach is risky for those involved. More recently there have been a number of proposals for the customization of shaving equipment for women. However, such design improvements have ostensively been limited to handles and color stories.
[0010] Difficulties arise in the placement of a straight edged razor blade across body zones having lesser planar components. For example, the bikini line is often not cleanly shaved enough to prevent unwanted extensions of pubic hair outside of the surface coverage of undergarments or swimwear, as discussed above.
[0011] Standard razor blades have evolved over the years into designs purported to address the needs of women. However, this ‘evolution’ ostensively is less concerned with technical issues than with packaging and marketing concerns. For example, changes in razor handle and colors (mostly Pastel-based) have yet to impact upon the basic constraint of the conventional size of the razor head, which has remained at least about one and one-half inches.
[0012] Feminine shaving products adhering to the standard or safety razor designs and sizes of the day seem to be directed at aspects of a woman's body other than the bikini line area. This large area of focus includes both the legs and underarms, which are separate matters entirely. Likewise, alternate means have proven to have drawbacks since creams, jells, and electronic solutions have not proven sufficient for most women to date, there remains a strong demand and extreme need for the teachings of the present invention.
[0013] In order to address the clearly longstanding need of providing a means for safely and effectively removing hair from a woman's bikini line, the instant teachings are herewith offered for consideration and believed to constitute a modicum of progress in the pursuit of science and the useful arts on such basis.
OBJECTIVES AND SUMMARY OF THE INVENTION
[0014] Accordingly, it is an object of the present invention to provide a compacted razor head.
[0015] Another objective is to provide a shaving apparatus having a blade length smaller than the conventional standard safety razor size for shaving a bikini line or groin area more precisely.
[0016] Still another objective is to provide a razor means that fits more easily and comfortably within the constraints of shaving a woman's bikini line, or the pubic area of either sex, which is compatible with conventional handles, blade guards, and related cutting edge shaving accoutrements.
[0017] These and still further objectives are defined in the claims appended hereto, whereby the teachings of the present invention are differentiated from conventional technology.
[0018] The foregoing objectives are achieved in apparatus for reducing levels of visible hair present within the bikini line region which includes a blade means for cutting, ranging from at least about half of an inch to nine-tenths of an inch, effective for use with any ergonomic, or known handle member for closely adhering to a predetermined spatial orientation, wherein a surface area of the blade means and the handle are preferably in a predetermined ratio or from at least about 5.1 to about 1.0 units of surface area.
[0019] Briefly stated, Bikini™ Blade apparatus for reducing levels of visible hair present within the bikini line region, or the groin area of a user, is made up of a blade having a cutting edge ranging from at least about 0.60 inches to about 0.90 inches, in combination with conventional attachment, handle and refillable and disposable specialized handle structures, with which it is compatible. A method of use and kit are likewise disclosed.
[0020] According to a feature of the present invention there is provided a kit, which comprises, a razor blade defined by a cutting edge having length of between about 0.60 and about 0.90 inches, a means for attaching the razor blade to a handle member and, a handle member.
[0021] Likewise, a method of using a bikini™ blade includes the steps of providing a blade measuring from about 0.6 to 0.9 inches and preferably between about 0.75 and 0.83 inches, and utilizing the same at a predetermined spatial angle in relation to a user's skin to remove hair from an area of the user's skin.
[0022] Similarly, a method of making a bikini™ blade comprises providing a miniaturized blade as previously defined, having a fixed dimensional proportion in relation to a handle, and combining the same with a handle to form an integral unit.
[0023] Finally, a kit includes a bikini™ blade, as defined above, and a means for fixedly attaching the same to a handle member, and the handle member itself, and with conventional specialty handles that are effective for releasing shaving cream or disposable, blade guards, and related cutting edge shaving accoutrements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a schematized illustration of an exemplary bikini™ blade type of blade member, according to the teachings of the present invention, in a top or plan view;
[0025] [0025]FIG. 2A is a schematized illustration of another bikini™ blade type of blade featured with a blade enclosure adapted to be used with the instant teachings, with;
[0026] [0026]FIG. 2B being a refillable razor handle means using conventional click-on technology for mounting a bikini™ blade type of blade according to the teachings of the present invention; and,
[0027] [0027]FIG. 3A, 3B and 3 C each being a schematic of a bikini™ blade type of blade in conjunction with a disposable type of conventional razor handle assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present inventor has discovered that in seeking enhanced precision in razor based hair removal, a smaller and narrower razor head likewise brings the unexpected benefit of nonencroachment upon critical non-hair growing regions (such as the greater labial zone, or area of a women's body that is centered between the two narrow hair-growing passages running from the frontal region of the pubic hair through the legs towards the buttocks). To these ends, an appropriately sized and fitted shaving device is an asset for specific hair removal needs in the bikini line area, and likewise may assist with related difficulty angled shaving zones. Similarly, by providing a compacted razor blade a customized shaving apparatus for special needs has been developed without the need for specialized handles or the like means which compromise the mechanical integrity of the shaving system.
[0029] According to the teachings of the present invention, the present inventor has discovered that a razor blade that has a smaller blade length, for example, at least about 0.60 inches, in comparison to the standard or conventional razor blade length (1.5 inches) more easily and comfortably fits into, and removes unwanted hair from, a woman's bikini line area, inter alia.
[0030] As detailed above, the driving force behind the instant discovery is the fact that the bikini line area of a woman's body encompasses areas smaller than the width of a conventional razor, and invention resulted because a smaller and more spatially compact razor blade means, in combination with conventional technology for enclosure and mounting, addresses this longstanding need, while imparting significant related benefits inherent in the novel, nonobvious and new design of the present invention.
[0031] In order to remove unwanted hair from a woman's bikini line the instant teachings were developed and the improved shaving system engendered by solving this problem is herewith offered for consideration. As defined herein, ‘razor head’ comprises conventional blade razor blade housing and/or mounting technology, such that applicant's novel miniaturized blade configuration is positioned to shave a user. Likewise ‘blade’ is used interchangeably with the instant term herein.
[0032] Referring now to FIG. 1, bikini™ blade type of blade 22 , which is effective for use with known razor heads, is constructed of conventional materials, including known metals or alloys, Shape Memory Alloys (SMAs) and the like and is preferentially defined by a set of dimensional requirements, whereby a predetermined ratio of length X to width Y is maintained.
[0033] For example, according to preferred embodiments, blade 22 is between about 0.60 inches and 0.90 inches in length in preferred embodiments, as a measurement of the X dimension. While Y is able to be gauged at least about 0.4375 inches, similar to conventional razor blades.
[0034] Blade 22 is effectively housed in conventional protective and storing razor blade enclosures (not shown) which generally span no more than 0.0625 of an inch in width and do not exceed to overall blade enclosure length of 0.4375 inches. Top and bottom housings are known (thus not shown), and for example with blade 22 of the instant invention, bottom housings and protective strips likewise would adhere to the standard 0.0625 inch width and the overall razor head length of 0.90 inches. Similarly, the top housing and protective blade strip (not shown) do not exceed the overall razor blade head length of 0.90 inches and may be up to 0.25 of an inch to incorporate lubricating strips (also known and not shown).
[0035] [0035]FIG. 2A and 2B each shows blade 22 , in combination with handle 38 , which may be angled as illustrated to craft a desired pubic hair line along the bikini line of a woman. Refillable handle technology which works with the instant teachings is known, for example, from the GILLETTE COMPANY (Boston, Mass. 02199), as is the click-on technology for mounting blade 22 in a razor cartridge, onto handle 38 .
[0036] To craft a desired pubic hair line, handle 38 is grasped by user and blade 22 used to navigate narrow passages to eliminate unwanted pubic hair extending outside of the bikini line, and/or remove hair within said zone by controlled and pressured placement along the surface of user's skin, whereby each hair follicle is extended from is existing obtuse angle until sliced by blade 22 , as known to those skilled in the art of shaving, and enjoyed by any shavers using standard technology.
[0037] Blade 22 is manoeuvred easily along the user's bikini line owing to the novel enhanced blade length (X). Unwanted hair is thus able to be accessed and removed without the danger of having the extra blade length impact the delicate skin of the user, and tear, perforate or otherwise insult the same.
[0038] Handle 38 , and blade 22 function with known technology for elimination or minimization of shaving injuries, or ‘nicks’ including but not limited to lubricated strips, and protective blade strips made by the GILLETTE COMPANY (Boston, Mass. 02199), as well as the know refillable cartridge-type of handle also made by the same company, inter alia.
[0039] [0039]FIG. 3A, 3B and 3 C each shows a disposable model incorporating blade 22 , and handle 38 which may have known tapers, angulation, or variations upon the same, and be made of disposable, reconstituted, recycled or any known plastics as is well known, for example, as available from the GILLETTE COMPANY (Boston, Mass. 02199). Blade 22 , is used at a length X of between about 0.60 and 0.90 inches. As defined above, blade 22 is housed conventionally forming razor heads with known means.
[0040] Since a blade of between about 0.60 and 0.90 results in a razor head which more naturally, comfortably and safely can be angled to shave the bikini line area, it likewise better services the narrow hair growing passages that run between women's legs toward the buttocks. When removing unwanted hair from such uniquely feminine and delicate skin areas, it is imperative to use extreme caution so as not to expose non-hair growing regions to the cutting edges of the razor head.
[0041] A smaller and narrower razor head likewise brings the unexpected benefit of nonencroachment upon critical non-hair growing regions (such as the greater labial zone, or area of a woman's body that is centered between the two narrow hair-growing passages running from the frontal region of the pubic hair through the leg towards the buttocks) which is essential in the event that a woman elects manual hair-removal. Since creams, jells, and electronic solutions have not proven sufficient for most woman to date, there remains a longstanding need for the teachings of the present invention.
[0042] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. | Bikini™ Blade apparatus for reducing levels of visible hair present within the bikini line region, or the groin area of a user, is made up of at least a blade in a razor blader head assembly, which is otherwise conventional, except for having a cutting edge ranging from at least about 0.50 inches to about 0.90 inches, in combination with conventional attachments, handles and refillable and disposable specialized handle structures, with which it is compatible. A method of use and kit are likewise disclosed whereby at least one of a user's groin area and bikini line are rendered substantially free of visible hairs. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a National Stage of International Application No. PCT/JP2012/069153 filed Jul. 27, 2012, claiming priority based on Japanese Patent Application No. 2011-164570 filed Jul. 27, 2011, the contents of all of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The present invention relates to a tire in which a circumferential groove extending in a tire circumferential direction is formed, and particularly relates to a tire having a sufficient water drainage performance even when a lug groove component is reduced.
BACKGROUND ART
Conventionally, in a pneumatic tire (hereinafter, referred to as tire) mounted on a passenger vehicle, for example, a method for forming a plurality of circumferential grooves in a tread has been widely used in order to ensure a water drainage performance on a wet road surface.
Further, there is known a tire in which a plurality of protrusions to be inclined relative to a tire circumferential direction are formed on a groove bottom of a circumferential groove in order to aggressively drain rainwater that has entered such a circumferential groove (for example, Patent Literature 1). According to such a tire, a spiral water flow is hardly generated in the rainwater that has entered the circumferential grooves, resulting in the improvement of a water drainage performance.
In recent years, along with an introduction of an electric vehicle or a hybrid automobile in which both an internal combustion engine and an electric motor are used, a further reduction of noise generated by a tire is demanded. Further, even in an automobile mounted thereon with an internal combustion engine, along with a reduction of noise generated by the automobile itself, a further reduction of noise generated by a tire is demanded than ever. Main examples of the noise generated by a tire include a pattern noise resulting from a tread pattern (pitch noise) and a road noise resulting from an unevenness on a road surface. As a method of reducing a pattern noise, it is possible to consider reducing a lug groove component in a tread.
However, even with the tire in which a lug groove component is thus reduced, it is necessary to ensure a water drainage performance at least equal to that of a conventional tire.
CITATION LIST
Patent Literature
[Patent Literature 1] Japanese Patent Publication No. 2005-170381
SUMMARY OF INVENTION
A tire according to a first feature comprises: a circumferential groove extending in a tire circumferential direction; and a land portion that is adjacent to the circumferential groove and that extends in the tire circumferential direction. The circumferential groove is formed with: a first swelling portion that swells from one lateral wall of the circumferential groove toward a center in a widthwise direction of the circumferential groove; and a second swelling portion that swells from the other lateral wall of the circumferential groove toward the center in the widthwise direction of the circumferential groove. The first swelling portion has, in a tread surface view of the tire, a tapered shape in which a size in the tread widthwise direction is narrower as it goes in a first direction in the tire circumferential direction. The second swelling portion has, in the tread surface view of the tire, a tapered shape in which a size in the tread widthwise direction is narrower as it goes in a second direction that is opposite to the first direction in the tire circumferential direction. The first swelling portion and the second swelling portion are formed in plural with a predetermined interval in the tire circumferential direction. A groove extending in the tire circumferential direction is formed between the first swelling portion and the second swelling portion opposite to the first swelling portion in the tread widthwise direction.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a development plan view illustrating a part of a pneumatic tire 10 according to an embodiment.
FIG. 2 is an enlarged perspective view of a circumferential groove 20 according to the embodiment.
FIG. 3 is an enlarged view of the circumferential groove 20 as seen from a tire circumferential direction D C according to the embodiment.
FIG. 4 is a cross sectional view of the circumferential groove 20 according to the embodiment.
DESCRIPTION OF EMBODIMENTS
Next, a tire (pneumatic tire) according to an embodiment will be explained with reference to drawings. It is noted that, in the following description of the drawings, the same or similar reference numerals are used to designate the same or similar portions. It is appreciated that the drawings are schematically shown and the ratio and the like of each dimension are different from the real ones.
Accordingly, specific dimensions and the like should be determined in consideration of the explanation below. Moreover, among the drawings, the respective dimensional relations or ratios may differ.
(1) Schematic Configuration of Pneumatic Tire
FIG. 1 is a development plan view illustrating a part of a pneumatic tire 10 according to the present embodiment. As illustrated in FIG. 1 , on the pneumatic tire 10 , a plurality of circumferential grooves 20 extending in a tire circumferential direction D C are formed. Further, the pneumatic tire 10 includes a land portion 30 extending in the tire circumferential direction D C , adjacently to each circumferential groove 20 . It is noted that the pneumatic tire 10 may be filled with, instead of air, an inert gas such as nitrogen gas.
In the pneumatic tire 10 , a plurality of circumferential grooves 20 are formed; a lug groove component extending in a tread widthwise direction D T is not formed. It is noted that a thin groove or a siping not illustrated extending in the tread widthwise direction D T may be formed. The pneumatic tire 10 may be favorably used for an electric automobile or a hybrid automobile in which both an internal combustion engine and an electric motor are used because a pattern noise is reduced due to a reduction in lug groove component.
Inside the circumferential groove 20 , a first swelling portion 110 and a second swelling portion 120 are arranged. Between the first swelling portion 110 and the second swelling portion 120 opposite to the first swelling portion 110 in the tread widthwise direction D T , a groove 200 extending in the tire circumferential direction D C is formed. Specifically, the groove 200 is formed to be inclined relative to the tire circumferential direction D C , and a plurality of grooves 200 are repeatedly formed in the tire circumferential direction D C .
(2) Shape of Circumferential Groove
FIG. 2 is an enlarged perspective view of the circumferential groove 20 . FIG. 3 is an enlarged view of the circumferential groove 20 as seen from the tire circumferential direction D C . FIGS. 4( a ) to ( c ) are cross sectional views of the circumferential groove 20 . Specifically, FIG. 4( a ) is a cross sectional view, of the circumferential groove 20 , taken along a line F 4 A to F 4 A illustrated in FIG. 3 . FIG. 4( b ) is a cross sectional view, of the circumferential groove 20 , taken along a line F 4 B to F 4 B illustrated in FIG. 3 . FIG. 4( c ) is a cross sectional view, of the circumferential groove 20 , taken along a line F 4 C to F 4 C illustrated in FIG. 3 .
As illustrated in FIG. 2 to FIG. 4 , the first swelling portion 110 and the second swelling portion 120 are formed in plural with a predetermined distance (for example, about 30 mm) in the tire circumferential direction D C .
The first swelling portion 110 swells from one lateral wall 21 of the circumferential groove 20 toward a center in a widthwise direction of the circumferential groove 20 . Further, the first swelling portion 110 has, in a tread surface view of the pneumatic tire 10 , a tapered shape in which the size in the tread widthwise direction D T is narrower as it goes in a first direction (upward direction in FIG. 2 and FIG. 3 ) in the tire circumferential direction D C .
The second swelling portion 120 has a shape similar to that of the first swelling portion 110 . Specifically, the second swelling portion 120 swells from the other lateral wall 22 of the circumferential groove 20 toward a center in the widthwise direction of the circumferential groove 20 . Further, the second swelling portion 120 has, in a tread surface view of the pneumatic tire 10 , a tapered shape in which the size in the tread widthwise direction D T is narrower as it goes in a second direction (downward direction in FIG. 2 and FIG. 3 ) opposite to the first direction in the tire circumferential direction D C .
A lateral surface 111 of the first swelling portion 110 along the lateral wall 21 has, in the cross section along the tread widthwise direction D T and the tire radial direction D R , an arc-like shaped portion recessed toward the lateral wall 21 (see FIG. 4( c ) ). Similarly, a lateral surface 121 of the second swelling portion 120 along the lateral wall 22 has, in the cross section along the tread widthwise direction D T and the tire radial direction D R , an arc-like shaped portion recessed toward the lateral wall 22 (see FIG. 4( a ) ).
Further, an end 110 b at a wider width side in the tread widthwise direction D T of the first swelling portion 110 and the second swelling portion 120 is located inside, in the tire radial direction D R , from a tread surface of the land portion 30 adjacent to the circumferential groove 20 . On the other hand, an end 110 a at a narrower width side in the tread widthwise direction D T of the first swelling portion 110 is located at the approximately same height as that of a tread surface of the land portion 30 in the tire radial direction D R . Similarly, an end (end 120 a described later) at a narrower width side in the tread widthwise direction D T of the second swelling portion 120 is located at the approximately same height as that of a tread surface of the land portion 30 in the tire radial direction D R . According to the shape of such first swelling portion 110 and second swelling portion 120 , the groove 200 can be formed as a spiral-like form inside the circumferential groove 20 .
A bottom surface of the groove 200 is communicated, as one seamless surface, to the lateral surface 111 of the first swelling portion 110 . Further, the bottom surface of the groove 200 is communicated, as one seamless surface, to the lateral surface 121 of the second swelling portion 120 . That is, the bottom surface of the groove 200 has no portion in which an unevenness or a ridge is formed, and has a shape that little disturbs a flow of rainwater that has entered the groove 200 .
(3) Operation and Effect
According to the pneumatic tire 10 , between the first swelling portion 110 and the second swelling portion 120 , a plurality of grooves 200 extending in the tire circumferential direction D C are formed. The first swelling portion 110 has, in a tread surface view of the pneumatic tire 10 , a tapered shape in which the size in the tread widthwise direction D T is narrower as it goes in a first direction in the tire circumferential direction D C . Similarly, the second swelling portion 120 has, in a tread surface view of the pneumatic tire 10 , a tapered shape in which the size in the tread widthwise direction D T is narrower as it goes in a second direction in the tire circumferential direction D C .
Rainwater flowing in such a groove 200 flows in a spiral form from the bottom surface of the groove 200 toward the lateral surface 111 of the first swelling portion 110 and the lateral surface 121 of the second swelling portion 120 . Thus, the rainwater that has entered the circumferential groove 20 flows smoothly without creating a large turbulence inside the circumferential groove 20 . That is, even when a lug groove component is reduced as in the pneumatic tire 10 , it is possible to provide a sufficient water drainage performance.
In the present embodiment, the lateral surface 111 of the first swelling portion 110 is of arc-like shape recessed toward the lateral wall 21 . Further, in the present embodiment, the lateral surface 121 of the second swelling portion 120 is of arc-like shape recessed toward the lateral wall 22 . Thus, the rainwater that has entered the circumferential groove 20 is more easily flown in a spiral form, resulting in further increasing a water drainage performance.
In the present embodiment, the end 110 b (end 120 b ) at a wider width side of the first swelling portion 110 (second swelling portion 120 ) is located inside, in the tire radial direction D R , from a tread surface of the land portion 30 . Further, the end 110 a (end 110 b ) at a narrower width side of the first swelling portion 110 (second swelling portion 120 ) is located at the approximately same height as that of a tread surface of the land portion 30 in the tire radial direction D R . Moreover, the bottom surface of the groove 200 is communicated, as one seamless surface, to the lateral surface 111 of the first swelling portion 110 , and communicated, as one seamless surface, to the lateral surface 121 of the second swelling portion 120 .
As a result, it is possible to bring a flow of rainwater having entered the circumferential groove 20 in a spiral form having a large radius of rotation, resulting in a further improvement of water drainage performance.
In particular, the water led to the first direction along a direction in which the groove 200 extends travels over the end 110 b at a wider width side of the first swelling portion 110 , and thereafter, the water is prevented by the end 110 a at a narrower width side of the first swelling portion 110 after which it is led to the other lateral wall 22 of the circumferential groove 20 from one lateral wall 21 of the circumferential groove 20 . Further, the water is prevented by the end 120 a at a narrower width side of the second swelling portion 120 and the other lateral wall 22 of the circumferential groove 20 , resulting in a turbulent flow to be led to the first direction. As a result of such a flow of water being continuing, the flow of water is brought in a spiral form.
(4) Other Embodiments
So far, the contents of the present invention are disclosed through the above embodiment of the present invention. However, it should not be interpreted that the statements and drawings constituting a part of the present disclosure limit the present invention. From this disclosure, a variety of alternate embodiments, examples, and applicable techniques will become apparent to one skilled in the art.
For example, in the above-described embodiment, the bottom surface of the groove 200 is communicated, as one seamless surface, to the lateral surface 111 of the first swelling portion 110 , and communicated, as one seamless surface, to the lateral surface 121 of the second swelling portion 120 ; however, the bottom surface of the groove 200 may not necessarily be communicated, as one seamless surface like this, and may have a portion where a slight unevenness or ridge is formed.
In the above-described embodiment, the lateral surface 111 of the first swelling portion 110 and the lateral surface 121 of the second swelling portion 120 are of arc-like shape; however, may not necessarily be of arc-like shape, and may be liner in a cross section along the tread widthwise direction D T and the tire radial direction D R .
As described above, needless to say, the present invention includes various embodiments and the like not described here. Therefore, the technical range of the present invention is to be defined only by the inventive specific matter according to the adequate claims from the above description.
INDUSTRIAL APPLICABILITY
According to a characteristic of the present invention, even when a lug groove component is reduced, it is possible to provide a tire having a sufficient water drainage performance. | A tire wherein a first bulge part and a second bulge part are formed in a circumferential direction groove. The first bulge part has a narrow-tip shape such that, in the tire tread plan view, the size in the tread width direction diminishes along a first direction in the tire circumferential direction. The second bulge part has a narrow-tip shape such that, in the tire tread plan view, the size in the tread width direction diminishes along a second direction opposite to the first direction in the tire circumferential direction. A plurality of first bulge parts and second bulge parts are provided at predetermined intervals in the tire circumferential direction. A groove part which extends in the tire circumferential direction is provided between the first bulge part and the second bulge part which opposes the first bulge part in the tread width direction. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a parts assembly method and the equipment to carry out the method, for assembling parts or components such as instrument parts in a structure member such as an instrument panel, and especially a parts assembly method and device which is able to automatically assemble the parts or components in a reliable manner.
2. Description of the Prior Art
Usually, in an assembly line such as those for automobiles, the instrument to be assembled in an automobile is made up by assembling various kinds of parts or components in an instrument panel used as a receiving member or structure member. A production line system is usually adopted for making up these instruments in consideration of its effective operation. In this type of conventional parts assembly method, the instrument panel is set in a fixed position in a fixture mounted on a conveyor, and the instrument panel is transported by means of the conveyor to an assembly stage. Then, each part is assembled in sequence, by manual operation, into the transported instrument panel at the assembly stage.
This method of assembly, using manual labor, is very inefficient, and consequently the need for automatic assembly has become very pronounced.
Accordingly, automatic equipment such as robots is provided for conventional parts assembly devices at each stage of the assembly, and these robots carry out the parts assembly operation through teaching data prepared in advance.
However, in this type of conventional parts assembly method, the instrument panel having a plurality of mounting portions for receiving parts or components is maintained in a fixed attitude on the conveyor to transport it. For this reason, the mounting portions provided for receiving the parts or components in the instrument panel face in different directions. In this case, when the parts or components are inserted into or mounted to the mounting portions in the instrument panel, their access direction must correspond to the direction in which each mounting portion faces. For this reason, it is necessary to have many multishaft robots which are capable of complicated movements to assemble such parts. Therefore, the cost of the parts assembly device itself becomes very large, and depending on the assembly direction, poor assembly can result from displacement of the part or component caused when screws are being tightened to secure the part or component in place. In addition, it could become impossible to carry out assembly, as a result of problems with the shape of the instrument panel and the space available when the parts or components are inserted and the screws tightened, if interference develops between the instrument panel and the robot arm or the screw tightening device.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a parts assembly method and device with which it is possible to automatically mount parts or components to a structure member in an assembly with high reliability.
Another object of the present invention is to provide a parts assembly method and device with which it is possible to use many automatic machines or devices which have simple movements.
A further object of the present invention is to provide a parts assembly method and device with which it is possible to set the structure member in a convenient direction in which assembly conditions are good for the structure member to receive its parts or components.
Briefly described, these and other objects of the present invention are accomplished by the provision of an improved automatic parts assembly apparatus which includes a securing jig which removably supports a structure member for assembly; a transportation device for transporting the structure member and the securing jig to the parts assembly stage; a setting jig which is provided on the parts assembly stage for positioning the abovementioned securing jig and setting the structure member in the prescribed attitude; and an automatic device which is provided on the assembly stage for mounting the parts from a prescribed direction into the structure member. In the parts assembly device, the structure member for assembly is previously secured by means of the securing jig, and the structure member for assembly is transported together with the securing jig to the parts assembly stage. Subsequently the securing jig is set in a fixed position in the setting jig, and, using the setting jig, the mounting portions or openings of the structure member for receiving the parts or components are set in a fixed direction, and the parts or components are assembled into the structure member.
The parts or components are automatically assembled from a fixed direction so that an automatic device having simple movements can be mainly used. In addition, the structure member being assembled can be set in an optional direction in which conditions are more suitable for the assembly. Costs are not increased and the parts or components are reliably and automatically assembled into the receiving member.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features, and advantages of the present invention will be more apparent from the following description of a preferred embodiment, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective, explanatory view of the essential portions in one example of a conventional assembly device for parts or components.
FIG. 2 is an exploded perspective view showing each part or component to be mounted to an instrument panel.
FIG. 3 is a perspective view generally showing one embodiment of the parts assembly device according to the present invention.
FIG. 4 is a perspective view of the essential portion of the embodiment in FIG. 3.
FIG. 5 is a plan view showing one embodiment of the securing jig.
FIG. 6 is a partially broken end view of the embodiment of FIG. 5, viewed in the direction of the arrow VI.
FIG. 7 and FIG. 8 are partially broken cross-sectional views taken along the lines VII--VII and VIII--VIII of FIG. 5.
FIG. 9 is a front elevational view of one example of a setting jig.
FIG. 10 is a plan view of the setting jig of FIG. 9.
FIG. 11 is a partial cross-sectional view taken along the line XI--XI in FIG. 10.
FIG. 12 is a perspective view showing one example of a parts assembly robot.
FIG. 13 is a schematic view illustrating the operation of the robot shown in FIG. 12.
FIG. 14A to FIG. 14G are schematic views showing the mutual relationships among the transportation device, the securing jig and the setting jig.
FIGS. 15A and 15B to FIGS. 24A and 24B are exploded perspective views and schematic sectional views showing the assembly status of each part or component respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
To facilitate the understanding of the present invention, a brief reference will be made to a prior art head access mechanism illustrated in FIG. 1.
As shown in the drawings, in the prior art parts assembly mechanism, there is a conveyor 1, and there are fixtures 2 which position an instrument panel I in a fixed position on the conveyor 1, and, the instrument panel I secured in a fixed position on the conveyor 1 is transported to an assembling stage. Provided on each assembling stage are robots R, R', which assemble each of the parts or components representatively designated by reference numeral 3 and 4.
In the parts assembling mechanism having the configuration outlined above, the instrument panel I which is being transported on conveyor 1 is maintained in a fixed attitude, so that mounting portions on the instrument panel I, representatively designated by reference numeral 5 and 6 for the parts are open in various directions. Therefore, the conventional device, as previously outlined, requires a multishaft robot, so that problems such as poor parts assembly can develop.
The present invention has been successful in eliminating such problems and will now be described with reference to FIG. 2 to FIGS. 24A and 24B.
In describing a parts assembly device which is an embodiment of the present invention, we will first explain the parts or components to be assembled in an instrument panel and the assembly line.
Referring to FIG. 2, here, all the parts or components which are assembled in the instrument panel are shown.
As parts or components to be assembled in an instrument panel I having a plurality of openings such as a grill opening Ia, there are provided an instrument pad 10 which connects to the instrument panel and covers the upper surface of the panel and one part of the side surface inside an automobile compartment; a combination meter 11 in which are included all types of instruments, such as the speedometer, etc.; a side ventilator 12 which is inserted into and supported by the grill opening Ia and an opening 10a of the instrument pad 10 which corresponds with the grill opening Ia; a first cluster lid 13 which covers the perimeter of the combination meter 11 and have a center ventilator 13a and a side ventilator 13b built therein; instrument lamps 14 installed in the edge portion of the top surface front window panel of the instrument panel I; a glove box 15; a reinforcing member 16 for supporting the glove box 15; a hinge pin 17 which supports the glove box 15 and makes its rotation possible; a locking striker 18 with which a latch (not shown) provided in the glove box 15 engages and disengages; an ash tray outer panel 19 which supports an ash tray; two side ventilator ducts 20 which connect to the left and right side ventilators 12, 13b respectively; a second cluster lid 21 which connects to the bottom side of the first cluster lid 13; and switch parts 22,23 for a mirror control switch and a rear defogger mounted in the second cluster lid 21.
Referring to FIG. 3, this drawing illustrates one example of an assembly line for assembly of the instruments in the instrument panel I. This line is made up of, for example, thirteen assembly stages. In first and second assembly stages S1 and S2, expansion nuts (not shown) are mounted on the instrument panel I so as to form the threaded section for screws. At a third assembly stage S3, the tightening of the screws in the instrument panel 10 is carried out, and at a fourth assembly stage S4, along with the temporary assembly of the combination meter 11, the side ventilator 12 is mounted. At a fifth assembly stage S5, the tightening of the screws of the combination meter 11 is carried out, and at a sixth assembly stage S6, the temporary assembly of the first cluster lid 13 and the instrument lamps 14 takes place, while at seventh and eighth assembly stages S7 and S8 the tightening of the screws of the first cluster lid 13 and the instrument lamps 14 is carried out. At a ninth assembly stage S9, the reinforcing member 16 for supporting the glove box 15, the striker 18 for the lock of the glove box 15, and the ash tray outer panel 19 are temporarily mounted, and at a tenth assembly stage S10, the tightening of the screws of all the parts or components which were temporarily mounted at the ninth assembly stage S9 is carried out. The glove box 15 and the hinge pin 17 of the glove box 15 are mounted at a eleventh assembly stage S11. The side ventilator duct 20 is temporarily mounted at a twelfth assembly stage S12, and the tightening of the screws in the side ventilator duct 20 is carried out at a thirteenth assembly stage S13. Furthermore, the mirror control switch 22 and the switch parts 23 are assembled in a second cluster lid 21 on a subline S', and then this second cluster lid 21 is assembled into the instrument panel I.
Referring to FIGS. 3 and 4, these drawings illustrate an embodiment of a parts assembly device according to the present invention applied to an assembly line as outlined above. This parts assembly apparatus comprises a securing jig F which removably secures the instrument panel I on a transportation apparatus H which transports the instrument panel I together with the jig F to parts assembly stages S1 to S13; a setting jig G provided on the parts assembly stages S1 to S13 to position the securing jig F so as to set the instrument panel I in a prescribed attitude; and robots R1 to R13. Each of these parts or components is assembled, from a prescribed direction, into the instrument panel I by means of automatic machines such as the parts assembling robots R1 to R13.
The securing jig F, as shown in FIG. 4 to FIG. 8, comprises a rectangular frame 30 surrounding the instrument panel I, and a plurality of support plates 31 are installed to the frame 30 facing the inside of the frame 30. In addition, provided on each support plate is a receiving section 31a which is formed to correspond with the shape of each part of the instrument panel I to support the instrument panel I. Also provided on the support plates 31 are clampers 32 each comprising a mounting base 33 secured in the support plate 31, an operating lever 34 supported in a rotatable manner on the mounting base 33, and a pivoting arm 35 pivotally supported on the mounting base 33 and joined through toggles to the operating lever 34 so as to rotate following the lever 34. Furthermore this pivoting arm 35 has a press means 36 mounted on a freely rotatable tip of the pivoting arm 35 so as to retain the instrument panel I between the receiving section 31a and the press means 36. By means of the pivoting action of the operating lever 34 up to the clamp position, the rotating arm 35 is restrained at the clamp position, and the instrument panel I is retained by the press means 36. Also, on the receiving section 31a of the support plate 31 which is positioned in the center of either longitudinal side of the frame 30, a positioning hole is opened (not shown on the drawings). A positioning projection (not shown) provided in the center of the longitudinal side of the instrument panel is inserted into this positioning hole. At the same time, on either transverse side of the frame 30, a positioning leaf 37 is provided which positions the transverse side section of the instrument panel I. A guide section 37a which expands in the outward direction is formed on this positioning leaf 37. This guide section 37amoves as a guide when the instrument panel I is placed between the positioning leaves 37. Furthermore, the movement of the clamper 32 may be activated by means of a cylinder, or in a like manner.
The transporting mechanism H can be made up of a lift and carry type conveyor as is shown in FIG. 3 and FIG. 4. Specifically, the transporting mechanism H comprises a first transportation section H1 which is made up of a pair of shuttle bars 40 placed so that they traverse the parts assembly stages S1 to S8; a second transportation section H2 which is made up of a pair of shuttle bars 40 placed so that they traverse the parts assembly stages S9 to S13; and a transfer section H3 which transfers the instrument panel and securing jig assembly from the first transportation section H1 to the second transportation section H2 in sequence. On the pair of shuttle bars 40, a pair of fixtures 41 are provided on each stage in the longitudinal direction of the shuttle bars 40, such that the fixtures engage with and removed from the securing jig F comprising both longitudinal sides of the frame 30 as shown in FIG. 5, specifically through mating holes 42a and 42b provided corresponding to the fixtures 41. It will be noted in the drawing that the mating hole 42b is formed as a long hole to compensate for the pitch aberration between the mating holes 42a and 42b.
The setting jig G, as shown in FIG. 4 and in FIG. 9 to FIG. 11, has a pair of vertical supporting struts 51 each extending from a stand 50 at the center of the transverse side member thereof. A rotating member 53 is provided in a casing 52 set in the upper section of each of the supporting struts 51. The rotating member 53 turns with a shaft which is extended in the longitudinal direction of the instrument panel and securing jig assembly as the rotational center. Rotation is provided from a pulse motor 55 mounted on the casing 52 through a gear mechanism 56, and the rotating member 53 is pivotally supported through bearing 54 in the casing 52. A substantially L-shaped bearing plate 57 which supports the securing jig F projects outward so as to oppose the similar bearing plate of the rotating member 53 of the opposite strut. On the horizontal surface of this bearing plate 57, a positioning pin 58 also protrudes outward. The positioning pin 58 is inserted into a positioning hole 59 which is established in the center of each transverse side member of the frame 30. In addition, a hole section 60 is formed axially through the rotating member 53. A movable, positioning shaft 61 is provided to extend through this hole section 60 and the hole section 52a in the casing 52. The base end section of this positioning shaft 61 is connected to a fixed supporting member 62 through a bearing 63. The fixed supporting member 62 is securely connected to a piston rod 65a on an air cylinder 65 which is mounted by means of a bracket 64 on the casing 52. The positioning shaft 61 moves in a reciprocal manner as a result of the reciprocal motion of the piston rod 65a of the air cylinder 65, and, when the positioning shaft 61 advances, it extends outward from the opposite end opening of the rotating member 53. The advanced positioning shaft 61 is inserted into a positioning hole 67 in a protruding leaf 66 erected in the center of each transverse side member of the frame 30. In the assembly stages other than the assembly stages S1 to S13, the instrument panel and securing jig assembly is temporarily placed on a platform. In addition, as shown in FIG. 10, a striker 68 which vertifies the reciprocal action of the positioning shaft accompanying the reciprocal action of the positioning shaft 61 is provided together with a detection element 69, which could be, for example, a limit switch which is arranged to act corresponding to the advancing position or the retreating position of the striker 68 when a prescribed position is reached by the striker 68.
Also, the parts assembly robots R1 to R13, as shown in FIG. 3, are equipped with necessary devices or hands for assembling the parts in the instrument panel I. By means of prescribed teaching actions, at the mounting position of the instrument panel I, the parts are mounted from above respectively. For example, as shown in FIG. 12 and FIG. 13, at the first assembly stage S1, a double-shafted arm Ra is provided in the parts assembly robot R1 to move in the horizontal direction. An expansion nut driving mechanism A is provided in the arm Ra. The driving mechanism A has a base member 70 secured in the arm Ra, a driving member 71 mounted so that reciprocal action is possible in the vertical direction opposed to the base member 70, and a mounting head 72 which maintains the position of an expansion nut N as a part provided on the tip of the driving member 71. The driving mechanism A further has a stocker 73 in which the expansion nuts N which are to be mounted on the base member 70 are temporarily stored in sequence, and a setting member 74 which sets on the mounting head 72 the expansion nuts N within the stocker 73. The driving mechanism A, as shown in phantom lines in FIG. 12, is first, corresponding to the teaching action of the robot R1, located close to a parts feeder 75, and receives expansion nuts N through a chute 76 and places them in the inside of the stocker 73. Following this, the driving mechanism A, as indicated in solid lines in FIG. 12, corresponding to the teaching action of the robot R1, is transported to a prescribed location. Then the expansion nuts N in the stocker 73 are set in the mounting head 72 through the setting member 74. After this, the expansion nuts N are driven and set by the driving member 71 in a mounting hole 77 of the instrument panel I which has been positioned in the prescribed angled location. Further, as shown in FIG. 13, a positioning-coupling mechanism 78 is provided to position the stocker 73 and the chute 76 in alignment.
Accordingly, when all the parts or components are assembled in the instrument panel I, utilizing this parts assembly mechanism, it is effective to secure the instrument panels in the securing jigs F, respectively, before successively transporting the instrument panels I secured in the securing jigs F on the transport mechanism H. In this case, the instrument panel I is positioned in the frame 30 of the securing jig F by means of the positioning leaves 37 and of the engagement between the positioning hole and a positioning protrusion (not shown), and is reliably secured in the frame 30 by means of the clamper 32. Accordingly, the instrument panel I is transported to the transport mechanism H in an intergrated manner along with the securing jig F .
In this status, the instrument panel I, as shown in FIG. 3, is transported to each parts assembly stage S1 to S13 insequence by the transport mechanism H, and is loaded onto the setting jig G at each of the parts assembly stages. That is, the fixtures 41 of the shuttle bars 40 which form the transport mechanism H, engage with the matching holes 42a and 42b on the frames 30 of the securing jig F, as shown in FIG. 4. For this reason, the instrument panel I which is placed on a pedestal (not shown) or on the setting jig G, as shown in FIG. 14A to FIG. 14C, is raised up when the shuttle bars 40 are up, due to the engagement between the fixture 41 and the securing jig F. The instrument panel I, as shown in FIG. 14D and FIG. 14E, after being transported to the next stage by the forward movement of the shuttle bar 40, is placed onto the pedestal or the setting jig G on that stage when the shuttle bar 40 descends, releasing the engagement between the fixture 41 and the securing jig F. Then the shuttle bar 40, which had descended, moves backward and returns to its original position as shown in FIG. 14F.
At that time, in the instrument panel I which is placed onto the setting jig G, the securing jig F is positioned according to the engagement of the positioning hole 58 of the securing jig F and the positioning pin 58 of the setting jig G, and is supported on the bearing plate 57 of the setting jig G. For this reason, the instrument panel I is positioned in the setting jig G. In this case, the securing jig F becomes separated from the setting jig G in the upward direction. However, by means of instructions from a control mechanism (not shown), the positioning shaft 61 of the setting jig G protrudes forward, and engages with the positioning hole 67 in a protruding leaf 66 of securing jig F, the securing jig F becomes fixed in a reliable manner to the setting jig G. The instrument panel I is secured to the setting jig G through this securing jig F.
After this, the pulse motor 55 of the setting jig G based on an instruction signal from a control mechanism (not shown), pivots by a fixed angle only, and accompanying this action, as shown in FIG. 4 and FIG. 14G, the securing jig F is made to pivot to a prescribed fixed angle around the postioning shaft 61 as center. For this reason, the instrument panel I is set in an attitude at a prescribed angle. In this case, the attitude of the instrument panel I is set so that the mounting portions for the parts face in an upward direction in the assembling stages S1 to S13. In this status, the parts assembly robots R1 to R13 at the assembling stages S1 to S13 mount sequentially the respective parts from above, according to a specified teaching action, down to the mounting portions of the respective instrument panels I maintained in a specific angular attitude.
To explain this further in more detail, at the first assembly stage S1, as shown in FIG. 15A and FIG. 15B, the expansion nuts N1 to N6 for the combination meter 11, the first cluster lid 13 and the glove box striker 19 are mounted in the mounting portions T1, T2, and T3 of the instrument panel I. In this case, the driving direction P of the expansion nuts N1 to N6 by means of the parts assembly robot R1 is fixed, while the instrument panel I is positioned in sequence, by means of the setting jig G, in specified angular attitudes. For this reason, the mounting portions T1, T2, and T3 of the instrument panel I are placed in a position opposing the driving direction P of the expansion nuts N1 to N6. Furthermore, in the drawing, the arrow M shows the clamp position of the instrument panel I in the securing jig F. In addition, at the second assembly stage S2 , as shown in FIG. 16A and FIG. 16B, the expansion nuts N1 to N10 used for the combination meter 11, the first cluster lid 13 and the second cluster lid 21 are mounted from the fixed driving direction P on the mounting positions T1, T2, and T3 of the instrument panel I which is set in specific angular attitudes. Also, at the third assembly stage S3, as shown in FIG. 17A and FIG. 17B, the instrument pad 10 temporarily mounted at the manual line is tightened with screws B, while the instrument panel I is set at specific angular attitudes. The parts assembly robot R3 screws in the screws B in sequence from the fixed direction P. Subsequently, the respective parts assembly operations are carried out in the assembly stages S3 to S13. Further, in FIG. 18A and FIG. 18B the temporary assembly of the combination meter 11 and the instrument lamp 14 is shown, while in FIG. 19A and FIG. 19B the portions to be secured by the screws B are shown. FIG. 20A and FIG. 20B show the temporary assembly of the cluster lid 13 and the side ventilator 12, while FIG. 21A and FIG. 21B show the portions to be secured by the screws B. FIG. 22A and FIG. 22B show the temporary assembly of the reinforcing member 16 of the glove box 15, and of the striker 18, while FIG. 23 shows the portions to be secured by the screw B. FIG. 24A and FIG. 24B show the mounting of the glove box 15 and its hinge pin 17. In this case, the reinforcing member 16 of the glove box 15, the hinge pin 17, and the striker 18 are assembled in the instrument panel I from the direction shown by the arrow P' with reference to the mounting position, but the other parts are assembled in the instrument panel I from the fixed direction P. Then, on completion of the parts assembly at all the stages, the instrument panel I positioned in one assembly stage, by means of the setting jig G, returns to the attitude at transportation time. Subsequently the instrument panel I is transported to the next stage by means of the shuttle bars 40 used for the transportation mechanism H, and passes through all the assembly stages. All the parts are now assembled on the instrument panel I, which provides a fully constructed instrument.
In the above embodiment of the present invention, the securing jig F is provided with a rectangular frame 30, but the present invention is not restricted to such a configuration, and so long as the instrument panel I can be fixed, any appropriate design change may be carried out. In addition, the setting jig G turns the instrument panel I and sets it in a prescribed angular attitude, but the present invention is not restricted to such a configuration, and the instrument panel I may be swung into and set in the prescribed attitude. Furthermore, in this embodiment of the present invention, the instrument panel I is given as an example of a structure member for assembly, but the present invention is by no means restricted to such an instrument panel, and any appropriate member can of course be selected. In this embodiment of the present invention, the parts are assembled in the vertical direction, but the present invention is by no means restricted to this direction.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof. | A parts assembly method and a device which utilizes this method, in which the structure for receiving parts member for assembly is set in prescribed attitudes, and the parts are automatically assembled in that member by assembly from a fixed direction, so that an automatic device having simple movements can be mainly used. The structure member being assembled can be set in an optional direction in which conditions are more suitable for the assembly. There is no increase in cost, and the parts are reliably and automatically assembled into the receiving member. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a hydraulic circuit for a large crane having a detachable counterweight carriage and, more particularly, to a hydraulic circuit for such large crane, capable of synchronously controlling both the swivel motion of the crane unit and the traveling motion of the counterweight carriage.
Description of the Prior Art
Conventionally, a large crane is furnished with a counterweight carriage connected to the rear end of the swivel unit of the crane arrangement to enhance the lifting capacity, and the wheels of the counterweight carriage are driven when the swivel unit of the crane arrangement is swiveled so that the counterweight carriage will travel about the center of swivel motion of the swivel unit as the swivel unit is swiveled. Such a conventional large crane has two separate hydraulic circuits, namely, a hydraulic circuit for driving the swivel unit of the crane arrangement for swivel motion and a hydraulic circuit for driving the wheels of the counterweight carriage. Accordingly, it is the fact that the swiveling speed of the swivel unit of the crane arrangement and the traveling speed of the counterweight carriage do not match is liable to occur and one of the swivel unit and the counterweight carriage impede the motion of the other, making accurate crane work impossible and remarkably deteriorating the efficiency of the work of the crane. Furthermore, when the counterweight carriage is disconnected from the crane arrangement and the crane arrangement is operated independently, the working fluid discharged by the oil pump for supplying the working fluid to the hydraulic motor for driving the driving wheels of the counterweight carriage is uselessly circulated and returned to the tank so as to thus waste energy.
SUMMARY OF THE INVENTION
The present invention has been made to solve such problems in the conventional large crane. It is therefore an object of the present invention to provide a hydraulic circuit for a large crane combined with a counterweight carriage, capable of driving the swivel unit of the crane and the counterweight carriage connected to the swivel unit so that the swiveling speed of the swivel unit and the traveling speed of the counterweight carriage match to enable the swivel unit to swivel and the counterweight carriage to travel synchronously with each other for accurate and efficient crane work, and also capable of effectively utilizing the working fluid discharged by the oil pump for supplying the working fluid to the hydraulic motor for driving the driving wheels of the counterweight carriage so as to enhance energy saving effect when the crane is operated without the counterweight carriage.
To achieve the foregoing object of the invention, the present invention provides a hydraulic circuit for a large crane furnished with a counterweight carriage detachably connectable to the rear end of the swivel unit of the crane arrangement thereof, comprising: a first variable displacement pump; a second variable displacement pump; first hydraulic motor for driving the swivel unit of the crane arrangement of the crane for swivel motion; a first control valve for controlling the flow of the working fluid from the first variable displacement pump to the first hydraulic motor; a third control valve for controlling the operation of the first control valve; a first flow control circuit for controlling the discharge rate of the first variable displacement pump according to a signal pressure applied thereto from the third control valve; a second hydraulic motor for driving the driving wheels of the counterweight carriage; a second flow control circuit for controlling the discharge rate of the second variable displacement pump according to a signal pressure applied thereto from the third control valve, a hydraulic circuit for joining the flow of the working fluid discharged from the second variable displacement pump with the flow of the working fluid discharged from the first variable displacement pump when the counterweight carriage is disconnected from the swivel unit; and changeover means provided in the first flow control circuit for selectively changing the state of the first flow control circuit between a state for applying the signal pressure provided by the third control valve to a controller for controlling the discharge rate of the first variable displacement pump and a state for applying a signal pressure produced by reducing the former pressure at a reduction ratio to the controller for controlling the discharge rate of the first variable displacement pump.
When the swivel unit is swiveled with the counterweight carriage connected thereto, the discharge rate of the second variable displacement pump for supplying the working fluid to the second hydraulic motor for driving the driving wheels of the counterweight carriage which travels along a larger radius is increased beyond the discharge rate of the first variable displacement pump for supplying the working fluid to the first hydraulic motor for driving the swivel unit which swivels along a smaller radius so that the respective angular speeds of the counterweight carriage and the swivel unit coincide with each other. When the counterweight carriage is disconnected from the swivel unit and the crane arrangement is operated independently, the working fluid discharged from the second variable displacement pump is joined to the working fluid discharged from the first variable displacement pump to utilize the working fluid discharged from the second variable displacement pump effectively for driving the swivel unit, so that the energy efficiency of the crane is enhanced, the swiveling speed of the swivel unit is increased and the efficiency of the swivel motion of the swivel unit is improved.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a hydraulic circuit, in a preferred embodiment, according to the present invention;
FIGS. 2 and 3 are graphs showing the discharge rate control characteristics of first and second variable capacity pumps, respectively; and
FIG. 4 is a general side elevation of an exemplary large crane incorporating the hydraulic circuit of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
First, the general constitution of a large crane will be described with reference to FIG. 4. The crane arrangement 1 of a crane comprises a traveling unit 2, a swivel unit 3, a main jib 4, a hanging gadget 5, a mast 6, a guy line 7 for guying the main jib 4, and a guy line 8 for guying the mast 6. A counterweight carriage 10 is provided with a plurality of wheels 11 and is mounted with a counterweight 12. The wheels 11 are each turnable about a vertical axis and rotatable about a horizontal axis. The counterweight carriage 10 is detachably connected to the rear portion of the swivel unit 3 of the crane arrangement 1 by means of a coupling member 9 such as a coupling beam and is also connected detachably to a guy line 13 suspended from the upper end of the mast 6.
Referring to FIG. 1 showing a hydraulic circuit for controlling the principal components of the large cane, shown therein are a first variable displacement pump 14, a second variable displacement pump 15, a first discharge line 16 connected to the discharge port of the first variable displacement pump 14, a second discharge line 17 connected to the discharge port of the second variable displacement pump 15, a joining line 18 interconnecting the first discharge line 16 and the second discharge line 17, a check valve 19 which permits the flow of the working fluid from the second discharge line 17 to the first discharge line 16 and which checks the reverse flow of the working fluid, a first control valve 20 for controlling the swivel motion of the swivel unit 3, a second control valve 21 for controlling the trowel of the counterweight carriage 10, a first hydraulic motor 22 for driving the swivel unit 3 for swivel motion, a second hydraulic motor 23 for driving the wheels 11 of the counterweight carriage 10, connected to the second control valve 21 through a detachable tube coupling 25 or the like, a tank 24, and a third control valve 26 for operating the swivel unit 3 and counterweight carriage 10 for swivel motion.
The third control valve 26 includes a controllable pressure reducing valve which is operated by means of a control lever 27 and which applies signal pressures each corresponding to the direction and angle of operation of the control lever 27 on the signal lines 28 and 29. A pressure source 26A is connected thereto. The first control valve 20 and the second control valve 21 may be spool type directional control valves, however, the first control valve 20 and the second control valve 21, ordinarily, are pressure control valves such as, for example, four-check valves, capable of changing the direction of flow of the working fluid and controlling the pressure of the working fluid to be supplied to the hydraulic motors 22 and 23. The control position of the second control valve 21 is dependent on the swivel motion signal pressure applied on signal lines 30 and 31.
On the other hand, a line 33 is connected through a high pressure selector valve 32 to the signal lines 28 and 29. A first flow control line 34 and a second flow control line 35 are branched from the line 33. The second flow control line 35 is connected to a flow regulator 15a for controlling the second variable displacement pump 15. A line 37 has one end connected through a changeover valve unit 36 (changeover means) to the first flow control line 34 and the other end connected to a flow regulator 14a for the first variable displacement pump 14. The changeover valve unit 36 comprises a solenoid valve 38, a proportional pressure reducing valve 39, a line 40 and a high pressure selector valve 41. The solenoid valve 38 is capable of changing the position between a left position for connecting the first flow control line 34 to the line 40 and a right position for connecting the first flow control line 34 to the proportional pressure reducing valve 39. The high pressure selector valve 41 connects either the line 40 or the proportional pressure reducing valve 39 to the line 37 depending on the pressure of the working fluid working in the line 40 and the pressure of the working fluid regulated by the proportional pressure reducing valve 39.
The manner of operation of the hydraulic circuit will be described hereinafter. To swivel the swivel unit 3 with the counterweight carriage 10 connected thereto, the wheels 11 of the counterweight carriage 10 are directed in a traveling direction by means of steering means (not shown), then the solenoid valve 38 is shifted to the right position, and then the control lever 27 is shifted, for example, to a left position. Consequently, the third control valve 26 applies a signal pressure Pi 1 to the left signal line 28 to change over the first control valve 20 so that the working fluid discharged from the first variable displacement pump 14 is supplied to the first hydraulic motor 22 to drive the first hydraulic motor 22 for rotation in the normal direction, whereby the swivel unit 3 of the crane arrangement 1 is swiveled, for example, in a counterclockwise direction. The signal pressure Pi 1 is also applied to the signal line 30 to change over the second control valve 21 so that the working fluid discharged from the second variable displacement pump 15 is supplied to the second hydraulic motor 23 to drive the second hydraulic motor 23 for rotation in the normal direction, whereby the wheels 11 of the counterweight carriage 10 are driven to make the counterweight carriage 10 travel in synchronism with the swivel motion of the swivel unit 3. While the swivel unit 3 is swiveling with the counterweight carriage connected thereto, the position of the control lever is regulated, and thereby the signal pressure Pi 1 is regulated accordingly. The respective valve positions of the first control valve 20 and the second control valve 21 are regulated according to the signal pressure Pi 1 to control the pressure of the working fluid supplied to the first hydraulic motor 22 and the second hydraulic motor 23 accordingly.
The signal pressure Pi 1 is further applied through the high pressure selector valve 32 and lines 33 and 35 to the flow regulator 15a of the second variable displacement pump 15 to control the discharge rate Q 2 of the second variable displacement pump 15 so as to follow a curve shown in FIG. 3, whereby the flow rate of the working fluid being supplied to the second hydraulic motor 23 is controlled so as to control the traveling speed of the counterweight carriage 10.
On the other hand, the signal pressure Pi 1 is also applied through the signal line 28, the high pressure selector valve 32, line 33, line 34 and the solenoid valve 38 of the changeover valve unit 36 to the proportional pressure reducing valve 39 of the changeover valve unit 36. The proportional pressure reducing valve 39 reduces the signal pressure Pi 1 to a signal pressure Pi 2 . Then the signal pressure Pi 2 is applied through the high pressure selector valve 41 and the line 37 to the flow regulator 14a of the first variable displacement pump 14 to control the discharge rate Q 1 of the first variable displacement pump 14 so as to follow a curve shown in FIG. 2, whereby the flow rate of the working fluid being supplied to the first hydraulic motor 22 is controlled accordingly so as to control the swiveling speed of the swivel unit 3.
Thus, the signal pressure Pi 1 is applied to the flow regulator 15a of the second variable displacement pump 15, while the signal pressure Pi 2 produced by reducing the signal pressure Pi 1 by the proportional pressure reducing valve 39 is applied to the flow regulator 14a of the first variable displacement pump 14. The signal pressure reduction ratio is dependent on the ratio of the discharge rate Q 2 necessary for driving the second hydraulic motor 23 for driving the counterweight carriage 10 to the discharge rate Q 1 necessary for driving the first hydraulic motor 22 for driving the swivel unit 3. The signal pressure reduction ratio can be easily determined by varying the area ratio of the proportional pressure reduction valve 39. The swiveling speed of the swivel unit 3 and the traveling speed of the counterweight carriage 10 are made to match perfectly by properly determining the signal pressure reducing ratio, so that the swivel unit 3 swivels smoothly together with the counterweight carriage.
To operate the swivel unit 3 without the counterweight carriage 10, the counterweight carriage 10 is disconnected from the crane arrangement 1, the line connecting the second hydraulic motor 23 to the hydraulic circuit are disconnected at the detachable tube coupling 25 from the hydraulic circuit, and the solenoid of the solenoid valve 38 is de-energized to assume in the same position shown in FIG. 1. Then, the control lever 27 is shifted, for example, to the left. Then, as described before, the third control valve 26 provides the signal pressure Pi 1 , which is applied through the signal line 28 to the first control valve 20 to change the position of the first control valve 20.
On the other hand, the signal pressure Pi 1 is applied through the high pressure selector valve 32, the line 33, first flow control line 34, the solenoid valve 38, the line 40, the high pressure selector valve 41 and the line 37 to the flow regulator 14a of the first variable displacement pump 14, and is also applied through the second flow control line 35 to the flow regulator 15a of the second variable displacement pump 15. Since the signal pressure Pi 1 is applied through the line 40 to the line 37 bypassing the proportional pressure reducing valve 39, the signal pressure Pi 2 applied to the flow regulator 14a is equal to the signal pressure Pi 1 . The discharge rate Q 1 of the first variable displacement pump 14 is controlled in accordance with the signal pressure Pi 2 so as to follow the curve indicated by the broken line in FIG. 2. As is obvious from FIG. 2, the discharge rate Q 1 in this state is greater than that in the state where the counterweight carriage 10 is connected to the crane arrangement 1. The working fluid thus discharged from the first variable displacement pump 14 is supplied through the first control valve 20 to the first hydraulic motor 22.
The signal pressure Pi 1 is applied further through the second control line 35 to the flow regulator 15a of the second variable displacement pump 15 to control the discharge rate Q 2 of the second variable displacement pump 15 so as to follow the curve shown in FIG. 3. Since the flow of the working fluid discharged from the second variable displacement pump 15 is blocked by the detachable tube coupling 25, the working fluid flows through the joining line 18 and the check valve 19 and joins with the working fluid discharged from the first variable displacement pump 14. Then, the flow of the working fluid discharged from the first variable displacement pump 14 and the working fluid discharged from the second variable displacement pump 15 flows through the first control valve 20 into the first hydraulic motor 22.
Thus, when the swivel unit 3 is swiveled without the counterweight carriage 10, the working fluid is supplied to the first hydraulic motor 22 from both the first variable displacement pump 14 and the second variable displacement pump 15, so that the working fluid discharged from the second variable displacement pump 15 is used effectively to enhance the energy-saving effect of the hydraulic circuit, the working fluid is supplied to the first hydraulic motor 22 at a high rate and thereby the swiveling speed of the swivel unit 3 is increased to improve the efficiency of the swiveling motion of the swivel unit 3.
In accordance with the present invention, there has been disclosed an effective hydraulic circuit which, when the swivel unit is operated with the counterweight carriage, increases the discharge rate of the second variable displacement pump for supplying the working fluid to the second hydraulic motor for driving the counterweight carriage which travels on a radius greater than that on which the swivel unit swivels over the discharge rate of the first variable capacity pump for supplying the working fluid to the first hydraulic motor for driving the swivel unit, to match the angular speed of the counterweight carriage and that of the swivel unit so that the counterweight carriage travels in synchronism with the swivel motion of the swivel unit so that the swivel unit swivels smoothly to improve the accuracy of the swivel motion. When the swivel unit is operated without the counterweight carriage, the hydraulic circuit joins the working fluid discharged from the second variable displacement pump with the working fluid discharged from the first variable displacement pump to supply both the working fluids to the first hydraulic motor to utilize the working fluid discharged from the second variable displacement pump effectively, so that the energy-saving effect of the hydraulic circuit is enhanced, the swiveling speed of the swivel unit is increased and the efficiency of the swivel motion of the swivel unit is improved remarkably.
Although the invention has been described in its preferred form with a certain degree of particularity, it is understood to those skilled in the art that many changes and variations are possible in the invention without departing from the scope and spirit thereof. | A hydraulic circuit for a large crane furnished with a counterweight carriage detachably connectable to the swivel unit of the crane. The hydraulic circuit includes first and second variable displacement pumps for supplying the working fluid to a hydraulic motor for driving the swivel unit and a hydraulic motor for driving the counterweight carriage, respectively, first and second control circuits including valves for controlling the respective discharge rates of the first and second variable displacement pumps, respectively, in accordance with a signal pressure provided by a third control valve for controlling the operation of the swivel unit and the counterweight carriage, a hydraulic circuit for joining the flows of the working fluid discharged from the first and second variable displacement pumps when the swivel unit is operated without the counterweight carriage, and a changeover mechanism for selectively changing the state of the first flow control circuit so that the discharge rate of the first variable displacement pump is regulated properly according to the operating condition of the swivel unit. The discharge rates of the first and second variable displacement pumps are regulated so that the counterweight carriage is driven for movement in perfect synchronism with the swivel motion of the swivel unit. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 62/312,369 filed Mar. 23, 2016, which application is incorporated herein by reference as if fully set forth in their entirety. This application is related to co-pending U.S. application Ser. No. 14/899,997.
STATEMENT OF GOVERNMENTAL SUPPORT
[0002] The invention described and claimed herein was made in part utilizing funds supplied by the U.S. Department of Energy under Contract No. DE-AC02-05CH11231 between the U.S. Department of Energy and the Regents of the University of California for the management and operation of the Lawrence Berkeley National Laboratory. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] Field of the Invention
[0004] The present invention relates to the field of Lithium-Sulfur Batteries.
[0005] Related Art
[0006] Breakthroughs in electrochemical energy storage that enable energy-dense, high-power, and low-cost storage are necessary to catalyze a societal shift from fossil fuels to a carbon-neutral future powered by renewable energy. Of the forward-looking battery chemistries, lithium-sulfur (Li—S) cells are well poised to usurp the dominance of Li-ion owing to the high theoretical specific capacity of the sulfur cathode (1675 mAh g −1 vs. 272 mAh g −1 for a LiCoO 2 cathode), the low cost of sulfur (<$200 ton −1 ), the low environmental impact of sulfur, and the improved safety of the cell. Nevertheless, persistent challenges associated with the sulfur cathode must be overcome for Li—S cells to become practical. Namely, while sulfur cathodes have been engineered extensively for high energy density and durability, design rules are still lacking for high power while also attaining high specific energy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings.
[0008] FIG. 1A illustrates an overview of perylene bisimide (PBI) redox chemistry, self-assembly of PBI into supramolecular polymers through n-stacking, cathode preparation with Ketjenblack (KB) and sulfur on graphene oxide (S-GO), and in operando redox activation of the PBI binder in a functioning cathode. The neutral PBI binder is activated to a dianionic state (Li 2 -PBI) upon reduction at 2.5 V vs. Li/Li + . FIG. 1B illustrates a SEM image of a PBI cathode showing bundles of supramolecular polymer wires dispersed with KB and S-GO; FIG. 1C illustrates a SEM image of a PVDF cathode with KB and S-GO; FIG. 1D illustrates a SEM image of a the PBI/PVDF cathode with KB and S-GO. Scale bars represent 400 nm.
[0009] FIGS. 2A-2C illustrate cyclic voltammograms and electrochemical performances of the PBI, PVDF and PBI/PVDF composite binder cathodes. Cyclic voltammograms of the PBI, PVDF and PBI/PVDF composite binder cathodes at a scan rate of 0.1 mV s −1 . FIG. 2D illustrates voltage profiles of the PBI, PVDF, and PBI/PVDF composite binder cathodes at the second cycle. FIG. 2E illustrates rate capability of the PBI, PVDF and PBI/PVDF, composite binder cathodes. The charge C-rate was fixed at 0.1 C. FIG. 2F illustrates cycling performances and coulombic efficiency of the PBI, PVDF, and PBI/PVDF composite binder cathodes at 1.0 C discharge.
[0010] FIGS. 3A-3C illustrate voltage profiles of PBI, PVDF and PBI/PVDF composite binder cathodes at 0.1 C. Cathodes were discharged or charged in stages for 45 min, followed by 1 h of equilibration time. (0% SOC is relative to the specific discharge capacity of the cathode at the end of discharge). Points are numbered in conjunction with data discussed in FIGS. 4A-4F . FIG. 3D illustrates a plot of polarization overpotential measured between the end of the current step and the end of the relaxations step.
[0011] FIGS. 4A-4F illustrate nyquist plots of the PVDF cathode during discharge ( FIG. 4A ) and charge ( FIG. 4B ), PBI cathode during discharge ( FIG. 4C ) and charge ( FIG. 4D ), and PBI/PVDF composite binder cathode during discharge ( FIG. 4E ) and charge ( FIG. 4F ) in the frequency range of 10 mHz to 1 MHz. Numbered spectra correspond to the points labeled in FIGS. 3A-3C .
[0012] FIG. 5 illustrates a SEM of a PBI suspension dropcast from 1,3-dioxolane onto a silicon wafer. The scale bar is 10 μm.
[0013] FIG. 6 illustrates a SEM image of an S-GO nanocomposite with the EDS spectrum.
[0014] FIG. 7 illustrates TGA result of the S-GO nano-composite under Ar atmosphere with a temperature ramping rate of 5° C. min −1 .
[0015] FIG. 8 illustrates SEM of the PBI cathode. Fibrous supramolecular bundles of π-stacked PBI are visible. The scale bar is 2 μm.
[0016] FIG. 9 illustrates a SEM of the PVDF cathode. The scale bar is 2 μm.
[0017] FIG. 10 illustrates a SEM of the PBI/PVDF composite cathode. The scale bar is 2 μm.
[0018] FIG. 11 illustrates a contact angle measurement for the PBI cathode with an electrolyte droplet (56°). PBI/PVDF and PVDF cathodes were instantly wetted.
[0019] FIG. 12A illustrates a cyclic voltammogram and FIG. 12B illustrates cycling performance of the PBI cathode without S-GO nanocomposite. CV was conducted at 0.1 mV s −1 and the cathode was galvanostatically discharged at 1.0 A per g electrode .
DETAILED DESCRIPTION
[0020] In the discussions that follow, various process steps may or may not be described using certain types of manufacturing equipment, along with certain process parameters. It is to be appreciated that other types of equipment can be used, with different process parameters employed, and that some of the steps may be performed in other manufacturing equipment without departing from the scope of this invention. Furthermore, different process parameters or manufacturing equipment could be substituted for those described herein without departing from the scope of the invention.
[0021] These and other details and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings.
[0022] Various embodiments of the invention show that transport bottlenecks for ions and electrons in composite sulfur cathodes, presently limiting high-power applications, can be relieved when the conventional polymer binder is supplanted with a custom-purposed supramolecular polymer binder that is also a redox-mediator for the sulfur battery chemistry.
[0023] FIG. 1A illustrates an overview of perylene bisimide (PBI) redox chemistry, self-assembly of PBI into supramolecular polymers through n-stacking, cathode preparation with Ketjenblack (KB) and sulfur on graphene oxide (S-GO), and in operando redox activation of the PBI binder in a functioning cathode. The neutral PBI binder is activated to a dianionic state (Li 2 -PBI) upon reduction at 2.5 V vs. Li/Li + . FIG. 1B illustrates a SEM image of a PBI cathode showing bundles of supramolecular polymer wires dispersed with KB and S-GO; FIG. 1C illustrates a SEM image of a PVDF cathode with KB and S-GO; FIG. 1D illustrates a SEM image of a the PBI/PVDF cathode with KB and S-GO. Scale bars represent 400 nm.
[0024] These supramolecular redox mediators consist of n-stacked perylene bisimide (PBI) molecules, which are reduced electrochemically in operando during the first discharge at potentials below 2.5 V vs. Li/Li + . We show that upon activation, the cell impedance is dramatically reduced and commensurate with stable cycling at both moderate and high rates. We also note unexpected synergies between these redox-mediating supramolecular binders and conventional polymer binders when both are present in the sulfur cathode. These synergies manifest as a powerful new means to direct the evolution of cell impedance to a state that is lower than cells assembled with either of the binders on their own; furthermore, we show that this state of the battery is sustainable indefinitely throughout high-rate cycling. Our work highlights the multi-faceted role played by these underappreciated components in the sulfur cathode, and where new concepts in adaptive materials can be applied to solve challenges in charge transport.
[0025] Binders for composite sulfur cathodes should aid in film processing and drying onto aluminum current collectors, electrolyte wetting during cell assembly, ion transport, and mechanical integrity upon cycling to accommodate the volume changes associated with S 8 —Li 2 S interconversion. Polyvinylidene difluoride (PVDF) is the most prevalent binder used today, although recent reports have suggested that PVDF can block the pores of mesostructured conductive carbons, which negatively impacts the available surface area for Li 2 S electrodeposition. Alternative binders—including gelatin, polyvinylpyrrolidone (PVP), PVP blends with Nafion, PAMAM dendrimers, polycationic β-cyclodextrins, polyacrylic acid, polyethylene oxide, and carboxymethylcellulose:styrenebutadiene-rubber (CMC:SBR) have therefore focused on addressing one or more of these binder attributes as a means to improve cathode performance.
[0026] Some of the most successful binders have been shown to mitigate the migration of soluble polysulfides from the cathode into the electrolyte, which otherwise would lead to stranded sulfur in the cell or instabilities in the lithium anode. None have been reported that directly participate in the redox chemistry of sulfur or otherwise serve to enhance ion transport as needed for high-rate applications.
[0027] Nonetheless, we hypothesize that these attributes are critical to the further advancement of the sulfur cathode. Our perspective is that these functions can now be conferred to new binder materials based on supramolecular redox mediators. Supramolecular redox mediators offer both self-healing properties needed to accommodate the volume changes in the sulfur cathode on cycling and adaptive charge transport upon activation. Their role as such remains distinctive from electronically conductive polymers used to confine sulfur.
[0028] Redox mediators for sulfur cathode reactions, which nominally occur at 2.5 V and 2.1 V vs. Li/Li + , have only been recently reported. Those consisting of polycyclic aromatic hydrocarbons, and in particular perylene bisimide (PBI) and benzo[ghi]perylene imide (BPI), are amenable to supramolecular polymerization via π-stacking. Whereas previous accounts focused on the action of soluble redox mediators in Li—S cells, our focus here is instead on their action in the solid state as a binder. We were ultimately successful in sequestering PBI-based redox-mediators as self-assembled networks of nanowires, tens of microns in length, in a composite sulfur cathode by careful selection of the imide substituents inspired by Würthner and co-workers. The networked PBI binder architecture—readily apparent in the solid state (see FIG. 5 ) as well as in the cathode composite (see FIG. 1C and FIG. 8 )—remained intact upon electrolyte infiltration.
[0029] The redox-active PBI core of our supramolecular binder exhibits a fully reversible two-electron reduction around 2.5 V vs. Li/Li + (see FIG. 1A ), which aids in charge transfer to and from polysulfides in Li—S cells. Additionally, their manifestation as a percolated network suggests highly structured regions within the cathode that are both lithiated and solvated. We anticipate that this architecture helps localize Li + ions near active material as needed for high interfacial ion flux. We were also interested in mixed-binder approaches consisting of PBI/PVDF blends in that each component features complementary coordination for Li + (which is oxo-phillic, favoring PBI) and TFSI − (which is fluorophillic, favoring PVDF), respectively; this unusual complementarity could enable higher mobility for ionic charge carriers in the composite sulfur cathode.
[0030] To demonstrate the performance-enhancing features of PBI supramolecular polymers in Li—S cells, we interfaced them with a cetyltrimethyl ammonium bromide (CTAB)-modified sulfur-graphene oxide (S-GO) nanocomposite (80% S w/w, see FIGS. 6-7 ) as the active material in the cathode.
[0031] Three distinctive cathodes were prepared using CTAB modified S-GO, Ketjenblack (KB) as conductive carbon additive, and various binders in a 8:1:1 weight ratio; binders included pure PBI nanowire networks, pure PVDF, and a 1:1 blend of PBI and PVDF (PBI/PVDF). Slurries of these components in N-methyl-2-pyrrolidinone (NMP) were coated onto aluminum current collectors by doctor-blade coating and yielded cathodes with a sulfur content of 64% (w/w) after drying.
[0032] Scanning electron micrographs of each composite sulfur cathode indicated macroscopic film homogeneity, however, differences in the PBI network architecture were observed for cathodes prepared using PBI when compared to those prepared using PBI/PVDF blends (see FIGS. 1B-1D and FIGS. 8-10 ). More specifically, the introduction of PVDF to the PBI cathode appears to disrupt the bundling of PBI nanowires in the solid state, indicative of high interfacial area between the two materials as well as higher interfacial area with S-GO and KB. Reduced bundling of PBI nanowires in the PBI/PVDF cathode also improved the bulk electrolyte wettability relative to the PBI cathode (see FIG. 11 ).
[0033] FIGS. 2A-2C illustrate cyclic voltammograms and electrochemical performances of the PBI, PVDF and PBI/PVDF composite binder cathodes. Cyclic voltammograms of the PBI, PVDF and PBI/PVDF composite binder cathodes at a scan rate of 0.1 mV s −1 . FIG. 2D illustrates voltage profiles of the PBI, PVDF, and PBI/PVDF composite binder cathodes at the second cycle. FIG. 2E illustrates rate capability of the PBI, PVDF and PBI/PVDF, composite binder cathodes. The charge C-rate was fixed at 0.1 C. FIG. 2F illustrates cycling performances and coulombic efficiency of the PBI, PVDF, and PBI/PVDF composite binder cathodes at 1.0 C discharge.
[0034] The electrochemical behavior of sulfur cathodes prepared with PBI, PVDF, or PBI/PVDF binders was investigated using cyclic voltammetry (CV) over the potential range 1.5-2.8 V vs. Li/Li + and at a scan rate of 0.1 mV s −1 (see FIGS. 2A-2C ). All three cathodes showed two reduction peaks and one oxidation peak during the discharge and charge processes, respectively.
[0035] However, the CV peak characteristics of the three cathodes were significantly different. After the first cycle, two reduction peaks and an anodic peak of the PBI cathode were located at 2.3, 1.9 V and 2.6 V, respectively (see FIG. 2A ), whereas those of the PVDF cathode were located at 2.1, 1.6 V and 2.7 V (see FIG. 2B ), indicating that larger peak shifts occurred in the CV of the PVDF cathode than that of the PBI cathode due to the larger overpotential of the PVDF cathode.
[0036] Moreover, the redox peaks in the CV for the PVDF cathode were broader and less distinguishable than those of the PBI cathode. The incomplete anodic peak of the PVDF cathode is especially noteworthy and reflects the slow reaction kinetics of the PVDF cathode. In contrast, the PBI/PVDF composite binder cathode exhibited the lowest overpotential with sharp peaks located at 2.3 V and 2.0 V for the cathodic peaks and at 2.55 V for the anodic peak, indicating that the highest reaction rate for the sulfur cathode is facilitated by the PBI/PVDF binder blend.
[0037] To evaluate the impact of these distinctive electrochemical behaviors on cell performance, PBI, PVDF, and PBI/PVDF composite binder cathodes were galvanostatically cycled at 1.0 and 0.5 C (1.0 C=1672 mA g −1 S) for the discharge and charge processes, respectively (see FIG. 2D ). During the discharge process at 1.0 C, the PBI cathode showed two major discharge plateaus with a capacity of 582 mAh g −1 S, whereas the PVDF cathode showed no obvious second plateau associated with the formation of Li 2 S, which caused a low sulfur utilization of only 323 mAh g −1 S. On the other hand, the PBI/PVDF composite cathode delivered the highest discharge specific capacity of 700 mAh g −1 S with the lowest discharge and charge overpotentials during the cycle.
[0038] The rate capabilities of PBI, PVDF, and PBI/PVDF composite binder cathodes were also evaluated at various discharge C rates from 0.1 C to 3.0 C and then back to 0.1 C. At 0.1 C, both the PBI and PVDF cathodes showed similar specific discharge capacities of about 1050 mAh g −1 S, however, the specific discharge capacity of the PVDF cathode decreased dramatically as the test C-rate increased, and finally, a specific discharge capacity of only about 320 mAh g −1 S was obtained at 1.0 C discharge.
[0039] In contrast, the PBI cathode retained a specific discharge capacity of about 600 mAh g −1 S at 1.0 C discharge, indicating that the PBI cathode could provide an electrode structure more suitable for high C-rates than the PVDF cathode. Furthermore, the PBI/PVDF composite binder cathode exhibited the best rate capability with a highly reversible discharge capacity of about 800 and 350 mAh g −1 S at C-rates of 1.0 and 3.0 C, respectively, and the specific discharge capacity recovered quickly to 1066 mAh g −1 S, when the C-rate was decreased back to 0.1 C.
[0040] To understand the longevity of Li—S cells configured with the different binders, cycling performance at 1.0 C over 150 cycles was evaluated for PBI, PVDF, and PBI/PVDF derived cathodes (see FIG. 2F ). Compared to the PVDF cathode, the PBI cathode exhibited a reversible discharge capacity approximately 1.5-2 times higher after 150 cycles with a Coulombic efficiency above 99.4%. The Coulombic efficiency of the PVDF cathode was unstable, possibly due to incomplete Li 2 S formation, accounting for the lack of a second discharge plateau shown in FIG. 2D .
[0041] On the other hand, the PBI/PVDF composite binder cathode exhibited excellent cycling performance at 1.0 C discharge with an initial discharge capacity around 700 mAh g −1 S. A specific discharge capacity of 600 mAh g −1 S was obtained after 150 cycles, which corresponds to a capacity retention of 86%. During 150 cycles, the Coulombic efficiency of the PBI/PVDF composite binder cathode was above 99.8%, reflecting the superior reversibility of the electrochemical reaction between sulfur and lithium during cycling with this binder blend.
[0042] Collectively, these initial experiments point to impressive gains in high-rate performance when PBI is used as a binder in place of PVDF, and even greater gains when the PBI/PVDF blend is used. While there is a myriad of microscopic processes that dictate Li—S cell characteristics, the presence of these new PBI binders with turn-on activation for charge transfer and charge transport only amplifies that complexity as does the role played by PBI/PVDF interfaces. Thus, we were interested in applying additional electroanalytical techniques to our cathodes that might more directly relate the specific influence of the adaptive charge-transporting PBI networks on the observed cell performance.
[0043] FIGS. 3A-3C illustrate voltage profiles of PBI, PVDF and PBI/PVDF composite binder cathodes at 0.1 C. Cathodes were discharged or charged in stages for 45 min, followed by 1 h of equilibration time. (0% SOC is relative to the specific discharge capacity of the cathode at the end of discharge). Points are numbered in conjunction with data discussed in FIGS. 4A-4F . FIG. 3D illustrates a plot of polarization overpotential measured between the end of the current step and the end of the relaxations step.
[0044] To that end, we applied a galvanostatic intermittent titration technique (GITT) to study the evolution of ion-transport behaviors within the cathodes upon cycling. PBI, PVDF, and PBI/PVDF composite binder cathodes were cycled at 0.1 C with 45-min-long galvanostatic pulses, interrupted by 1 h of equilibration time between pulses (see FIGS. 3A-3C ). Overpotentials at each point, determined by the potential difference between the end of the current step and the end of the equilibration step, are plotted as ΔE vs. state of charge (SOC) (see FIG. 3D ). From these data, it was readily apparent that the open circuit potentials measured after the equilibration times were equivalent for all three cathodes; however, the hysteresis of the cathodes were significantly different. In principle, the sudden potential change at short times is mainly due to an iR drop generated by the ohmic resistance of the cell, and the PVDF cathode showed the highest overpotential at nearly all states of charge compared to the other two cathodes containing supramolecular PBI binder (see FIG. 3D ).
[0045] Notably, the PBI/PVDF blended binder cathode showed the lowest overpotential among all cathodes. At SOCs between 20-0% and 80-100% during discharge and charge processes, respectively, all three cathodes showed dramatic increases in the overpotential. In those regions, dissolved lithium polysulfides are re-deposited onto the embedded current collector surface, essentially forming insoluble Li 2 S or sulfur films during discharge or charge, respectively. This deposition increases the internal resistance of the cell by impeding both electron and lithium ion conduction due to their insulating nature. Although PBI and PVDF cathodes each show similar overpotentials during the initial discharge, there is a pronounced drop in charging overpotentials for the PBI cathode once it has been electrochemically activated, indicating a redox-mediating effect or, alternatively, a change in the local solvation of the PBI network upon reduction and lithiation.
[0046] FIGS. 4A-4F illustrate nyquist plots of the PVDF cathode during discharge ( FIG. 4A ) and charge ( FIG. 4B ), PBI cathode during discharge ( FIG. 4C ) and charge ( FIG. 4D ), and PBI/PVDF composite binder cathode during discharge ( FIG. 4E ) and charge ( FIG. 4F ) in the frequency range of 10 mHz to 1 MHz. Numbered spectra correspond to the points labeled in FIGS. 3A-3C .
[0047] Further insight into the emergent in operando behavior unique to cathodes prepared with PBI binders was gleaned from EIS measured at the end of every equilibration step throughout the GITT analysis (see FIGS. 4A-4F ). Nyquist plots of the PVDF cathode showed relatively large, depressed semicircles that increased in diameter as the SOC approached 0% and returned to near the original diameter upon charging to 100% SOC (see FIGS. 4A-4B ), likely due to deposition and then dissolution of insulating Li 2 S.
[0048] A much more complex evolution of impedance spectra was observed in the case of PBI, where a depressed semicircle at high frequencies and a long sloping line at low frequencies was initially observed at 100% SOC (see FIGS. 4C-4D ). Upon discharge, a second semicircle in the middle frequency region began to emerge (points 2-6) and by 27% SOC (point 7) the middle frequency semicircle began to dominate the spectra with a sloping tail growing in the region between 40-80 mHz (points 7-9). Growth of a middle frequency semicircle has been previously attributed to the formation of a resistive Li 2 S (or Li 2 S 2 ) film on the sulfur cathode, which impedes diffusion of counterions and polysulfides to the current collector. At the end of discharge (point 10) the semicircle in the middle frequency region and sloping line at low frequency are completely merged. This increase in impedance at 0% SOC may be due to mass-transport issues arising from the lower wettability of this cathode coupled with Li 2 S deposits blocking ion transport near the current collector. Immediately upon charging, the large semicircle in the middle and low frequency regions disappeared and the impedance of the cell decreased dramatically.
[0049] On the other hand, the PVDF/PBI composite binder cathode exhibited unique electrochemical behavior (see FIGS. 4E-4F ), where the impedance decreased as the SOC approached 0% during discharge and the size of the semicircles remained small and nearly constant during the charge process, suggesting a unique activation had occurred in operando. Compared to the fully discharged PBI cathode, the PBI/PVDF composite binder cathode did not show any electrochemical behavior in the low frequency region that is associated with mass-transfer limitations. Instead, the EIS semicircles of the PBI/PVDF cathode were much smaller than those of the other two cathodes throughout the GITT, which is a sign of lower cell impedance overall and is in agreement with the enhanced rate capability during normal cell operation. Furthermore this lowest-impedance state appears to be sustainable at different SOCs.
[0050] Our findings suggest a re-examination may be in order for the ideal binder paradigm for composite electrodes. Whereas passive binders impart many useful functions as noted, redox-active binders offer a powerful new means to adapt the electrode's transport behaviors in operando and on demand.
[0051] Against conventional wisdom, we show that it is not necessary to configure the binder as a covalent high-polymer. Indeed, supramolecular approaches are also suitable; in fact, these may be preferred for electrode materials undergoing significant volume changes associated with conversion or alloying reactions, as is the case with sulfur and silicon electrodes. With this in mind, the networked architecture of the binder in the solid state and it's relationship to the electrode's active materials and embedded current collector become key to understanding cell performance—with high interface density contributing favorably to high rate-performance as observed here with the PBI/PVDF-derived sulfur cathodes.
[0052] We also suggest that we are only beginning to reveal the synergies between binder components, particularly with respect to their interactions with each other and with ions in the supporting electrolyte. For example, we hypothesize that the evolved, low, and sustained cell impedance that we observe only in the case of electrochemically-activated PBI/PVDF blends may arise from improved charge-separation of both Li + (which coordinates to reduced Li 2 -PBI) and TFSI − (which coordinates to PVDF), which would improve their mobility within the composite and thus enable the high-rate performance. These foundational concepts in adaptive transport behaviors begin to map forward an exciting path in materials discovery at the interface of organic, polymer, supramolecular, and electrochemistry.
Instrumentation.
[0053] Contact angle measurements were performed using a Krüss EasyDrop. Scanning electron micrographs were taken using the in-lens detector of a Zeiss Gemini Ultra-55 outfitted with energy-dispersive X-ray spectroscopy (EDS, JEOL JSM-7500F) for elemental mapping. Thermogravimetric analysis (TGA) was used to determine the weight content of the S in the CTAB-modified S-GO nanocomposite with a heating rate of 10° C. min −1 under N 2 atmosphere. Battery testing was performed on an Arbin BT2000 cycler. Electrochemical impedance spectroscopy was conducted with a BioLogic VMP3 potentiostat.
Materials.
[0054] PBI was synthesized according to a literature procedure. Lithium metal (99.98%) was purchased from Cyprus Foote Mineral. Sodium sulfide (Alfa Aesar, Na 2 S, anhydrous), sulfur (Alfa Aesar, S, ˜325 mesh, 99.5%) Graphene oxide ACS Material, cetyltrimethyl ammonium bromide (Sigma Aldrich, CTAB, CH 3 (CH 2 ) 15 N(Br)(CH 3 ) 3 .) formic acid (Aqua Solutions).
Preparation of the CTAB-Modified S-GO Nanocomposite.
[0055] The CTAB-modified S-GO nanocomposite was prepared via a method as described in co-pending U.S. application Ser. No. 14/899,997. Briefly, 0.58 g of sodium sulfide powder was dissolved in 25 mL ultrapure water to form a Na 2 S solution. 0.72 g elemental sulfur powder was added to the Na 2 S solution and stirred with a magnetic stirrer at 60° C. until the solution became transparent orange color (a sodium polysulfide (Na 2 S x ) solution). 18 mL of single layer graphene oxide dispersion (GO, 10 mg/mL) in water was diluted to form a GO suspension (180 mg of GO in 180 mL of ultrapure water). 2.5 mM of cetyltrimethyl ammonium bromide (CTAB, CH 3 (CH 2 ) 15 N(Br)(CH 3 ) 3 ) were added to the GO suspension and stirred for 2 h with a magnetic stirrer.
[0056] Then, the prepared Na 2 S x solution was added to the GO-CTAB composite solution and stirred overnight. The as-prepared Na 2 S x -GO-CTAB composite solution was slowly added to 100 mL of 2 M formic acid (HCOOH) and stirred for 2 h to precipitate elemental S onto the GO. Finally, the CTAB-modified S-GO nano-composite was filtered and washed with acetone and ultrapure water several times to remove salts and impurities. The obtained powder sample was dried at 50° C. in a vacuum oven overnight. The dried powder sample was ground using mortar and pestle and heat-treated in a tube furnace at 155° C. for 12 h under Ar atmosphere.
Contact Angle Measurement.
[0057] Composite cathodes identical to those tested in coin cells were prepared with PBI, PVDF, and PBI/PVDF. The EasyDrop instrument was placed in a glove bag and purged with N 2 for 1 h to prevent water uptake by the hygroscopic electrolyte from altering the measurement. PVDF and PBI/PVDF electrodes wet immediately by electrolyte and would not sustain a drop for contact angle measurement, whereas the PBI electrode showed a contact angle of 56° as is depicted in FIG. 11 .
Li—S Cell Electrochemical Measurements.
[0058] The sulfur cathodes were prepared by mixing the S-GO nanocomposite, carbon black (Ketjenblack) with a binder (either the PBI, PVDF, or PBI/PVDF composite binder 1:1 by weight) at a weight ratio of 8:1:1 in N-methyl-2-pyrrolidone (NMP) solvent to form a slurry using magnetic stirrer. All Slurries were heated to 100° C. while stirring to completely dissolve the PBI binder into NMP and uniformly casted via a doctor blade on aluminum foil.
[0059] The cathode was first dried at room temperature for 24 h, and then dried in a vacuum oven at 50° C. for 24 h to fully eliminate any solvent residue. The average sulfur loading of the cathodes was 0.8-1.0 mg cm −2 . 1 M Lithium Bis(Trifluoromethanesulfonyl)Imide (LiTFSI) in N-methyl-N-butylpyrrolidinium bis(trifluoromethane sulfonyl)imide (PYR 14 TFSI)/dioxolane (DOL)/Dimethoxyethane (DME) (2:1:1, v/v) containing 1 wt % LiNO 3 was prepared for the electrolyte. CR2325-type coin cells were fabricated with a lithium metal foil as counter/reference electrode and a porous polypropylene separator (2400, Celgard) in a glove box filled with Ar gas.
[0060] Cyclic voltammetry for the prepared cells was conducted using a potentiostat with a voltage range of 1.5 to 2.8 V for 5 cycles at a constant scan rate of 0.1 mV s −1 . The prepared cells were discharged and charged at 0.1 C rate using a procedure that consisted of galvanostatic discharge and charge pulses, each 45 min long, followed by 1 h of relaxation time, with open circuit status until the cell voltage reaches 1.5 V and the electrochemical impedance was measured from 10 mHz to 1 MHz using a potentiostat at the end of every relaxation step during discharge and charge. Galvanostatic cycling test of the coin cells was performed using a battery cycler between 1.5 and 2.8 V at 1.0 C and 0.5 C for discharge and charge, respectively. Rate capability tests were also performed at various discharge C rates from 0.1 C to 3.0 C and then back to 0.1 C.
[0061] All manipulations involving lithium metal were performed in an Ar-filled glove box with water and O 2 content below 2.0 ppm.
PBI Control Cell.
[0062] PBI and related rylene molecules are known organic cathode materials for Li-ion cells; therefore, a control cathode composed solely of supramolecular PBI binder and Ketjen black in a 1:1 weight ratio was subjected to CV and galvanostatic cycling (see FIGS. 12A and 12B ). Even with PBI as 50% of the cathode mass a minimal capacity of 35 mAh/g (PBI) was measured, confirming that the capacity contribution of PBI to the PBI cathodes containing S-GO nanocomposite as active material is negligible.
[0063] Various embodiments of the invention describe a battery. In one embodiment, the battery comprises a cathode comprising a redox-active supramolecular polymer binder and a cetyltrimethyl ammonium bromide (CTAB) modified graphene oxide-sulfur (GO-S) nanocomposite, wherein GO further comprises a plurality of functional groups and S is bonded to carbon atoms. The battery may also comprise a separator, an anode, and an electrolyte.
[0064] The redox-active supramolecular polymer binder may comprises π-stacked perylene bisimide (PBI) molecules. The redox-active supramolecular polymer binder may comprise nanowires.
[0065] The cathode may further comprise a polyvinylidene difluoride (PVDF) polymer. Alternatively, the cathode may further comprise other types of binders including styrene butadiene rubber (SBR). polyethylene oxide (PEO), and carboxy methyl cellulose (CMC).
[0066] The cathode may further comprise Ketjenblack (KB) or carbon black (CB) or any other type of conductive additive.
[0067] The battery may include a separator comprising a porous polypropylene. The porous polypropylene may include a Celgard 3501, Celgard 2400, or other Celgard separators.
[0068] The battery may include an electrolyte comprising an ionic liquid-based electrolyte. The electrolyte may comprise a mixture of 1,3-dioxolane (DOL) and dimethoxyethane (DME) with lithium bis(trifluoromethylsulfonyl)imide (LiTFSI). The ionic liquid may comprise (n-methyl-(n-butyl) pyrrolidinium bis(trifluoromethanesulfonyl)imide (PYR14TFSI). The electrolyte may comprise a lithium nitrate (LiNO 3 ) additive. The electrolyte may comprise PYR 14 TFSI-LiTFSI-PEGDME. The electrolyte may comprise LiTFSI-PEGDME. The electrolyte may comprise Lithium Bis(Trifluoromethanesulfonyl)Imide (LiTFSI) in N-methyl-N-butylpyrrolidinium bis(trifluoromethane sulfonyl)imide (PYR 14 TFSI)/dioxolane (DOL)/Dimethoxyethane (DME) (2:1:1, v/v) containing 1 wt % LiNO 3 . | To address the need for multi-functional binders specifically tailored for sulfur cathodes π-stacked perylene bisimide (PBI) molecules are repurposed as redox-active supramolecular binders in sulfur cathodes for Li—S cells. In operando lithiation of PBI binders permanently reduces Li—S cell impedance enabling high-rate cycling, a critical step toward unlocking the full potential of Li—S batteries. | 7 |
BACKGROUND
[0001] This invention relates to dispensing of currency.
[0002] Currency dispensers are found, for example, in automatic teller machines (ATMs), including those for so-called off-premises use (for example, at an airport, grocery store, or other location not controlled by a financial institution).
[0003] A typical currency dispenser includes a removable supply container called a cassette. A stack of currency is loaded into the cassette and then delivered to and loaded into the dispenser.
[0004] The dispenser receives signals from control circuitry in the ATM when a user asks for cash. The signals could, for example, instruct the dispenser to dispense $300 in $20 bills to the user.
[0005] The dispenser includes paper transporting mechanisms that remove the needed number of bills from the supply container, one after another. Each removed bill is fed along a paper path to a position at which the bill is ejected to the outside world, where the user can reach it.
[0006] If the dispenser determines that a bill traveling along the path should not be dispensed, the bill is diverted into a locked reject cassette.
[0007] An example of a bill dispenser is shown in United States published application number 20050098622, published May 12, 2005, the contents of which are incorporated here by reference.
SUMMARY
[0008] In general, in one aspect, a paper passageway delivers bills that have been picked from a bill supply container to a location at which the bills are to be dispensed, the paper passageway and the bill supply container are structurally coupled together at least temporarily to form an integrated bill dispensing structure, and at least one of the bill supply container and the paper passageway are functionally incomplete in the absence of the other.
[0009] Implementations may include one or more of the following features. The bill supply container lacks a wall to support bills, the wall being provided by the paper passageway in the integrated bill dispensing structure. Side walls of the bill supply container are coupled to the wall provided by the paper passageway. Each of the side walls of the bill supply container is coupled to the passageway wall at an upper location and a lower location. The bill supply container is configured to enable access by a picker to bills stored in the supply container, and the paper passageway is configured to receive bills delivered from the picker. The bill supply container is generally box-shaped and includes an integral extension from the box to couple the bill supply container to the paper passageway. The integral extension extends under the picker and is attached to the paper passageway. Opposite sides of the integral extension are coupled to side walls of the picker when the picker is installed. An underside of a base of the bill supply container includes molded strengthening features that provide structural strength to the integrated bill dispensing structure. Control electronics are housed in the base of the bill supply container and supported by the strengthening features. The bill supply container includes molded feet for mounting the integrated bill dispensing structure. The bill supply container includes electrical terminals to which the picker mates. The bill supply container includes a plate to apply pressure to a stack of the bills that are in the container and ready for dispensing and a one-piece guide rail to guide the plate back and forth toward and away from the stack of bills, the guide rail piece forming a floor of the bill supply container. The one-piece guide rail is snapped at its ends to respective side walls of the bill supply container and provides structural strength for the side walls. The plate is biased toward the bill stack and the apparatus also includes a locking mechanism to hold the plate away from the bill stack for loading of bills. The locking mechanism comprises a rotating key formed of two plastic elements that mate through a hole in a front wall of the bill supply container.
[0010] In general, in another aspect, a paper passageway delivers bills that have been picked from a bill supply container to a location at which the bills are to be dispensed or a location at which the bills are to be rejected, a reject container holds rejected bills in a stack in which the bills are oriented vertically, and the bills are accessible to a user from an open top of the container.
[0011] Implementations may include one or more of the following features. The reject container comprises a single integral piece. The reject container comprises a vertically configured box open at the top to receive bills fed by gravity from a reject path of the paper passageway. The reject container comprises a rear wall sloped to direct bills fed by gravity into the reject container attached to the paper passageway. The reject container comprises an angled bottom floor to cause each of the bills fed by gravity into the reject container to be oriented vertically and in a position that causes each successive bill to be placed in front of the prior bill until the tray is full.
[0012] In general, in another aspect, a paper passageway to deliver bills that have been picked from a bill supply container to a location at which the bills are to be dispensed, the paper passageway and the bill supply container are coupled at least temporarily to form a structure, a picker is positioned within the structure to enable the picker to pick bills from the bill supply container and move them along a predetermined path for delivery to the paper passageway, and the picker is removable from the position within the structure by sliding the picker in a direction perpendicular to the predetermined path.
[0013] Implementations may include one or more of the following features. The picker includes an anti-backup roller requiring periodic maintenance. The picker is latched into and unlatched from the position using a single hand-operated knob. Guide features aid the sliding of the picker.
[0014] In general, in another aspect, a bill dispensing structure including a bill supply container, a paper passageway to deliver bills that have been picked from a bill supply container to a location at which the bills are to be dispensed through a wall to a user, a reject tray to receive bills that are diverted from the paper passageway and are not dispensed through the wall, and a mounting mechanism to support the bill dispensing structure on the wall, the bill dispensing structure being self supporting and rigid without additional support.
[0015] Implementations may include one or more of the following features. The mounting mechanism comprises mounting elements near the top of a side of the bill dispensing structure that faces the wall. The mounting elements comprise pins each having an end connected to the bill dispensing structure and a free end projecting from the bill dispensing structure in a direction parallel to the wall. The mounting mechanism comprises four pins any two of which are adequate to support the bill dispensing mechanism on the wall.
[0016] In general, in another aspect, a picker is removed from a position at which the picker can pick bills from a bill supply container and move them along a predetermined path for delivery to a paper passageway from which they are to be dispensed, the picker being removed by sliding it in a direction perpendicular to the predetermined path. Implementations may include one or more of the following features.
[0017] Implementations may include one or more of the following features. Locators on one end of the picker are mated with receptors on the paper passageway. A tab lock is activated to hold the picker in place.
[0018] Other advantages and features will become apparent from the following description and from the claims.
DESCRIPTION
[0019] FIGS. 1, 2 , 5 , 6 , 9 , 10 , and 14 are, respectively, front left perspective, front right perspective, bottom perspective, rear, rear left perspective, left side, and schematic left side views, respectively, of a bill dispenser.
[0020] FIGS. 3 and 4 are left rear perspective and right bottom perspective views, respectively, of a bill supply container.
[0021] FIGS. 7 and 8 are perspective views of a lock.
[0022] FIGS. 11 and 12 are side and perspective views, respectively, of a reject tray.
[0023] FIG. 13 is a partial internal perspective view of a bill supply container.
[0024] FIGS. 15, 16 , 17 , 18 , and 19 are left side, perspective, right side, perspective (showing relationship with other parts of the bill dispenser), and perspective (showing drive mechanism) views of a picker.
[0025] FIG. 20 is a perspective view of one side of the paper passageway housing.
[0026] A bill dispenser 10 includes a bill supply container 12 from which bills 14 that are stacked are withdrawn by a picker 16 one at a time from an opening 18 of the container and delivered to the bottom end of a paper passageway assembly 20 . After testing the bill to see if there is a reason to reject it (for example, if a double bill has been fed), each bill is then driven up along the paper passageway to an upper location 22 at which it is dispensed through a wall 24 , such as a wall of an automated teller machine (ATM). A customer on the other side of the wall can then take the bill. If the bill is to be rejected, it is diverted (before reaching the dispensing location) by a vane 25 that routes the bill to a reject tray 26 .
[0027] The bill supply container 12 is molded of PC-ABS blended plastic and has two side walls 30 , 32 , and a front wall 36 that are integrally formed. A rear wall for the container is provided by a front wall 37 of the paper passageway and a front wall 39 of the picker. A floor 38 of the container is molded as a separate piece to include a central guide 40 , and two grooved regions 42 , 43 that permit a stack of bills to slide along in the direction 46 of the picker as bills are withdrawn and the stack gets thinner. Spring side guides locate into the opposite side walls at locations 48 , 50 , 52 , 53 in a way that helps to support and maintain the flatness of the sidewalls. The guide rails 106 , 108 also support and maintain flatness of the sidewalls.
[0028] An arm 54 extends from one edge of the floor of the container toward the bottom of the paper passageway and leaves clearance for the picker which rests in space 56 between the paper passageway and the bill supply container. The arm includes a hole 57 through which a bolt 58 can be used to attach the arm to the bottom of the paper passageway and two ribs 59 for guiding a location guide tab on the picker frame as the picker is inserted or removed.
[0029] The rails along the arm of the bill container guide a rib so the picker is led across the surface. The picker mates with location pin features on the left side (determined by looking from the outside paper path) and is held in on the other by two pin features (on the bill container) for location and a quarter turn snap fastener (located on the right frame) on the other. No permanent fasteners are used, only the pin locaters on both ends of the picker and the quarter turn fastener.
[0030] One side 60 of the arm 54 includes two pins 64 , 66 , and a hole 68 . The pins fit within two holes 70 , 72 in an end wall of the picker when the picker is in an installed position. A screw connects to the hole 68 through a hole 75 in the right frame 224 when the picker is the installed position. The pins aid alignment and registration for the picker when it is installed.
[0031] The bottom 76 of the bill supply container, including the arm, bear a pattern of ridges 78 designed to provide rigidity and strength to the container. The pattern of ridges also provides an available space for mounting a circuit board 80 that is used to control the operations of the bill dispenser and its components. One end of the circuit board includes socket 82 into which a plug 84 on the picker fits when the picker is inserted into its installed position. The connection of the socket and plug provides power to a motor 86 on the picker.
[0032] The other end of the circuit board bears two sockets 88 , 90 that are used for power and communication respectively. A channel 92 in the bottom of the arm can carry a cable between a port 94 on the board and a double detect circuit and other sensors on the paper passageway.
[0033] Inside the bill supply container, a pressure plate 96 includes a flat surface 98 that bears against a stack of bills 100 (only a portion of which is shown), two ends 102 , 104 that ride on supports 106 , 108 , two finger grips 110 , 112 , that enable a user to pull the plate back away from the stack for loading or reloading the stack, and a latching structure 114 that mates with a related grip 116 on a rotating lock 118 that is mounted on the front wall of the container.
[0034] The two supports 106 , 108 are mounted through slots 120 , 122 , on opposite side walls of the container.
[0035] On each side of the container, beneath the supports 106 , 108 are spring-loaded drive wheels 124 , which are connected to the ends 102 , 104 to pull the plate towards that stack of bills.
[0036] Also inside the bill supply container are two vertical guides 128 , 130 and two horizontal guides 130 , 134 that define a channel within which the stack of bills rides.
[0037] The rotating lock 118 is formed of two plastic pieces 140 , 142 that mate and form an integrated lock when the two pieces are inserted in opposite directions through a mounting hole in the front wall of the container and are pressed together. Once mounted, the lock can be rotated so that the grip 116 can be mated to and unmated from the latching structure 114 in order to hold the plate and prevent it from springing back on the stack of bills or to release the plate, as desired. A finger 144 on the grip presses against a surface 114 of the plate in the locked position.
[0038] The container includes two feet 150 , 152 that permit it to be securely mounted on a base, for example, a part of an ATM.
[0039] The picker has three drive wheels 154 , 156 , 158 that rotate to pick individual bills from the top of the stack and drive each of them downward and into the double detector where it can be picked up by the paper passageway. The drive wheels are held on a shaft 160 that is rotationally mounted on both ends of the picker and is driven by a gear 162 on one end of the picker. Gear 162 is driven by a gear train including gears 164 , 166 , and in turn driven by a worm gear 168 on a shaft of the motor.
[0040] The arm of the container includes guiding surfaces 170 , 172 and ribs 59 that correspond to surfaces and slots on the picker and enable the picker to be inserted and removed easily and with good alignment.
[0041] To insert the picker, the end 171 of the picker opposite the motor is inserted into the space between the bill supply container and the paper passageway with the guiding surfaces and slots of the picker are mated with the corresponding guiding slots and ribs of the container arm. The picker is slid into place. Two pins on the end of the picker mate fit into two corresponding holes of a side piece of the paper passageway. The electrical terminal 84 automatically makes connection with the circuit board beneath the bill supply container, as explained earlier. The picker is held in place using a quarter turn knob 169 , FIG. 10 . To remove the picker a reverse series of steps is used.
[0042] The picker is easily removed and replaced which makes maintenance and cleaning of its parts simple and easy. When installed the picker is precisely aligned as required for reliable picking.
[0043] The reject tray 26 is an integral molded plastic unit that has an open top 181 and is easily accessible at any time to a person who has authority to maintain the bill dispenser or unload the reject bills. The reject tray is not a locked cassette. Rather bills may be unloaded at any time directly from the bill dispenser.
[0044] The reject tray has two parallel side walls 180 , 182 , spanned by a front wall 184 and a rear wall 186 . The rear wall is generally flat and has a projection 188 away from the inside of the tray that provides finger room to reach behind a stack of bills when the stack is to be removed. The front wall has a cutout 190 to permit a user to reach down to retrieve a stack of bills and another finger projection 192 to make it easier to grasp the stack. The contours of the front and rear walls and the bottom 194 are arranged so that bills dropped by gravity from the reject path into the tray will automatically stack themselves into a vertically oriented stack of bills. When a bill 196 is delivered from the gentle curve of the paper passageway reject path, the bill follows a path 198 . Driven by gravity downward and by inertia towards the front wall of the reject tray, the bill strikes the front wall at curved surface 200 and follows the curve downward. The leading edge of the bill strikes the bottom wall at point 212 and slides down to point 214 . Eventually the upper edge of the bill falls over 216 to takes its place on stack 218 . Even if a given bill does not fall over to join the stack, the next bill or bills will feed themselves onto the front-wall side of the previously received bill and eventually the bills will fall over onto the stack.
[0045] The paper passageway 18 is defined within a bill delivery assembly 22 . The bill supply container is bolted to the bill delivery assembly to form a strong rigid structure. Two bolts 220 , 222 , on each side of the bill supply container connect the container to two side frames 224 , 226 of the bill delivery assembly. In addition, the end of the arm 54 of the bill supply container is bolted to the bottom of bill delivery assembly on a piece 228 that spans between the two side frames.
[0046] The picker is arranged to peel one bill at a time from the stack in the supply container and to deliver it to the paper passageway. The picker also reorients the bills from their vertical arrangement in the supply container to a horizontal orientation for delivery to the paper passageway. The picker is held in position, but can be removed and reinserted easily and quickly by sliding it in a direction that is perpendicular to a path along which bill moves from the supply container to the paper passageway.
[0047] A bill that has been delivered from the supply container to the paper passageway is driven upward along the paper passageway by four pairs of frictional rollers 230 , 232 , 234 , 236 that are mounted on two parallel shafts 238 , 240 .
[0048] At the lower end of the paper passageway a curved surface 241 reorients the bill from horizontal to vertical for its trip up the paper passageway a direction of motion that is perpendicular to the direction in which the bill leaves the supply container.
[0049] At the upper end of the paper passageway, the traveling bill can either be diverted by a curved surface 250 into the reject tray or by a curved surface 256 to the dispensing location. Which way the bill travels depends on the position of a control vane that can be rotated (about an axle) between two positions. The vane is spring-biased to a default position that rejects bills into the reject tray and must be driven to the dispensing position. (The default routing is applied only to the first bill in the series after which the remaining bills in the series are routed by default to the dispensing location, unless one of those remaining bills is also determined to be flawed.)
[0050] A bill that is diverted to the dispensing location is driven out of the paper passageway by two additional pairs of frictional rollers 263 , 264 . A bill that is diverted to the reject tray is driven by two pairs of frictional rollers 258 , 259 .
[0051] The bottom end of the paper passageway supports a double-detect mechanism 270 that is used to determine, for example, when more than one bill has been withdrawn from the supply container at one time. If so, the dispenser leaves the vane in the rejection position and the multiple bills are rejected into the reject tray. Otherwise, the vane is forced to the dispensing position and the single bill is dispensed to the customer.
[0052] The double-detect mechanism determines whether more than one bill has been withdrawn from the supply container by measuring the thickness of the bill and comparing it to a maximum thickness value.
[0053] Additional details concerning the paper passageway, the components that embody it, and the steps to assemble it, can be found in the published United States patent application cited earlier which describes similar features of a paper passageway.
[0054] Because the dispenser is assembled from a small number of lightweight, easy to manipulate parts, assembly is fast and inexpensive, and the resulting dispenser is small, lightweight, and inexpensive. Maintenance can be done easily and inexpensively in case any part breaks or malfunctions.
[0055] The bill dispenser is designed for a low volume bill dispensing environment, for example, in a small retail context. A store owner, for example, can fill the bill supply container with money directly from the cash register in the store. The cassette is filled in place inside the safe that holds the dispenser. The dispenser is filled “in the public eye”, or before a store opens. The safe may, for example, not be stronger than a business hour rating so it must be near a human and not hidden away from public. Bank filling or “cash in transit” typically would not be used for this dispenser which does not have a removable or sealed cassette.
[0056] Other implementations are within the scope of the following claims. | A paper passageway delivers bills that have been picked from a bill supply container to a location at which the bills are to be dispensed, the paper passageway and the bill supply container are structurally coupled together at least temporarily to form an integrated bill dispensing structure, and at least one of the bill supply container and the paper passageway are functionally incomplete in the absence of the other. The paper passageway delivers bills alternatively to a location at which the bills are to be rejected, a reject container holds rejected bills in a stack in which the bills are oriented vertically, and the bills are accessible to a user from an open top of the container. The paper passageway and the bill supply container are coupled at least temporarily to form a structure, a picker is positioned within the structure to enable the picker to pick bills from the bill supply container and move them along a predetermined path for delivery to the paper passageway, and the picker is removable from the position within the structure by sliding the picker in a direction perpendicular to the predetermined path. A mounting mechanism supports the bill dispensing structure on a wall through which the bill is to be dispensed to a user, the bill dispensing structure being self supporting and rigid without additional support. | 1 |
BACKGROUND OF THE INVENTION
Broadband noise jammers can destructively interfere with each other in space in a manner similar to that well-known for continuous wave jammers. This destructive interference between broadband jammers occurs with each other for time periods which are on the order of the reciprocal of their effective bandwidths. In general, the effective bandwidth of the jammers is that bandwidth which can enter a radar receiver (i.e., the radar bandwidth). This destructive interference allows two or more noise jammers located at different azimuth angles from the main radar antenna to cancel each other (e.g., at the radar antenna) for short periods of time, and simultaneously to not cancel each other at one or more auxiliary antennas at a different location from the main radar antenna. Cancellation, or destructive interference can occur (at the radar antenna) between two or more jamming signals while constructive interference between the jamming signals at one or more of the auxiliary antennas is simultaneously present.
During periods of cancellation between interfering broadband noise signals, limited bandwidth loops, generally important elements of sidelobe cancellers, cannot respond quickly enough to a sudden reduction of the jamming signal (i.e., "dropout") in the received radar signal. (A typical signal canceller employing loops of this nature is described in U.S. Pat. No. 3,202,990 to P. W. Howells.) Because the canceller loops cannot respond quickly enough, they continue to subtract (from the radar signal) a signal proportional to the strength of the jamming signal being received. Since the jamming signal simultaneously being received at the auxiliary antenna is not correlated with any signal from the main radar antenna, the subtraction itself has the same effect as if the main radar signal were being interfered with by a uncancelled jammer signal.
The present invention provides a technique for utilizing the unmodified radar signal during periods when the jammer signals are reduced or cancelled at the radar antenna.
SUMMARY OF THE INVENTION
The present invention is a technique for improving performance of radar systems that utilize sidelobe canceller subsystems. This technique prevents the canceller from introducing spurious undesirable anti-jamming signals into the received radar signal during periods when jamming signals are, in effect, not present at the main radar antenna but are present at auxiliary antennas.
The technique of the present invention interrupts and prevents utilization of the canceller output signal upon sensing reduction or cancellation of jammer interference in the main channel when accompanied by an increased sidelobe canceller output signal. Sensing the reduction in jamming signal is accomplished by first forming a difference signal between two successive signals from the radar antenna and a difference signal between two successive signals from the sidelobe canceller, and then multiplying these two difference signals together. The product signal is then indicative of reduced jamming interference in the radar channel accompanied by increased canceller output signal. This product signal is then utilized to control further use of the sidelobe canceller output signal.
It is therefore an object of the present invention to improve performance of radar systems employing sidelobe cancellers in a multiple jamming environment;
It is another object of the present invention to prevent a sidelobe canceller from introducing spurious undesirable anti-jamming signals into a received radar signal during periods when jamming signals are present on at least one auxiliary antenna but not effectively present at the radar antenna.
Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings wherein:
DESCRIPTION OF THE DRAWINGS
The Figure depicts, in schematic block diagram, a preferred embodiment (implementing the technique) of the present invention.
DETAILED DESCRIPTION
Referring to the Figure, a main Radar Antenna 10 is coupled to a main input of a Sidelobe Canceller 12. It should be noted here that the output of the Radar Antenna is taken to generally include "front end" or other components necessary for early stages of incoming radar signal processing. A plurality of Auxiliary Antennas 14 are coupled to corresponding auxiliary input terminals of Sidelobe Canceller 12.
A pair of identical Signal Processing Networks 16, 18 are utilized in this described embodiment of the present invention. Each of the Networks 16, 18 has an input terminal "a" and an output terminal "b". Each of the Networks 16, 18 has a Signal Detector 20 coupled to its input terminal "a". Signal Detector 20 has an output terminal "c" coupled to the input of an Inverter Device 22 and a Delay Device 24. An Add Device 26 has a first input terminal coupled to an output terminal "d" of Inverter 22, and has a second input terminal coupled to an output terminal "e" of Delay Device 24. The output terminal "b" is formed by the output terminal of Add Device 26.
First Signal Processor 16 has its input terminal "a" connected to the output of Radar Antenna 10, while the Second Signal Processor 18 has its input terminal a connected to the output of sidelobe canceller 12.
A multiplier device 30 has a first input connected to output terminal b of processing network 16, and has a second input connected to output terminal b of processing network 18. The output of multiplier 30 is connected through an inverting amplifiers 32 to a first input terminal of an inhibit gate 34. A second input terminal of inhibit gate 34 is connected to the output of sidelobe canceller 12.
In operation, the embodiment of the present invention senses reduction in jamming signal interference to the main signal accompanied by increased sidelobe canceller output. Upon sensing this reduction, the described embodiment blocks the canceller output signal from being further processed by the radar system.
The radar input signal V R .sbsb.n is applied to the sidelobe canceller 12, and to the first signal processing network 16. (Subscript n denotes the n th return signal pulse being processed.)
Detectors 20, 20' incorporate an output filter matched to the video bandwidth of the radar signal being received. The previously detected video output signal V R .sbsb.n from detector 20' is delayed (in delay device 24') by one radar pulse length (i.e., the reciprocal of the radar bandwidth). The undelayed output signal V R .sbsb.n is inverted by inverter 22' and added to V R .sbsb.n-1 to yield the difference signal (V R .sbsb.n-1 -V R .sbsb.n) at the network 16 output terminal b'.
The output signal V o .sbsb.n of sidelobe canceller 12 is applied to the input terminal a of signal processing network 18. In a manner similar to that just described for signal processing network 16, signal V o .sbsb.n is processed to form an output signal (V o .sbsb.n-1 -V o .sbsb.n) at output terminal b of network 18.
The signals (R R .sbsb.n-1 -V R .sbsb.n) and (V o .sbsb.n-1 -V o .sbsb.n) and then multiplied together to obtain a signal V=(V R .sbsb.n-1 -V R .sbsb.n)·(V o .sbsb.n-1 -V o .sbsb.n) at the output of multiplier 30.
The product signal V is amplified and inverted, and then used to control (i.e., open or close) gate 34 through which the sidelobe canceller output signal V o .sbsb.n passes. If V is negative, gate 34 is inhibited (closed), but if V is positive, gate 34 is open.
Signal V will be negative when (V R .sbsb.n-1 -V R .sbsb.N) is positive if at the same time (V o .sbsb.n-1 -V o .sbsb.n) is negative (arising from a reduction in jamming signal in the "main channel" accompanied by increased output ("increased residue") signal from the sidelobe canceller). This negative V indicates that the canceller output signal should be blocked from use by the radar system. Signal V will also be negative if (V R .sbsb.n-1 -V R .sbsb.n) is negative and if at the same time (V o .sbsb.n-1 -V o .sbsb.n) is positive (indicative of a signal increase in the main channel, but with decreased signal canceller output). It is desirable but not necessary to have the sidelobe canceller output signal blocked in this instance.
Signal V will be positive if both (V R .sbsb.n-1 -V R .sbsb.n) and (V o .sbsb.n-1 -V o .sbsb.n) are negative or positive. Both (V R .sbsb.n-1 -V R .sbsb.n) and (V o .sbsb.n-1 -V o .sbsb.n) would be negative during receipt by the radar antenna 10 of a desired signal which should not be blocked or cancelled. If both (V R .sbsb.n-1 -V R .sbsb.n) and (V o .sbsb.n-1 -V o .sbsb.n) are positive, the loops are functioning properly and the output from the sidelobe canceller should not be blocked.
The technique of the present invention thereby allows design of signal canceller loops having bandwidths reduced enough to prevent their cancelling incoming signal without suffering from spurious cancelling introduced by a sudden reduction in the effective jamming signal due to destructive cancellation.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | A technique for improving sidelobe canceller performance by blocking the canceller output signal upon sensing reduced main channel interference accompanied by an increased sidelobe canceller output. Two signal processing networks form the difference between successive output signals from a radar antenna and sidelobe canceller respectively. The difference signals are multiplied together and the product used to control passage and preclude utilization of the canceller output signal when reduced jamming interference occurs. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to application Ser. No. 61/303, 354, Attorney Docket TN005US, entitled “APPARATUS AND METHODS FOR SUPPLYING POWER AND DATA TO ELECTRONIC DEVICES”, and filed on Feb. 11, 2010 and application Ser. No. 61/375,847, Attorney Docket TN005USP2, entitled “APPARATUS AND METHODS FOR COMMUNICATING POWER AND DATA WITH ELECTRONIC DEVICES”, and filed on Aug. 22, 2010, Application Ser. No. 13/024,310, Attorney Docket TN005US1, entitled “APPARATUS AND METHODS FOR COMMUNICATING POWER AND DATA WITH ELECTRONIC DEVICES”, and filed on Feb. 9, 2011, and Application Ser. No. 61/450,122, Attorney Docket TN005USP3, entitled “APPARATUS AND METHODS FOR COMMUNICATING POWER AND DATA WITH ELECTRONIC DEVICES”, and filed on Mar. 7, 2011, each application is considered as being part of the disclosure of the accompanying application and is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] Various embodiments described herein relate to apparatus and methods for providing electrical power and data to electronic devices.
BACKGROUND INFORMATION
[0003] It may be desirable to provide off grid power or data to an electronic device having a self-contained storage element using a multiple function secondary power, memory, backup, and data transceiving device. The present invention is such a device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1A is a simplified top view diagram of an electronic device memory, data, and power supply apparatus according to various embodiments with a mechanical device interface member refracted.
[0005] FIG. 1B is a simplified top view diagram of an electronic device memory, data, and power supply apparatus according to various embodiments with a mechanical device interface member deployed.
[0006] FIG. 1C is a simplified side view diagram of an electronic device memory, data, and power supply apparatus according to various embodiments with a mechanical device interface member refracted.
[0007] FIG. 2A is a block diagram of an architecture including an electronic device memory, data, and power supply apparatus coupled to a USB chargeable DC powered device according to various embodiments.
[0008] FIG. 2B is a block diagram of an architecture including an electronic device memory, data, and power supply apparatus coupled to a powered USB device according to various embodiments.
[0009] FIG. 3A is a block diagram of an architecture including another electronic device memory, data, and power supply apparatus coupled to a USB chargeable device according to various embodiments.
[0010] FIG. 3B is a block diagram of an architecture including another electronic device memory, data, and power supply apparatus coupled to a powered USB device according to various embodiments.
[0011] FIG. 3C is a block diagram of an architecture including another electronic device memory, data, and power apparatus coupled to a powered device specific interface device according to various embodiments.
[0012] FIGS. 4A to 4D are flow diagrams illustrating several methods according to various embodiments.
[0013] FIG. 5A is a top view of an electronic device memory, data, and power supply apparatus according to various embodiments with a device interface member retracted.
[0014] FIG. 5B is a bottom view of an electronic device memory, data, and power supply apparatus according to various embodiments with a device interface member retracted.
[0015] FIG. 5C is another top view of an electronic device memory, data, and power supply apparatus according to various embodiments with a device interface member retracted.
[0016] FIG. 5D is a bottom view of an electronic device memory, data, and power supply apparatus according to various embodiments with a device interface member deployed.
[0017] FIG. 5E is a side view of an electronic device memory, data, and power supply apparatus according to various embodiments.
[0018] FIG. 6 is a block diagram of a communication architecture comprising electronic devices, an EDPP, and base station according to various embodiments.
DETAILED DESCRIPTION
[0019] FIG. 1A is a simplified top view diagram of an electronic device memory, data, and power supply apparatus 10 according to various embodiments with a device interface member (DIM) 12 A retracted ( 316 of apparatus 300 in FIG. 5D ). FIG. 1B is a simplified top view diagram of an electronic device memory, data, and power supply apparatus 10 according to various embodiments with a device interface member deployed 12 A. FIG. 1C is a simplified side view diagram of an electronic device memory, data, and power supply apparatus 10 according to various embodiments with a device interface member 12 A retracted. The memory, power, and data supply (MPDS) apparatus 10 includes a retractable device interface member 12 A, a second deployable device interface member 12 B including a deformable cable 12 F ( 306 with deformable cable 305 of apparatus 300 of FIG. 5D ), a retraction control slide 12 C, a memory storage interface (MSI) 14 , at least one user detectable element 16 , a multiple contact button 18 , and a connectable hole 15 or carabineer 302 (as shown in FIGS. 5A-D ). The retractable device interface member (DIM) 12 A, 316 may be a universal serial bus (USB) type male interface. The USB DIM 12 A, 316 may include an orientation tab 12 D and several electrical contacts 12 E.
[0020] In an embodiment, the first and last USB DIM 12 A, 316 electrical contacts 12 E may be used to communicate electrical energy (receive from or provide to a device 130 ). The remaining, four electrical contacts may be used to communicate data. In an embodiment, the second, deployable DIM 12 B, ( 306 , FIG. 5D ) may be a mini-USB, micro-USB male interface or other interface type. In an embodiment the interface member 12 A, 316 and interface member 12 B, 306 may support USB and device specific interfaces including propriety device specific interfaces such as the Apple® 30-pin interface. The interface member 12 B, 306 may communicate data with a coupled device (such as 130 of FIG. 2A ). The interface member 12 B, 306 may also receive electrical energy from a coupled device 130 (to charge an internal storage element 56 of apparatus 10 , 300 ( FIG. 2A )) or provide electrical energy to a coupled device 130 via the electrical energy storage element 56 of apparatus 10 , 300 .
[0021] The user detectable element 16 may emit light, sound, vibration, or a combination thereof. In an embodiment, the element 16 may include at least one light emitting diode (LED). The multiple contact button 18 may enable selection of one or more functions of the MPDS apparatus 10 (such as functions as described with reference to FIGS. 4A to 4D ). In an embodiment the element 16 and contact button 18 (such as contact 312 of FIG. 5D ) may be a combined mechanism that generates a user detectable signal and enables a user to select one or more functions for the apparatus 10 . The MSI 14 may interface with one or more memory storage elements including a compact flash card, secure digital (SD), miniSD, microSD, SD high capacity (SDHC), miniSDHC, microSDHC, SD extended capacity, and memory stick. The MSI 14 may conform to the SD input-output (SDIO) standard to enable memory card and other devices to communicate with and through the MPDS apparatus 10 via the DIM 12 A, 316 , 12 B, 306 or wirelessly (via modem 67 A shown in FIG. 2A ). The other devices may include a Bluetooth interface and broadband data interface.
[0022] FIG. 2A is a block diagram of an EDPS architecture 100 A including an electronic device MPDS apparatus 10 coupled to a chargeable or powerable device 130 via an interface 32 (USB or other) according to various embodiments. It is noted that any wired interface 32 , 64 may be employed in addition to a USB interface, including a device specific interface such as shown in FIG. 3C . The connection 72 may represent the deployable connector 12 A, 316 and second deployable connector 12 B, 306 . The architecture 100 A includes a first MPDS device 10 and an interface for a chargeable or powerable device (USB chargeable or powerable device in an embodiment) 130 . The electronic device 130 , 30 may be powered and charged by a USB interface 64 , 264 ( FIG. 2A , 3 A) (deployable connector 12 A, 316 and second deployable connector 12 B, 306 ). The electronic device 130 may be coupled to a MPDS apparatus 10 , 200 via a cable 72 coupling the electronic device 130 , 30 interface 32 to a MPDS apparatus 10 , 200 interface 64 , 264 . The cabling 72 may be coupled to the deployable connector 12 A, 316 and second deployable connector 12 B, 306 in an embodiment. The cable 72 may also represent the deployable cable 12 F, 305 of interface 12 B, 306 , respectively. The MPDS apparatus 10 , 200 may provide electrical energy to one or more devices 130 , 30 via the interface 32 . The MPDS apparatus may also receive energy from one or more devices 130 , 30 via the interface 32 .
[0023] In an embodiment, the powerable or chargeable device 130 , 30 may include a rechargeable electrical storage element 36 . The MPDS apparatus 10 , 200 may provide electrical energy to one or more devices 130 , 30 via the interface 32 that is sufficient to a) power the devices 130 , 30 , b) charge an electrical storage element 36 of the device 130 , 30 , and c) simultaneously power a device 130 , 30 and charge an electrical storage element 36 of the device 130 , 30 . The electrical storage element 36 may be a re-chargeable battery (including chemical and non-chemical such as NiCad, lithium-ion), capacitor, or other device capable of temporarily storing electrical energy.
[0024] In an embodiment, the MPDS apparatus 10 , 200 may provide a direct current (DC) or alternating current (AC) electrical signal to a device 130 , 30 via the interface 32 . The electrical signal may have sufficient energy (power, voltage, and current) to power the device 130 , 30 and charge the electrical storage element 36 where the energy or power requirements of the devices 130 , 30 may vary. The MPDS apparatus 10 , 200 may auto-detect the energy or power requirements of a device 130 , 30 coupled to the MPDS apparatus 10 , 200 via the interface 64 , 264 and vary the electrical signal provided on wires 72 accordingly.
[0025] In an embodiment, the MPDS 10 , 200 may also communicate data to the device 130 , 30 via the interface 64 or wirelessly via a transceiver/modem 67 A coupled to the antenna 67 B. The data may be stored in one or more internal data storage elements ( 68 ) of the MPDS apparatus 10 , 200 or transferred from another device coupled to a memory storage or device interface 66 . As noted the memory storage interface 66 may enable communication with various memory storage elements and other devices that communicate with one or more known communication protocols including SDIO. A device 130 , 30 may be able to communicate data to a device or memory coupled to the memory storage interface 66 , 266 via the MPDS apparatus 10 , 200 or the transceiver/modem 67 A (via antenna 37 A and transceiver/modem 37 B).
[0026] In an embodiment, the device 130 , 30 , 132 ( FIG. 3C ) may store data in an internal data storage element or memory storage interface 39 . A MPDS 10 , 200 , 202 may passively or automatically backup all data, specific data, changed data, or specific changed data of a device 130 , 30 , 132 to one or both of the internal data storage elements ( 68 ) and the memory storage or device interface 66 . A user may be able to configure a MPDS 10 , 200 , 202 via a USB interface 64 , 264 , device specific interface 274 , or ASIC 210 , 212 to passively backup data located on a device 130 , 30 , 132 . The MPDS 10 , 200 , 202 may detect the data or changes to the data and backup all data or changes of data as a function of the elected backup configuration. A user may select different backup modes including full (all data) and incremental backup (only data that has changed since the last backup). A user may also select the type of data to be copied (backed up)—such as selecting one or more of personal contacts, music, video, pictures, word documents, spreadsheets, or other specific data types.
[0027] A user may also be able to configure a MPDS 10 , 200 , 202 to restore backed up to a specific device 130 , 30 , 132 . The user may also be to access the backup data to effectively transfer to a different device 130 , 30 , 132 or any other computer device (including a laptop, desktop, netbook, for example). In the MPDS 200 , 202 , the ASIC 210 , 212 may include internal memory and also include a memory storage interface 266 where device 130 , 30 , 132 data to be protected (backed up) may be stored and then restored to the device 130 , 30 , 132 , another device 130 , 30 , 132 , or other computing device with a data storage device. The MPDS 10 , 200 , 202 may also communicate backed up data wirelessly via a modem 67 A to another computing device. A user may specific the delivery or destination of backed up data during a restore. In another embodiment, a MPDS 10 , 200 , 202 may copy data from a device 130 , 30 , 132 and wirelessly communicate the data to another device for storage including a networked device or Internet coupled device. A user may be able to restore data from the network device to the device 130 , 30 , 132 without the MPDS 10 , 200 , 202 or via the MPDS 10 , 200 , 202 in an embodiment.
[0028] As explained with reference to FIG. 2B and FIG. 3B , 3 C, the MPDS apparatus 10 , 200 , 202 may also be able to receive an electrical signal via the interface 64 , 264 , 274 from a powered interface device 30 , 130 ( FIG. 2B , 3 B), 132 ( FIG. 3C ) that is sufficient to power the MPDS apparatus or charge an electrical storage element 56 of the MPDS apparatus 10 , 200 , 202 including via the interfaces 12 A, 12 B ( FIG. 1A) and 316 , 306 ( FIG. 5D ). The MPDS 10 , 200 may also communicate data with the device 130 , 132 via the interface 32 , 33 or transceiver/modem 67 A where the data may be stored in one or more internal data storage elements ( 68 ) of the MPDS apparatus 10 , 200 or transferred from another device coupled to the memory storage or device interface 66 , 266 . Accordingly, a device 130 , 132 may be able to communicate data to a device or memory coupled to the memory storage interface 66 , 266 via the MPDS apparatus 10 , 200 while providing electrical energy to the MPDS apparatus 10 , 200 . A MPDS 10 , 200 , 202 may also be able to communicate with devices coupled to a network, or network or networks (Internet) where the modem 67 A is able to communicate with a networked device such as a wireless router.
[0029] In another embodiment, a device 30 , 130 , 132 may be charged or powered by energy provided from the MPDS apparatus 10 , 200 , 202 as a function of the MPDS apparatus 10 , 200 , 202 energy capacity and its own capacity or link to another power source such another USB device or on-grid power supply. Such device 30 , 130 , 132 may subsequently provide energy to the MPDS apparatus 10 , 200 , 202 sufficient to power the MPDS apparatus 10 , 200 , 202 and charge one or more storage elements of the MPDS 10 , 200 , 202 . For example, the device 30 , 130 , 132 may be a portable computing device that includes an internal electrical energy storage element 36 and on-grid power coupling interface 35 where the power interface 35 may include a transformer or inverter. When the device 30 , 130 , 132 is coupled to an on-grid power source (AC or DC) 20 such as shown in FIG. 2B or its internal storage element 36 has sufficient energy, the device 30 , 130 , 132 may provide power on its interface 32 . In an embodiment, the power source 20 A may be an AC power source. The power source 20 A may be part of an electrical distribution network, independent electrical source, or localized electrical source including a battery 36 , generator, or solar generation module.
[0030] The MPDS apparatus 10 , 200 , 202 may detect when power is provided on the USB interface 64 , 264 , 274 via cable 72 , 73 . The MPDS apparatus 10 , 200 , 202 may then use this power to operate or charge one or more storage elements 56 . The device 30 , 130 , 132 may lose its on-grid power source 20 (become decoupled or power loss), or its internal storage element 56 may become depleted to a preset level where the device 30 , 130 , 132 does not provide power on the interface 32 , 33 . In such an embodiment or state, the MPDS apparatus may detect the lack of an electrical signal with a sufficient voltage or current level on the interface 64 , 264 , 274 .
[0031] The MPDS apparatus 30 , 200 , 202 as a function of its own internal storage elements 56 levels (voltage or current) may provide electrical energy on the interface 64 , 74 to the device 30 , 130 , 132 . This cycle may alternate as a function of the respective energy levels of the respective storage elements 36 , 56 and the presence of an on-grid power source 20 . In an embodiment, the MPDS apparatus 10 may employ a power sensor 42 to determine when the power or energy on the USB interface 64 is sufficient to power or charge the MPDS apparatus 10 and controls the switch 54 accordingly via a switch controller module 46 . It is noted that the device 30 , 130 , 132 may be a USB charger in an embodiment where the charger is coupled to an on-grid source 20 and charges the MPDS apparatus 10 , 200 storage elements 56 .
[0032] When the MPDS apparatus has detected insufficient energy or power levels on the USB interface 64 via the power sensor 42 , the switch controller module 46 may set the switch 54 to provide electrical energy from one or more storage elements 56 and the second transformer 45 to the USB interface until the storage elements 56 reach a minimal, preset level. The switch controller module 46 may then set the switch 54 to receive electrical energy (if any) from the USB interface 64 as shown in FIG. 2B . The switch controller module 46 may also set the switch 54 to receive electrical energy from the USB interface 64 when the power sensor 42 detects sufficient electrical energy on the USB interface 64 . In another embodiment, a device 30 , 130 , 132 may communicate data that it is able or unable to provide sufficient electrical energy to the MPDS apparatus 10 , 200 , 202 and the MPDS apparatus 10 may set the switch 54 via the switch controller module 46 accordingly.
[0033] The transformer 44 may convert the energy level (voltage and current received from a device 30 , 130 , 132 via the interface 64 to a level sufficient to power the MPDS apparatus 10 or charge one or more internal storage elements 56 via a charging module 48 . Accordingly, the MPDS apparatus may be able to be charged from a lower power USB source while providing a higher power charging signal or energy to another device 30 , 130 , 132 . The MPDS apparatus 10 , 200 may also include a user detectable device 58 where the device provides an indication of the charging or discharging state of the one or more storage elements 56 . The user detectable device 58 may also indicate data transfer activity with an internal memory 68 or a device coupled to the memory storage interface 66 .
[0034] In the MPDS apparatus 200 the power sensor 42 , the switch controller 46 , the switch 54 , the charging module 48 , the first transformer 44 , the second transformer 45 , the user detectable device, the internal memory 68 , the memory storage device 66 , and the USB interface 64 may be implemented in one or more application specific integrated circuits (ASIC). One or more elements may be separately coupled to the ASIC.
[0035] In an embodiment the MPDS 10 of FIGS. 2A , 2 B may further include a transceiver/modem module (TMM) 67 A and an antenna 67 B. The TMM 67 A may be any device capable of communicating data in one or more data communication formats including wireless and wired formats. Referring to FIG. 6 , the TMM 67 A may be included in an MPDS 10 , 200 , 202 , 300 . The MPDS 10 , 200 , 202 , 300 may be part of a wireless architecture 400 that may include one or more wireless or wired devices 30 , 130 , 132 and a wireless data or voice provider base station 420 . The TMM 67 A may include a transceiver and modem that may communicate digital data or voice signals with one or more electronic devices ( 30 , 130 , 132 A) and the digital data and voice signal base station or router 420 .
[0036] The base station 420 may be part of a larger network that may communicate with other base stations, electronics devices 30 , 130 , 132 A, MPDS 10 , 200 , 202 , computers, and networks of networks (commonly termed the “Internet”). In an embodiment, the base station 420 may communicate data with the MPDS 10 TMM 67 A using one or more known digital communication formats including a cellular protocol such as code division multiple access (CDMA), time division multiple access (TDMA), Global System for Mobile Communications (GSM), cellular digital packet data (CDPD), Worldwide Interoperability for Microwave Access (WiMAX), satellite format (COMSAT) format, and local protocol such as wireless local area network (commonly called “WiFi”) and Bluetooth.
[0037] In an embodiment, the TMM 67 A may act as an Internet Service Provider (ISP). Accordingly the TMM 67 A may enable local data communication between the wireless (or wired via interface 64 ) devices 30 , 130 , 132 A. The TMM 67 A may also communicate data requests to remote internet protocol “IP” addresses via a URL or IP address. In an embodiment, a TMM 67 A or MPDS 10 , 200 , 202 may employ the process 240 shown in FIG. 4B to process one or more electronic data (that may include electronic data or voice in an electronic format) requests from one or more electronic devices 30 , 130 , 132 . As noted an electronic device 30 , 130 , 132 may communicate a request for data via a physical or wired connection(s) such as connectors 12 A, 12 B shown in FIG. 1A or via a wireless signal.
[0038] As shown in FIG. 4B , upon receipt of a data request (activity 242 ) from an electronic device 30 , 130 , 132 via a wired or wireless signal, a MPDS 10 , 200 , 202 , 300 may first determine whether the requesting device is registered or permitted to employ the MPDS 10 , 200 , 202 to request data (from an external source via the TMM 67 A or locally via an memory device 66 or 68 as shown in FIG. 2A ). A MPDS 10 , 200 , 202 may require a requesting device 30 , 130 , 132 to register using a known protocol or provide a security key. A MPDS 10 , 200 , 202 may send webpages to a requesting device 30 , 130 , 132 where the webpage includes a registration or security questions. The registration or security webpage may enable an electronic device 30 , 130 , 132 to be registered with the MPDS 10 , 200 , 202 . Such registration may be time or data usage limited as a function of the device 30 , 130 , 132 registration or security information.
[0039] The webpage may also include options for data backup functions including options and restoring data from a backup. The webpage may allow a user to select the type of data and type of backup to be performed for the data. The webpage may also allow a user to designate multiple backup destinations including networked (via the modem 67 A) locations or devices. The data types may include device 30 , 130 , 132 such as operating system data, multimedia data (including music, video, and pictures), and business or personal data (such as contracts, calendars, word, spreadsheet, and presentation files).
[0040] A MPDS 10 , 200 , 202 may process the data request (activity 246 ) by determining whether the requested data is stored on the MPDS 10 , 200 , 202 or request is to a local device 30 , 130 , 132 , or request is outside the local network. When the data requested is on the MPDS, the MPDS may send the data to the requesting device (activity 248 ). Otherwise, the MPDS 10 , 200 , 202 may then generate a corresponding data request using the appropriate protocol (such as IP) and send the data request to either a local device 30 , 130 , 132 or to a base station 420 as appropriate. The MPDS 10 , 200 , 202 may then transceive data requests and responses between the requesting device 30 , 130 , 132 and the responding device 30 , 130 , 132 or base station 420 (activity 248 ). As shown in FIGS. 2A to 3C , the electronic device 30 , 130 , 132 may include a modem 37 B and an antenna 37 A to transceive signals with a MPDS 10 , 200 , 202 .
[0041] In an embodiment, the MPDS 10 , 200 , 202 TMM 67 A may communicate digital signals with the base station 420 using a first digital communication protocol and the electronic devices 30 , 130 , 132 A using a second, different communication protocol. For example, the MPDS 10 , 200 , 202 TMM 67 A may communicate with the base station 420 using a cellular protocol such as code division multiple access (CDMA), time division multiple access (TDMA), Global System for Mobile Communications (GSM), Worldwide Interoperability for Microwave Access (WiMAX) or COMSAT protocol and communicate with the electronic devices 30 , 130 , 132 using a local protocol including WiFi and Bluetooth.
[0042] As known to one skilled on the art the Bluetooth protocol includes several versions including v1.0, v1.0B, v1.1, v1.2, v2.0+EDR, v2.1+EDR, v3.0+HS, and v4.0. The Bluetooth protocol is an efficient packet-based protocol that may employ frequency-hopping spread spectrum radio communication signals with up to 79 bands, each band 1 MHz in width, the respective 79 bands operating in the frequency range 2402-2480 MHz. Non-EDR (extended data rate) Bluetooth protocols may employ a Gaussian frequency-shift keying (GFSK) modulation. EDR Bluetooth may employ a differential quadrature phase-shift keying (DQPSK) modulation.
[0043] The WiFi protocol may conform to a Institute of Electrical and Electronics Engineers (IEEE) 802.11 protocol. The IEEE 802.11 protocols may employ a single-carrier direct-sequence spread spectrum radio technology and a multi-carrier orthogonal frequency-division multiplexing (OFDM) protocol. In an embodiment, one or more electronic devices 30 , 130 , 132 may communicate with the MPDS 10 TMM 67 A via a WiFi protocol.
[0044] The cellular formats CDMA, TDMA, GSM, CDPD, and WiMax are well known to one skilled in the art. It is noted that the WiMax protocol may be used for local communication between the one or more electronic devices 30 , 130 , 132 may communicate with the MPDS 10 TMM 67 A. The WiMax protocol is part of an evolving family of standards being developed by the Institute of Electrical and Electronic Engineers (IEEE) to define parameters of a point-to-multipoint wireless, packet-switched communications systems. In particular, the 802.16 family of standards (e.g., the IEEE std. 802.16-2004 (published Sep. 18, 2004)) may provide for fixed, portable, and/or mobile broadband wireless access networks.
[0045] Additional information regarding the IEEE 802.16 standard may be found in IEEE Standard for Local and Metropolitan Area Networks—Part 16: Air Interface for Fixed Broadband Wireless Access Systems (published Oct. 1, 2004). See also IEEE 802.16E-2005, IEEE Standard for Local and Metropolitan Area Networks—Part 16: Air Interface for Fixed and Mobile Broadband Wireless Access Systems—Amendment for Physical and Medium Access Control Layers for Combined Fixed and Mobile Operation in Licensed Bands (published Feb. 28, 2006). Further, the Worldwide Interoperability for Microwave Access (WiMAX) Forum facilitates the deployment of broadband wireless networks based on the IEEE 802.16 standards. For convenience, the terms “802.16” and “WiMAX” may be used interchangeably throughout this disclosure to refer to the IEEE 802.16 suite of air interface standards.
[0046] As noted, one or more electronic devices 30 , 130 , 132 may be coupled the MPDS 10 , 200 , 202 via a physical connection such as via 12 A, 12 B shown in FIG. 1A and 316 , 306 shown in FIGS. 5A-5E . The TMM 67 A may employ one or more wired digital data communication protocols to communicate with an electronic device 30 , 130 , 132 in such an embodiment including the Ethernet protocol or Internet protocol (IP), IEEE 802.3. Using wired or wireless communication, a MPDS 10 , 200 , 202 may enable an electronic device 30 , 130 , 132 to communicate digital with the Internet and corresponding act as a “mobile hotspot”, mobile broadband device, and ISP. In an embodiment the antenna 67 B may be circular antenna with multiple, selectable connections to elect the wavelength/frequency of signals to be communicated with an electronic device 30 , 130 , 132 and base station 420 .
[0047] As noted above FIGS. 3A and 3B are block diagrams of a MPDS apparatus 200 that employs an ASIC 210 according to various embodiments. The MPDS apparatus 200 may include an Application Specific Integrated Circuit (ASIC) 210 , an antenna 67 B and an electrical storage element 56 . The ASIC 210 may include a TMM 67 A, memory storage interface 266 , USB interface 264 , and one or more user detectable signal generation modules 258 as part of or coupled to the ASIC 210 . The ASIC 210 may perform the functions of transformers 44 , 45 , a switch controller module 46 , a charging module 48 , a USB interface 64 , a memory storage interface 266 , an internal memory 268 , a TMM 67 A, and a multiple position switch 54 . In an embodiment, the MPDS apparatus 200 USB interface 264 may be one of a male or female based electrical contact interface and the device 30 , 130 USB interface 32 may be one of a female or male USB interface, respectively The interface 264 may also be device specific or other interfaces 12 A, 12 B, 316 , 306 .
[0048] In embodiment, the MPDS apparatus 200 ASIC 210 may receive an electrical signal from the USB interface 264 and the electrical storage element 56 . The ASIC 210 may determine whether the electrical signal provided by the storage element is sufficient to provide power one or more device(s) 30 and may direct energy from the electrical storage element 56 to provide an electrical signal on an USB interface 264 built into the ASIC 210 . An electrical cable 72 may couple the ASIC 210 USB interface 264 to the device 30 USB interface 32 where the cable 72 may represent the cable 12 F, 305 of interface 12 B, 306 , respectively. The interface 264 may include the interface 12 A, 12 B, 316 , or 306 to couple to the device 30 interface 32 . The ASIC 210 may also control the charging of the electrical storage element 56 when sufficient electrical energy is provided on the USB interface 264 ( FIG. 3B ).
[0049] The ASIC 210 may further transform the electrical energy provided by the USB interface 264 to the DC voltage/amperage rating needed to charge the electrical storage element 56 . The ASIC 210 via one or more user detectable signal generation modules 258 ( 16 or 18 of FIG. 1A and 312 of FIG. 5D ) may inform a user when the electrical storage element 56 is being charged, discharged, external power is present, and when one or more DC powered devices 30 , 130 , 132 are electrically coupled to the MPDS apparatus 200 . The one or more user detectable signal generation modules 258 ( 16 or 18 of FIG. 1A and 312 of FIG. 5D ) may also indicate data communication between the MPDS 10 , 200 , 202 and an electronic device 30 , 130 , 132 or base station 420 . In an embodiment, a user detectable signal generation module 58 , 258 , ( 16 or 18 of FIG. 1A and 312 of FIG. 5D ) may include one or more light emitting diodes (LEDs), other light generation devices, vibration modules, or audible generation devices (speakers).
[0050] FIG. 3C is a block diagram of another MPDS apparatus architecture 100 C according to various embodiments. The DC powered device 132 in the architecture 100 C may have a device specific interface 33 . The MPDS apparatus 202 may include an ASIC 212 that has a corresponding device specific interface 274 , an antenna 67 B, and an electrical storage element 56 . The ASIC 212 may include a TMM 67 A, a memory storage interface 266 , the device specific interface 274 , and one or more user detectable signal generation modules 258 as part of or coupled to the ASIC 212 . The ASIC 212 may receive from or provide electrical energy to the device 132 via the device specific interface 274 coupled via wires 73 to the device 132 device specific interface 33 where the wires 73 may represent the deformable wires or cables 12 F, 305 of interface 12 B, 306 . The device specific interface 274 may also be deployable such as interface 12 A, 316 of FIG. 1A and 5C , respectively.
[0051] FIG. 4A is a flow diagram illustrating several methods 220 according to various embodiments. A MPDS 10 , 200 , 202 may employ the method 220 illustrated by the FIG. 4A flow diagram. The method 220 may determine whether sufficient power is being provided by a device on the USB interface 12 A, 12 B, 64 , 264 , 316 , 306 or device specific interface 274 to power the MPDS apparatus 10 , 200 , 202 (activity 222 ). When a. the power is insufficient (activity 222 ); b. the storage element level is sufficient (activity 224 ); and c. at least one device 30 , 130 , 132 is coupled to the MPDS activity 10 , 200 , 202 , (activity 225 ), the method 220 may provide energy to the one or more devices 30 , 130 , 132 from an electrical storage element 56 (activity 226 ) and provide an indication of the electrical storage element status 56 via the user detectable signal generation device 58 , 258 , 16 , 18 , 312 (activity 228 ). In an embodiment, the method 220 may also require a user to depress a button 16 , 312 in one or more directions in addition to the conditions of activities 224 , 225 prior to providing electrical energy from a storage element 56 to a coupled device 30 , 130 , 132 .
[0052] When sufficient power is detected on the USB interface 64 , 264 , or device specific interface 274 (activity 222 ) and the electrical storage device 56 is not fully charged (activity 232 ) the method 220 may charge the electrical storage element 56 (activity 234 ) and provide an indication of the electrical storage element 56 charge level via the user detectable signal generation device 58 , 258 , 16 , 18 , 312 (activity 236 ). In an embodiment the method 220 may also power the MPDS apparatus 10 , 200 , 202 to communicate data between the apparatus 10 , 200 , 202 and a coupled device 30 , 130 , 132 , TMM 67 A, and internal memory 66 and a memory storage interface 68 .
[0053] FIG. 4C is a flow diagram illustrating several methods 320 according to various embodiments when a MPDS 10 , 200 , 202 , 300 is coupled to a device 30 , 130 , 132 via an interface 12 A, 12 B, 72 , 73 , 306 , 316 or wirelessly. A MPDS 10 , 200 , 202 , 300 may employ the method 260 illustrated by the FIG. 4C flow diagram to backup data stored on a device 130 , 30 , 132 (such in the device 130 , 30 , 132 memory 39 ). In the backup method 320 , when passive backup is active (been configured by a user to be active such as by a webpage from the MDPS 10 , 200 , 202 ) (activity 322 ), the method 320 may first determine the type of backup to be performed (activity 324 ). A user may elect to backup all data of selected types or only the selected data that has changed since the last backup (incremental backup). When the selected data types such as operating system data, multimedia data (including music, video, and pictures), and business or personal data (such as contracts, calendars, word, spreadsheet, and presentation files) includes changed data and incremental is selected, the method 320 may update backup data with the new or changed data (activity 324 , 326 , 328 ).
[0054] As noted the backup data may be stored locally on a MPDS 10 , 200 , 202 or on a networked device where the data is communicated from a device 130 , 30 , 132 to the networked device via a MPDS 10 , 200 , 202 modem 67 A. Similarly when a full backup has been configured, the selected data may be backed up locally on a MPDS 10 , 200 , 202 or on a networked device where the data is communicated from a device 130 , 30 , 132 to the networked device via a MPDS 10 , 200 , 202 modem 67 A (activity 332 , 334 ).
[0055] FIG. 4D is a flow diagram illustrating several methods 280 according to various embodiments. A MPDS 10 , 200 , 202 , 330 may employ the method 280 illustrated by the FIG. 4D flow diagram to enable a user to configure the backup options for data stored on a device 130 , 30 , 132 (such in the device 130 , 30 , 132 memory 39 ) or restore data previously backed up. The method 280 may enable a user to configure one or more backup options for the device 10 , 200 , 202 , 300 (activity 282 ). As noted a webpage may enable a user to configure various data backup options or to restore data from one or more backups (activity 288 ). The webpage may enable a user to select the type of data and type of backup to be performed for the data (activity 284 , 286 ). The webpage may also enable a user to designate multiple backup destinations including networked (via the modem 67 A) locations or devices (activity 284 ). The method 280 or webpage may also enable a user to select the device 30 , 130 , 132 data types to be protected or backed up including data types such as operating system data, multimedia data (including music, video, and pictures), and business or personal data (such as contracts, calendars, word, spreadsheet, and presentation files) (activity 286 ).
[0056] The method 280 may also enable a user to restore data from one or more backups to a device 130 , 30 , 132 or other computer device (activity 292 ). The method 280 may enable data from several locations including local to a MPDS 10 , 200 , 202 , 300 or networked to be used to restore data to a device 130 , 30 , 132 , other coupled device, or to a networked device (activity 292 ).
[0057] FIG. 5A is a top view of a MPDS apparatus 300 according to various embodiments with a device interface member 316 retracted. FIG. 5B is a bottom view of an MPDS apparatus 300 according to various embodiments. FIG. 5C is another top view of a MPDS apparatus 300 according to various embodiments. FIG. 5D is a bottom view of an MPDS apparatus 300 according to various embodiments with a device interface member 306 deployed. FIG. 5E is a side view of a MPDS apparatus 300 according to various embodiments. The MPDS apparatus 300 includes retraction slide 304 , mini-USB or micro-USB interface 306 in deployment mechanism 308 , a memory storage interface 314 , a retractable male USB interface 316 , an operation button 312 with LED, and a carabineer 302 all encased in a housing 301 . The button 312 may protrude from a section of the housing 301 . The retractable male interface 316 may also protrude from a section of the housing 301 . The mini-USB or micro-USB interface 306 may include a section adjacent the housing 301 . The mini-USB or micro-USB 306 and male USB 316 may be coupled to a USB interface 64 , 264 . The button 312 may have several contacts or positions that enable a user to charge and discharge an internal storage element 56 and couple and uncouple devices in the memory storage interface 314 .
[0058] The mini-USB or micro-USB 306 may include a deformable cable 305 and locking mechanism 308 . The locking mechanism 308 may be a flexible material including one or more tabs that engage the apparatus 300 housing 301 to hold the interface 306 in a stored position when not deployed. The user control-user perceptible device/button 312 may also enable a user to select or engage backup of data on a device 30 , 130 , 132 coupled to the apparatus 300 . In an embodiment a MPDS apparatus 10 , 200 , 202 , 300 may be about 2 to 4 inches in length, 0.5 to 2 inches in width, about 0.2 to 1 inch in height.
[0059] Any of the components previously described can be implemented in a number of ways, including embodiments in software. Any of the components previously described can be implemented in a number of ways, including embodiments in software. Thus, the transformers 44 , 45 , switch controller module 46 , charging module 48 , USB interface 64 , 264 , device specific interface 274 , TMM 67 A, and memory storage interface 68 may all be characterized as “modules” herein.
[0060] The modules may include hardware circuitry, single or multi-processor circuits, memory circuits, software program modules and objects, firmware, and combinations thereof, as desired by the architect of the architecture 10 and as appropriate for particular implementations of various embodiments. The apparatus and systems of various embodiments may be useful in applications other than a sales architecture configuration. They are not intended to serve as a complete description of all the elements and features of apparatus and systems that might make use of the structures described herein.
[0061] Applications that may include the novel apparatus and systems of various embodiments include electronic circuitry used in high-speed computers, communication and signal processing circuitry, modems, single or multi-processor modules, single or multiple embedded processors, data switches, and application-specific modules, including multilayer, multi-chip modules. Such apparatus and systems may further be included as sub-components within and couplable to a variety of electronic systems, such as televisions, cellular telephones, personal computers (e.g., laptop computers, desktop computers, handheld computers, tablet computers, etc.), workstations, radios, video players, audio players (e.g., mp3 players), vehicles, medical devices (e.g., heart monitor, blood pressure monitor, etc.) and others. Some embodiments may include a number of methods.
[0062] It may be possible to execute the activities described herein in an order other than the order described. Various activities described with respect to the methods identified herein can be executed in repetitive, serial, or parallel fashion. A software program may be launched from a computer-readable medium in a computer-based system to execute functions defined in the software program. Various programming languages may be employed to create software programs designed to implement and perform the methods disclosed herein. The programs may be structured in an object-orientated format using an object-oriented language such as Java or C++. Alternatively, the programs may be structured in a procedure-orientated format using a procedural language, such as assembly or C. The software components may communicate using a number of mechanisms well known to those skilled in the art, such as application program interfaces or inter-process communication techniques, including remote procedure calls. The teachings of various embodiments are not limited to any particular programming language or environment.
[0063] The accompanying drawings that form a part hereof show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. This Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.
[0064] Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.
[0065] The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted to require more features than are expressly recited in each claim. Rather, inventive subject matter may be found in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. | Embodiments of a system, topology, and methods for providing power and transceiving data to, and backing up data from electronic devices having a data interface are described generally herein. Other embodiments may be described and claimed. | 6 |
FIELD OF THE INVENTION
Glass-ceramic biomaterials containing canasite and apatite crystal phases.
BACKGROUND OF THE INVENTION
A glass-ceramic is a material having at least one crystalline phase thermally developed in a uniform pattern throughout at least a portion of a glass precursor. Glass-ceramics have been known for over 30 years since being described in U.S. Pat. No. 2,920,971 (Stookey). They find application in diverse areas, an area of particular interest being the fabrication of articles used in the preparation and serving of food. Such articles include cookware, bakeware, tableware and flat cooktops.
In general, production of a glass-ceramic material involves three major steps: melting a mixture of raw materials, usually containing a nucleating agent, to produce a glass; forming an article from tile glass and cooling the glass below its transformation range; crystallizing ("ceramming") the glass article by an appropriate thermal treatment. The thermal treatment usually involves a nucleating step at a temperature slightly above the transformation range, followed by heating to a somewhat higher temperature to cause crystal growth on the nuclei.
Use of a glass-ceramic as a biomaterial was initially proposed by W. T. MacCullouch in a publication entitled "Advances in Dental Ceramics" in British Dental Journal, 124:361-365 (1968). The glass-ceramics proposed were from the Li 2 O--ZnO--SiO 2 system for production of dentures.
Subsequently, numerous patents have issued disclosing bio-active glass-ceramic materials. Predominantly, the materials are phosphorus-containing, have an apatite crystal phase, and may contain a second crystal phase and a residual glassy phase. Among materials in clinical use are an apatite-phlogopite material in Europe and apatite-wollastonite materials in Japan. Substantial activity in the United States has been by L. Hench et al. at the University of Florida. This activity has centered on glass, and more particularly on development in vivo of a strong bond between bone and glass. This is said to involve formation of a hydroxycarbonate apatite (HCA) layer.
U.S. Pat. Nos. 4,386,162 and 4,397,670 (Beall) disclose glass-ceramics containing canasite as a predominant crystal phase. Canasite is described as a multiple chain silicate exhibiting an anisotropic, blade-like crystal habit, and having the formula Ca 5 Na 4 K 2 [Si 12 O 30 ]F 4 . The canasite-containing glass-ceramics have been found to exhibit exceptional mechanical strength and fracture toughness.
It would, of course, be highly desirable to provide bio-active glass-ceramics that have greater mechanical strength and toughness values than those found in the known bio-active glass-ceramics containing apatite. Therefore, it would be desirable to marry the strength and toughness of the chain silicate glass-ceramics to the bioactivity of the apatite glass-ceramics. It is a basic purpose of this invention to provide this desirable combination.
SUMMARY OF THE INVENTION
The invention resides in part in a glass-ceramic biomaterial having a bending strength greater than 25,000 psi (172 MPa), a fracture toughness greater than 2.5 MPa m 1/2 (2.3 Kpsi×in 1/2 ), a primary crystal phase of F-canasite, a secondary crystal phase of F-apatite, a crystal phase structure including interlocking blades of F-canasite with at least a portion of the F-apatite crystals within the interlocking F-canasite blades, and a residual glassy phase.
The invention further resides in a glass capable of being cerammed to a glass-ceramic containing F-canasite and F-apatite crystals consisting essentially of, as calculated in weight percent, on an oxide basis,
______________________________________Oxide Wt. % Oxide Wt. %______________________________________SiO.sub.2 42-70 F 3-11CaO 20-30 B.sub.2 O.sub.3 0-3Na.sub.2 O 6-12 Al.sub.2 O.sub.3 0-5K.sub.2 O 3-10 ZrO.sub.2 0-6P.sub.2 O.sub.5 2-13______________________________________
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 and 2 in the accompanying drawing are photomicrographs showing the representative microstructure of a typical material of the invention as a glass (FIG. 1) and as a glass-ceramic (FIG. 2).
PRIOR ART
In addition to the art noted earlier, attention is called to the following United States Patents:
U.S. Pat. No. 3,981,736 (Broemer et al.).
Discloses a glass-ceramic that is biocompatible, that is composed of 20-60% SiO 2 , 5-40% P 2 O 5 , 2.7-20% Na 2 O, 0.4-20% K 2 O, 2.9-30% MgO, 5-40% CaO, and 0.5-3% F, and that contains apatite crystals in a glassy matrix.
U.S. Pat. No. 4,643,982 (Kasuga et al.).
Discloses a high strength, biocompatible glass-ceramic containing apatite and anorthite crystals.
U.S. Pat. No. 4,652,534 (Kasuga).
Discloses a biocompatible glass-ceramic containing apatite and wollastonite crystals.
U.S. Pat. No. 4,775,646 (Hench et al.).
Discloses a fluoride-containing, bio-active, Na 2 O--CaO--P 2 O 5 --SiO 2 glass wherein a substantial part of tile CaO is present as CaF 2 .
U.S. Pat. Nos. 4,536,480 and 4,536,481 (Flannery et al.) disclose opal glasses having apatite-type crystals as the opacifying phase.
Applicant is unaware of any disclosure of a mixed canasite and apatite glass-ceramic, or of canasite as a biomaterial.
DESCRIPTION OF THE INVENTION
The present invention is based on discovery of a family of glass compositions that can be hatched and melted to produce relatively stable glasses. It is further based on the discovery that the glasses thus produced can be cerammed, that is thermally crystallized in situ, to produce glass-ceramic biomaterials.
These materials have a primary crystal phase, F-canasite, a secondary crystal phase, F--apatite, and a residual glassy phase or matrix. F-apatite has the formula Ca 5 (PO 4 ) 3 F. Fluorine is substituted for the hydroxyl group conventionally present in naturally-occurring apatite. In addition, the glass-ceramics may contain a small amount of cristobalite. The glasses are internally nucleated, generally dependent on the presence of CaF 2 and P 2 O 5 .
The glass composition family of the invention consists essentially of the following constituents expressed in percent by weight:
______________________________________Oxide Range (Wt. %)______________________________________SiO.sub.2 42-70P.sub.2 O.sub.5 2-13CaO 20-30Na.sub.2 O 6-12K.sub.2 O 3-10F 3-11B.sub.2 O.sub.3 0-3Al.sub.2 O.sub.3 0-5ZrO.sub.2 0-6______________________________________
Glass melts are produced in customary manner by formulating and mixing batches, melting the batches, pouring the melts and cooling. A cooled melt may be clear, opal, or partially crystallized, depending primarily on three factors: P 2 O 5 content, F content and cooling rate. As is commonly recognized, rapidly cooling a glass melt diminishes the tendency for an opal phase or crystals to form, Accordingly, it is common practice to pour a melt into cold water, that is, drigage the glass, to produce almost instantaneous cooling.
The tendency to opacify, or to form crystals, increases with P 2 O 5 content. Phase separation to form an opal may occur as low as 2.5% P 2 O 5 although quenching may control this up to about 8% P 2 O 5 . However, glasses containing over 8 wt. % P 2 O 5 invariably tend to form crystals of apatite on cooling. However, the crystals appear to be sufficiently dispersed that they do not interfere with subsequent ceramming to a strong glass-ceramic until a P 2 O 5 content of about 13 wt. % is reached.
Thermal crystallization of the glasses may be a one-step, or a two-step, treatment. The two-step treatment involves an initial nucleation step at a relatively low temperature followed by a crystallization step at a higher temperature. An initial nucleation step tends to produce many sites for ultimate crystallization. This, in turn, leads to development of finer crystals.
Fine crystals may also be obtained with glasses having a high phosphorous content in their composition. During melting, such glasses tend to phase separate, into a silica-rich phase and a phosphate-rich phase. The phosphate-rich phase forms small, well-dispersed, F-apatite crystals.
Glasses in the present composition system generally do not require addition of a component, such as TiO 2 , solely for nucleation purposes because they are self-nucleated. The self-nucleating agent may be P 2 O 5 , CaF 2 , or both, depending on the dominance of either agent in the composition.
Thus, there are two modes of nucleation. One mode commonly relies on P 2 O 5 nucleation, and occurs in glasses having a relatively high phosphate content. The other mode it occurs in glasses having a low P 2 O 5 content where CaF 2 becomes the major nucleating agent.
Crystallization may be achieved at time-temperature cycles varying from 550° C. for several hours to less than an hour at 950° C. However, I prefer an 850° C. for one hour cycle for a one-step treatment. For a two-step treatment, I prefer a two hour nucleation at a temperature in the range of 585°-635° C. followed by a two hour crystallization at 900°-950° C.
A high P 2 O 5 content glass requires little or no nucleation hold time. It is already phase separated and/or partially crystallized as melted. It is apparent, then, that crystallization schedules are composition dependent, particularly dependent on P 2 O 5 content.
FIGS. 1 and 2, in the accompanying drawing, are photomicrographs taken with a magnification of 30,000x.
FIG. 1 depicts a fractured and etched surface on a glass having the composition shown as Example 14 in TABLE I, infra. The glass is an opal having two droplet phases present which appear evenly dispersed. Droplets making up the larger phase are 0.1 to 0.2 microns in diameter. These are thought to be hexagonal F-apatite crystals. The smaller droplets are about 0.03 microns in diameter, and are thought to be phosphate-rich nodules.
The glass was crystallized by heating to a temperature of 850° C., and holding at that temperature for one hour before cooling. FIG. 2 depicts a fractured and etched surface on the glass-ceramic thus produced.
It will be observed that the cerammed microstructure is dominated by large interpenetrating blades of F-canasite. Interspersed within the F-canasite structure, as well as in interstitial glass, are spherulites and short, hexagonal crystallites of F-apatite.
TABLE 1 below, sets forth, in weight % on an oxide basis, the compositions of several glasses melted and studied in the course of determining the metes and bounds of the invention. The compositions are arranged in ascending order of P 2 O 5 content. Appearances (App.) of test pieces poured from glass melts are also presented.
These glasses are capable of being cerammed to produce glass-ceramics with F-canasite and F--apatite crystal phases and with a residual glassy phase. Examples 20 and 21 are included to show the effect of glasses; with more than about 13% P 2 O 5 . These glasses underwent such severe crystallization in the melt that they could not be cerammed to form a useful glass-ceramic material within the scope of the invention.
TABLE 1______________________________________ 1 2 3 4 5 6 7______________________________________SiO.sub.2 60.6 50.1 59.9 50.6 49.0 56.7 49.9CaO 20.6 25.6 20.5 27.8 26.8 23.1 27.6Na.sub.2 O 7.8 8.0 7.8 7.5 7.5 7.8 7.1K.sub.2 O 6.1 6.1 6.1 5.7 5.7 6.1 5.4P.sub.2 O.sub.5 1.6 2.4 2.5 3.0 3.0 3.1 3.9F 5.6 7.0 5.6 5.3 8.0 5.5 5.0Al.sub.2 O.sub.3 -- -- -- -- -- -- --B.sub.2 O.sub.3 -- -- -- -- -- -- --MgO -- 0.7 -- -- -- -- 1.1App. Clear Clear Opal Clear Opal Opal/ Clear Clear______________________________________ 8 9 10 11 12 13 14______________________________________SiO.sub.2 46.3 54.8 48.3 44.1 42.4 47.0 47.1CaO 28.0 22.0 27.4 28.6 25.2 28.5 26.1Na.sub.2 O 7.1 7.6 7.6 7.5 7.5 7.5 7.5K.sub.2 O 5.4 5.9 5.9 5.7 5.7 5.7 5.7P.sub.2 O.sub.5 4.0 6.8 7.6 8.2 8.2 8.2 8.2F 8.0 5.0 5.5 5.9 11.0 3.0 5.3Al.sub.2 O.sub.3 -- -- -- -- -- -- --B.sub.2 O.sub.3 -- -- -- -- -- -- --MgO 1.1 -- -- -- -- -- --App. Clear Opal Opal Opal/ Opal Clear/ Opal Crystal Opal______________________________________ 15 16 17 18 19 20 21______________________________________SiO.sub.2 44.7 44.7 44.7 53.5 43.8 39.0 31.7CaO 23.9 21.9 21.9 21.8 24.2 21.8 25.1Na.sub.2 O 9.7 9.7 9.7 7.8 7.5 7.5 6.1K.sub.2 O 7.4 7.4 7.4 5.9 5.8 5.7 4.7P.sub.2 O.sub.5 8.3 8.3 8.3 8.4 13.4 18.0 19.7F 6.0 6.0 6.0 4.9 5.3 8.0 4.9Al.sub.2 O.sub.3 -- 2.0 -- -- -- -- --B.sub.2 O.sub.3 -- -- 0.2 -- -- -- 7.7MgO -- -- -- -- -- -- --App. Opal Opal Opal Opal Opal Crystal Crystal______________________________________
A batch was formulated and mixed that corresponded to each composition. Batch materials employed included: Sand, monocalcium phosphate, calcium carbonate, sodium carbonate, potassium carbonate, calcium fluoride, alumina, boron phosphate and magnesium carbonate. A 2.2 lb. (1000 gram) batch of each composition was melted for 3 hours at 1450° C. in a covered platinum crucible, and the melt poured into water. The glass was dried and remelted for one hour at 1450° C. to reduce cord in the glass. The remelted glass was poured in 1/4" (6.4mm) thick patties which were annealed at 520° C.
Test pieces of selected glasses were converted to glass-ceramics employing preferred heat treating schedules. Crystal phases in the glass-ceramics were determined by X-ray diffraction patterns. TABLE 2 sets forth the heat treating schedules (°C./hr) and the crystal phases observed.
TABLE 2______________________________________Glass Schedule (°C./hr) Crystal Phase______________________________________14 850/1 FA + C6 585-635/4 C + minor FA6 585-635/4 C + CT + minor FA 900/2______________________________________ FA = Fapatite C = Canasite CT = Cristobalite
A two-step ceramming schedule (nucleation plus crystallization) favors optimum crystal growth where the composition has a low P 2 O 5 content; with compositions having higher P 2 O 5 contents, little difference is noted. Crystal grain size is also dependent on the crystallization temperature.
Test pieces of the glass of Example 6 were subjected to various different heat treatment schedules to determine the effect on grain size and strength. In each treatment, the glass was nucleated at a temperature in the 585°-635° C. range for varying times. The nucleation treatments were followed by two hour crystallization heat treatments at temperatures ranging from 685° C. to 1000° C.
TABLE 3 sets forth the nucleation time (Nuc. Time) in hours; the crystallization temperature (Cryst. Temp.) in °C.; the grain size of the cerammed glass as observed visually; modulus of rupture (MOR) as measured in Kpsi (MPa) by a 4 point bend method on abraded bars.
TABLE 3______________________________________ Cryst.Nuc. Time (hrs) Temp. (C.°) Grain MOR (Kpsi) (Mpa)______________________________________2 685 Glassy --2 735 Coarse --2 785 Coarse --2 850 Medium --2 900 Medium 27.7 (197)2 950 Fine 22.4 (159)4 779 Fine --4 850 Medium 19.4 (138)4 900 Very Fine 29.6 (210)4 950 Very Fine 29.5 (209)4 1000 Melted --6 850 Medium --______________________________________
Four of the glasses of TABLE 1 were cerammed by heating at 850° C. for one hour. Grain size and strength were determined as in TABLE 3.
TABLE 4______________________________________Glass Grain MOR (Kpsi) (MPa)______________________________________14 Very Fine 30.3 (215)18 Fine 19.6 (139) 9 Fine 16.7 (119)10 Fine 27.1 (192)______________________________________
By way of illustrating the superior physical characteristics of the present glass-ceramics having F-canasite and F-apatite crystal phases, TABLE 5 presents data comparing the glass-ceramics prepared from glasses 14 and 6 with three commercial products; two apatite-wollastonite compositions (A-W) and one apatite-phlogopite (A-P). TABLE 5A presents the data in metric units; TABLE 5B presents the data in U.S. units.
TABLE 5A______________________________________ 14 6 A-W A-W A-P______________________________________Young's Modulus (GPa) 116 83 117 -- 70-88Bending Strength (MPa) 209 204 220 170 100-160Compressive Strength -- 2103 1060 -- 500(MPa)Fracture toughness 3.86 3.11 2.0 2.5 0.5-1.0(MPa m.sup.1/2)______________________________________
TABLE 5B______________________________________ 14 6 A-W A-W A-P______________________________________Young's Modulus 16.8 12.0 17.0 -- 10.2-12.8(psi × 10.sup.6)Bending Strength 30.3 29.6 31.9 24.7 14.5-23.2(Kpsi)Compressive -- 304.9 153.7 -- 72.5Strength (Kpsi)Fracture Toughness 3.51 2.83 1.82 2.28 0.46-0.91(Kpsi × in.sup.1/2)______________________________________
A test piece of glass-ceramic produced from glass 6 of TABLE 1 was tested for biocompatibility and found to be non-cytotoxic and to meet the requirements of the Elution Test, USP XXII. A further polished test piece was placed in a simulated body fluid at 37° C. for a period of two weeks. SEM and XRD studies revealed that a layer of HCA had formed on the polished surface.
The glass-ceramics of this invention are bio-active materials that may be used in a variety of different forms. They may be molded, or otherwise formed, to a desired shape for use as a bone implant or partial replacement. For some purposes, a porous substrate is desired. The present glasses may be reduced to powders of desired particle size. They may then be mixed with a medium and shaped by standard powder processing techniques. The resulting bodies may then be sintered to provide porous F-canasite-F-apatite glass-ceramics. Powders may also be used as components of composites, that is, in cements, or as fillers.
It is well documented that certain glasses containing calcium and phosphorous oxides and/or fluorides are surface-active and may generate phases that promote bonding to bone. In view of this, I believe that the residual glassy phase in the present glass-ceramic biomaterials may play a very significant role. The alkali metal oxides and silica are thought to be the principal active components in the glassy phase for providing bioactivity. However, minor amounts of other oxides, such as MgO and B 2 O 3 , may be present in the glassy phase to the extent that they do not interfere with bioactivity. | A glass-ceramic biomaterial having high strength and toughness, a family of glasses from which the glass-ceramic biomaterial can be produced, and a method of production. The material has a primary crystal phase of F-canasite and a secondary crystal phase of F-apatite. The glass family is SiO 2 --CaO--Na 2 O--K 2 O--P 2 O 5 --F. The method may be a single stage heat treatment, or a two stage involving an initial nucleation and a subsequent crystallization. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation of U.S. patent application Ser. No. 14/803,154, dated Jul. 20, 2015, which is a continuation of U.S. patent application Ser. No. 13/940,217, filed Jul. 11, 2013, now U.S. Pat. No. 9,138,325, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/670,581 filed Jul. 11, 2012, and these applications are incorporated herein by reference in their entireties for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the field of lamina replacement.
[0004] 2. Description of the Related Art
[0005] Laminectomies, removal of the spinal lamina, are the most common surgical procedures in spinal surgery. Laminectomies are routinely performed in the cervical and lumbar spine to allow decompression of key areas of the spine.
[0006] Cervical laminectomies allow decompression of the spinal cord and nerve roots. Patients may present with a radiculopathy (pain in the arms), myelopathy (weakness in arms and legs), or a combination of both. Cervical laminectomies are performed over multiple cervical levels and are an effective technique for cervical decompression and relief of symptoms. Removal of the posterior spinal elements, the cervical lamina, predisposes the patient to develop spinal instability, deformity, and pain. The posterior spinal elements, lamina, allow posterior structural support for the spine and an attachment for the posterior neck muscles. Some surgeons will perform a spinal fusion after cervical laminectomy to prevent spinal deformity. Cervical fusion creates an unnatural state for the neck, however, as the entire fused neck segment is non-mobile. There is a high risk of adjacent level segment instability after cervical fusion since all of the force with motion is transferred to the segment above and below the fusion.
[0007] Cervical laminoplasty has been devised for decompression and reconstruction of the cervical lamina, but has certain limitations that have decreased its usefulness in spinal surgery. The primary issue is the technical difficulty of cervical laminoplasty. A “trough” needs to be drilled on one side of the junction of the lamina and lateral mass. This is a technically challenging technique. After a complete trough is formed on one side of the lamina-lateral mass junction, a partial trough is then formed on the opposite side. The lamina is then lifted off the dura and a wedge of bone is secured between the lifted-up side of the lamina Therefore, current cervical laminoplasty techniques allow adequate decompression of only one side of the spinal cord and nerve roots.
[0008] Lumbar laminectomies are performed for decompression of the cauda equina and nerve roots. As a large laminectomy defect is created, however, spinal instability can occur. There can also be additional scar formation, as the muscle has to rest directly on the dura after a traditional laminectomy. Some surgeons use hemilaminotomies, where only a portion of the lamina is removed to decompress the nerve roots. However, hemilaminotomies are technically difficult, time consuming, and cannot adequately decompress the bilateral nerve roots and central dura. Lumbar fusions are routinely performed after lumbar laminectomies, but represent a plethora of technical difficulties and predispose the patient to “adjacent level” instability as forces are displaced above or below the fusion. A fusion also involves the placement of large pedicle screws through the pedicle of the vertebral body. Misplacement of the screws has resulted in cerebrospinal fluid (CSF) leaks, nerve injury, and paralysis.
[0009] As such, there is still a need for a prosthetic implant for restoring the lamina after laminectomies while providing complete relief for the patient.
SUMMARY OF THE INVENTION
[0010] The present invention is directed towards a prosthetic implant for restoring lamina after a laminectomy. The implant is generally a lamina-sized construct having a hollow interior. The lamina removed during the laminectomy may be converted to autologous bone that may then be placed inside the hollow interior of the implant. The implant is then secured to the remaining portion of the spine at the site of the laminectomy. An attaching agent, such as one or more plates with screws, may be used to secure the implant to the spine. Over time, the autologous bone inside the hollow interior of the implant will solidify as bone grows through the interior of the implant.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a perspective view of the spine with the lamina removed.
[0012] FIG. 2A shows a rear view of the cervical region of the spine with the lamina removed with an embodiment of the present invention in place.
[0013] FIG. 2B shows a rear view of the lumbar region of the spine with the lamina removed with an embodiment of the present invention in place.
[0014] FIG. 3 shows a perspective view of an embodiment of the present invention with its parts separated and the attachment sites of the spine.
[0015] FIG. 4 show a cross-sectional perspective view of an embodiment of the present invention secured to the spine.
[0016] FIG. 5 shows a cross-sectional isometric top view of an embodiment of the present invention secured to the spine after bone growth.
DETAILED DESCRIPTION
[0017] The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions, features, and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0018] The present invention represents a novel implant and technique for the restoration of the lamina after cervical decompression or lumbar decompression. As seen in FIG. 1 , when a surgeon performs a cervical or lumbar laminectomy by removing the lamina 102 of a spine 100 , a gap is formed. In one embodiment of the present invention, an appropriately sized lamina replacement implant 200 may then be selected for attachment to the spine 100 on each side 106 of the gap.
[0019] This embodiment of the present invention, therefore, includes a lamina replacement implant 200 . As shown in FIG. 2A and FIG. 2B , it may be secured to the spine 100 at the site of the removed lamina The implant 200 is shaped in a way that allows attachment to the spine 100 while providing support for the spine 100 and/or protection for the spinal cord 108 . In a preferred embodiment, the implant 200 has a hollow body having a first arm 202 terminating at a first end 204 , a second arm 206 terminating at a second end 208 , connected together in a mid-section 210 . The hollow body may be made of PEEK (polyether ether ketone) or other suitable biocompatible material.
[0020] In the embodiment in FIG. 3 , the body of the implant 200 has a first arm 202 and a second arm 206 , with the first arm 202 and the second arm 206 connected to form the mid-section 210 . In this embodiment, the first arm 202 and second arm 206 are connected in a movable way to allow for adjustments to their orientation. Examples include the use of hinges, pivots, joints, or telescoping features. This allows the implant 200 to be adjusted to fit many of the different sizes of the spine 100 at different spinal levels. Accordingly, one such implant 200 could be adjusted outwardly to fit the largest lumbar spinal level or inwardly to fit a much smaller cervical spinal level so that it may be applicable to many or all of the spinal levels. Alternatively, a larger two-arm implant 200 could be fashioned to fit just the lumbar spinal levels and a smaller two-arm implant could be fashioned to fit just all or a portion of the cervical spinal levels. Once the adjustment has been made such that the ends of the two arms satisfactorily mate with the spine 100 , this particular orientation can be locked in place by a locking mechanism 218 , such as a screw, pin, glue, or any equivalents. The locking mechanism may be made of titanium, solidified bone graft material, or other biocompatible material. The two arms would mate with the lateral mass in the cervical spine and facet/pedicle in the lumbar spine.
[0021] In another embodiment, the body of the implant 200 is one piece or even multiple pieces but without a defined hinge or pivot portion. Such an implant 200 could have several mounting holes or slots so as to be able to mount to a range of spinal levels of several different sizes. Alternatively, such an embodiment could involve two flexible arms 202 , 206 or a flexible mid-section 210 . The flexible portion could be elastic such that it tends to spring back to a neutral shape until it is fixed to the spine 100 . Yet a further alternative would be that the flexible portion could be designed to readily plastically deform so that there is no significant tendency of the implant 200 to return to a neutral shape once flexed.
[0022] Once the surgeon adjusts the implant 200 and moves it into place, such as in FIGS. 2, 4 and 5 , the surgeon may secure the implant 200 to the spine 100 . This can be done by several different securing means. In the embodiment shown in FIG. 4 , the implant 200 is secured to the spine 100 using plates, braces, or brackets fixed to the implant 200 and/or the spine 100 by screws 214 , 216 Implant screws 214 of appropriate length may attach the plates 212 to the arms 202 , 206 of the implant 200 , and spinal screws 216 of appropriate length may attach the plate 212 to the spine 100 . In one preferred embodiment, the lengths are approximately 6 mm- 8 mm for the cervical region and approximately 12 mm- 14 mm for the lumbar region. In another embodiment, the plates 212 and screws 214 , 216 may comprise titanium or a titanium alloy for their biocompatible properties. In other embodiments, the securing means may instead be a malleable strap, a biodegradable material, or a durable or biodegradable adhesive.
[0023] The implant 200 should be attached so as to allow contact between the remaining portions of the exposed spine 100 and a region on or in the implant 200 that comprises a bone graft region 300 that can facilitate bone growth through the implant 200 . In one embodiment, at least a portion of the implant 200 may be hollow. These hollow portions 300 can be fitted securely so any bone graft material 500 will not leak out. In a preferred embodiment, the first and second ends of the arms also comprise bevels to allow the implant to more securely attach to the spine. When that midsection is adjusted, the angle of the bevels may change orientation as well. Because of this, in some embodiments, the mating faces of the arms may also be adjustable, malleable, or realignable so that the bevels are at a correct orientation to securely attach to the lateral mass 106 for ease of mating and alignment with the spine and to better ensure a tight fit therebetween. To further facilitate securement to the spine 100 , the first and second ends may further comprise one or more notches into which remaining portions of the spine are contoured, fitted or wedged. One or more additional buffers, such as linings, gap-filling adhesives, mating gaskets, or cushioning, may be added to prevent any leakages of bone graft material 500 from the secured implant 200 or to better fit and secure the implant to the spine 100 . The spine and/or the ends of the arms may be further shaped to each other's contours to form a more secure attachment. The inclusion of adjustable mating facings further reduces the time and effort required in contouring, fitting, or wedging the implant or spine.
[0024] Thus, in one embodiment, a hollow interior 300 of the implant 200 may be filled with bone graft material 500 that is intended to solidify through the implant. As shown in FIG. 5 , the bone graft material 500 may become as strong as bone and provide additional strength for the implant 200 . In one embodiment, after a spinal laminectomy, the removed portions of lamina may be crushed into autologous bone (autograft) and used as bone graft material 500 in the implant 200 . This would aid the implant 200 to solidify over time as bone continues to grow through the implant 200 . Such autologous bone graft material 500 may also decrease the chances that such material will be rejected by the patient's body. Indeed, PEEK implants in spinal surgery, filled with autograft and fitted in the disc space, have shown to produce robust bone growth through the interior where autograft has been placed. As PEEK has modules of elasticity that resemble that of bone, it may be a preferential template for lamina replacement, although other compositions may be used and new compositions are sure to prove useful with advancements in the field.
[0025] Alternatively, the bone graft material 500 could be composed of autograft material from other portions of the body, allograft material from the bones of other people (such as cadavers, donors, or stem cell cultures), xenograft material from animals, synthetic replacements, other similar substitutes, or a combination thereof. In one embodiment, the implant uses larger bone pieces or fragments or other bone graft material that may have been pre-solidified or partially solidified before it is implanted into a patient.
[0026] In one embodiment, as shown in FIG. 5 , the surgeon may drill into the exposed sections of the spine 100 and fill the void created thereby with bone graft material 500 that is also used to fill adjacent hollow portions 300 of the implant 200 so that new bone formed inside the ends of the implant and the new bone formed inside the drilled void within the adjacent spine can form together, allowing for a more secure bone attachment. The embodiment in FIG. 5 shows a drilled area with rounded edges, but other shapes may be used for stronger securement or greater surface areas. In one embodiment, a drill with a hollow center is used so the drilled area has a peg in the middle for greater surface area to promote bone growth. In another embodiment, several holes are drilled in each lateral mass 106 for increased surface area. Alternatively, the implant 200 may include a solid end mass that approximately mates with the interior surface of the void created in the spine 100 and design with a surface material and/or texture that facilitates bone growth or solidification, such surfaces may include nanostructured regions, including nanotextured and nanoporous regions. The solid end mass may also be a solid nub used for anchoring the implant in the bone. This solid nub can be made from titanium, bone made from bone graft material, or other biocompatible material.
[0027] Additionally, the implant portions themselves may be composed of biodegradable materials so that the bone graft material 500 solidifies with the spine 100 and the biodegradable implant later biodegrades ultimately to restore the spinal lamina 102 .
[0028] While the present invention has been described with regards to particular embodiments and some of their equivalents, it is recognized that additional variations of the present invention with their functionally equivalent features may be devised without departing from the inventive concept. | A prosthetic implant for restoring lamina after a laminectomy. The implant is generally a lamina-sized construct having a hollow interior. The lamina removed during the laminectomy may be converted to autologous bone that may then be placed inside the hollow interior of the implant. The implant may then be secured to the spine at the site of the laminectomy so that lamina restoration can occur as the hollow interior of the implant solidifies with bone growth. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to Telephony, Systems, multiplexed.
2. Description of the Prior Art
Various types of multiplexer systems have been known to the prior art for many years. In one type of multiplexer system, information on a plurality of terminals is serially transmitted relative to a multiplexer time clock through a communication line. The multiplexer transmitter and multiplexer receiver are each synchronized with the multiplexer time clock to enable the transmission of plural information on a single communication line over a given time period.
There have been many novel systems to extend the amount of information which could be handled by a single communication line. Of prime importance is to easily extend the number of information terminals of the transmitter and the receiver without rewiring the multiplexer system. For example, U.S. Pat. Nos. 3,691,304; 3,691,305; 3,723,658; and 3,737,677 disclose an extendable multiplexing system, wherein the number of multiplexer channels can be increased without rewiring the multiplexer system. However, the aforementioned improvements in the art restrict all of the transmitter or receiver units to be in a single location. Sometimes it is desirable to have several transmitters being remote from one another and connected through a communication line to several receivers which are remote from one another. The prior art has not provided a system which is readily adaptable to existing multiplexer systems to connect a plurality of transmitters, each of which may be remote from one another, to one end of a communication line for information transfer to a plurality of receivers on the other end of the communication line which receivers may be remote from one another. Such a system for expanding the number of transmitters and receivers on a communication line must be compatable with existing equipment in order to avoid reinstallation of the multiplexer system when addition units are desired.
Therefore an object of this invention is to provide a multiplexer transmitter terminator for connecting with a multiplexer transmitter on a communication line having a plurality of multiplexer transmitters which will connect and activate the multiplexer transmitter only at a specific time designated for operation of the multiplexer transmitter.
Another object of this invention is to provide a multiplexer transmiter terminator for connection with a multiplexer transmitter which resets the transmitter upon completion of transmission of all transmitters connected to the communication line.
Another object of this invention is to provide a multiplexer transmitter terminator for connection with a multiplexer transmitter which may be easily programed for use in any time sequence of the plurality of multiplexer transmitters on the communication line.
Another object of this invention is to provide a multiplexer transmitter terminator for connection with a multiplexer transmitter which is easily connected to existing multiplexer transmitters.
Another object of this invention is to provide a multiplexer transmitter terminator for connection with a multiplexer transmitter which is theoretically capable of operating with an unlimited number of multiplexer transmitters.
SUMMARY OF THE INVENTION
The invention may be incorporated into a circuit for a multiplexer unit in a system having a plurality of multiplexer units each being connected on a common communication line wherein each multiplexer unit has an operating period relative to a multiplexer time clock, comprising in combination: a counter circuit having an input connected to the multiplexer time clock for providing a counter output upon registering a preselected clock count which corresponds to the time period of the multiplexer unit; a line receiver connected to the communication line for providing a line receiver output upon detecting a predetermined period of signal absence on the communication line; means connecting said line receiver output to said counter circuit for resetting said counter circuit after said period of signal absence on the communication line; and means connecting said counter circuit output to the multiplexer unit to transfer information through the communication line only at the time period of the multiplexer unit.
Other objects and a fuller understanding of the invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a multiplexer system having a plurality of multiplexer transmitters connected to one end of a communication line by a plurality of transmitter terminators with a plurality of multiplexer receivers connected to the other end of the communication line by a plurality of receiver terminators;
FIG. 2 is a schematic diagram of a portion of the transmitter terminator shown in FIG. 1; and
FIG. 3 is a schematic diagram of a portion of the transmitter terminator shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram of a multiplexer system 9 having a communication line 10 with first through fourth transmitters 11A-14A connected through first through fourth transmitter terminators 11B-14B to one end of the communication line 10 with fist through fourth receiver terminators 11C-14C interconnecting the other end of communication line 10 with multiplexer receivers 11D-14D; respectively. Each of the transmitters 11A-14A are substantially identical each having a plurality of multiplexer inputs 15-18 respectively, whereas each of the receivers 11D-14D are substantially identical each having a plurality of multiplexer outputs 19-22, respectively. The inputs 15-18 correspond with the outputs 19-22 forming four transmitter-receiver units 11-14. In the prior art, a single transmitter for example 12A was directly connected by the communication line 10 to receiver 12D whereby the information on the inputs 16 was sequentially transferred through the communication line 10 to outputs 20 of the receiver 12D.
The second unit comprising transmitter 12A, transmitter terminator 12B, receiver terminator 12C, and receiver 12D has been expanded in size to show the internal circuits but it is understood that the same circuits exists in the remaining units 11, 13 and 14. The transmitter 12A comprises a multiplexer time clock 25 which is connected by a connector 27 to a multiplexer 28 to transfer the information on the inputs 16 sequentially in time on an output connector 30 of the multiplexer 28. The clock 25 regulates the time of transfer for each one of the plurality of inputs 16. The transmitter terminator 12B includes a line receiver 32 which is connected to the clock 25 by a connector 31 and is also connected by a connector 35 to the communication line 10 to provide an output on connector 37 when the line receiver detects an absence of signal on the communication line 10 for a predetermined period of time. The connector 37 is connected to a reset terminal of a counter 40 which counter is connected by the connector 31 to count the clock pulses of the clock 25 in the transmitter 12A. A program plug 41 is connected to the counter 40 to provide counter outputs on connectors 44 and 45 when the counter 40 counts the predetermined number of clock pulses from clock 25 determined by the program plug 41. The output 44 of the counter 40 enables gate 46 to pass signals from the output connector 30 of multiplexer 28 to the communication line 10. The output 45 of counter 40 activates the transmitter 12A to begin transmission on connector 30. A connector 50 interconnects the multiplexer 28 and the counter 40 to terminate the counter output on connector 44 to disenable gate 46 after the transmitter 12A has transmitted the information on inputs 16.
The receiver 12D comprises a multiplexer time clock 55 which is connected by connector 57 to a multiplexer 58 to separate the sequential information received on connector 60 to correspond the inputs 16 with the outputs 20. The receiver 12D is connected to the receiver terminator 12C which receiver terminator includes a line receiver 62 which is connected to the clock 55 by a connector 61 and is also connected by a connector 65 to the communication line 10 to provide a line receiver output on connector 67 when the line receiver detects an absence of signal on the communication line 10 for a predetermined period of time. The connector 67 is connected to a reset terminal of a counter 70 which counter is connected by the connector 61 to count the clock pulses of the clock 55 in the receiver 12D. The clock 55 may be included in the receiver 12D as shown in FIG. 1 or may be a separate clock in the receiver terminator 12C as shown in FIG. 2. A first and second programmable plug 71 and 72 are connected to the counter 70 to provide a counter output on connector 74 when counter 70 counts a first predetermined number of clock pulses from clock 55 determined by the first plug 71. The output on connector 74 is terminated when the counter 70 counts a second predetermined number of clock pulses determined by the second plug 72. A gate 76 transfers information from the communication line 10 to the input 60 of the multiplexer 58 when an output exists on connector 74 from the counter 70.
In the multiplexer system 9, each unit 11-14 is assigned a specific time period in which to transfer information from the inputs 15-18 to the outputs 19-22, respectively. For example, the first transmitter 11A and first receiver 11D may be assigned from 1 to 100 pulses whereas the second transmitter 12A and second receiver 12D may be assigned from 101 to 200 pulses whereas the third transmitter 13A and third receiver 13D may be assigned from 201 to 300 pulses and accordingly the fourth transmitter 14A and receiver 14D from 301 to 400 pulses. The assigned time period is programed into the transmitter terminator 12B by programmable plug 41 and is programed into receiver terminator 12C by programmable plugs 71 and 72. The assigned time periods are dependent upon the clock rate and the number of inputs to each multiplexer transmitter so the aforementioned times are only by way of example. It is also evident that a substantially unlimited number of transmitters and receivers may be incorporated into the system.
Upon applying power to the system 9 there will be an absence of signal on the communication line 10. The line receivers in the transmitter terminators 11B-14B and the receiver terminators 11C-14C including line receivers 32 and 62 will detect a predetermined period of signal absence on the communication line 10 and reset the counters in the transmitter and receiver terminators including counters 40 and 70. All counters commence counting and at the count of 001 pulses the counters in terminators 11B and 11C interconnect transmitter 11A to receiver 11D. The information from inputs 15 is transferred to outputs 19. The counters in terminators 11B and 11C disconnect transmitter 11A from receiver 11D at the count of 100 pulses. At count 101 pulses, counters 40 and 70 provide outputs on connectors 44 and 74 to enable gates 46 and 76. The counter output on connector 45 activates transmitter 12A to begin the sequential transmission of information on the inputs 16 through gate 46, communication line 10 and gate 76 to the outputs 20. The multiplexer 58 arranges the information on the outputs 20 to respectively correspond to the inputs 16 as well known to the art. When transmitter 12A completes transmission, a signal is transferred through connector 50 to the counter 40 to terminate the output on connector 44 to disenable gate 46. The preprogramed second programmable plus 72 connected to counter 70 terminates the counter output on connector 74 at count 200 pulses to disenable gate 76 and thereby disconnects the multiplexer receiver 12D from the communication line 10. The programming of plugs 41 and 71 must correspond to the beginning of the communication period whereas the programming of plug 72 must correspond to the termination of the communication period. Upon the count of 201 pulses terminators 13B and 13C will connect transmitter 13A to receiver 13D. The connection will be terminated at 300 pulses and upon the count of 301 transmitter 14A will be connected to receiver 14D by their respective terminators 14B and 14C. After transmitter 13A has completed transmission and the transmitter and the receiver 14A and 14D have been disconnected, the communication line 10 is silent. Passing of a predetermined period of time results in the line receivers resetting the terminator counters to begin the interconnection of the units 11-14 as heretofore described.
The foregoing description was for example only and in actual practice the connection and disconnection of the transmitters and receivers are more complex as will be hereinafter described. Units have been constructed in which a period of silence of 32 counts will reset all line receivers. All terminators begin counting from time 000 but the receiver terminator counters provide an output 6 counts after the transmitter terminator counters. This is due to an 8 count delay existing in the transmitters as described in the aforementioned U.S. Pat. Nos. 3,691,304; 3,691,305; 3,723,658; 3,737,677 which are owned by the assignee of the instant invention and are hereby incorporated by reference into this disclosure.
FIG. 2 is a schematic diagram of a portion of the transmitter terminator 12B of FIG. 1. Three of the four connections namely 31, 45 and 50 interconnecting the transmitter 12A to the terminator 12B are shown connected to circuit elements of the transmitter terminator 12B. When power is applied to the terminator by switch 80, input 81 of AND gate 83 is in a high bistable condition (HIGH) whereas input 82 is in a low bistable condition (LOW). The LOW output of AND gate 83 an line 86 disenables monostables 94 and 95 and disenables AND gate 87 to disconnect input to the reset line 45 to the transmitter 12A. The LOW on line 86 is applied to AND gate 91 to disenable monostable 88 and is simultaneously applied to AND gate 99 for blocking signals on connector 31 from the clock 25 in the transmitter 12A. Through an AND gate 108, the LOW on line 96 resets latches 111, 114, 116 and 118. The reset of latch 116 disenables a counter 120 and NAND gate 125 as will be hereinafter described. The LOW is also applied to NAND gates 125 and 126. The output of AND gate 108 is applied through NAND gate 135 along connector 137 to reset counter units 153-156 and also resets a pause counter 140 including counter units 141 and 142 through AND gate 130 and NAND gate 132. Capacitor 84 continues to charge through resistor 83 and eventually provides a HIGH to input 82 making the output of AND gate 83 HIGH. A HIGH on line 86 enables counting of the clock pulses from transmitter 12A by the counter units 153-156 and the circuit commences operation. This power on circuit functions only when power is first applied to the system.
The output from the multiplexer clock 25 on connector 31 is applied through AND gate 99 to the counter units 153-156 which are interconnected to provide binary outputs along the binary terminals some of which are shown as 160-166. The terminals will display a 0 or 1 output depending upon the number of pulses received by the counter units. The terminals may represent the number of counts received, for example, 160 may represent 2 0 ; 161 may represent 2 1 ; 162 may represent 2 3 ; 164 may represent 2 4 ; 165 may represent 2 5 ; and 166 may represent 2 6 . Consequently, if the time 101 pulses is assigned for transmission, the programmable plug 41 must interconnect terminals 166 (2 6 ), 165 (2 5 ), 162 (2 2 ), and 160 (2 0 ). The programmable plug 41 may be in the form of a multiple connector plug having internal jumper wires interconnecting various pins. Only when the counter units receive 101 pulses will inputs 166, 165, 162 and 160 all be HIGH which HIGH is transferred through terminal 169 to transistor 170.
Transistor 170 corrects and inverts the signal from terminal 169 and connects the inverted signal to clock monostable 94 by connector 173. The clock monostable 94 provides a HIGH first output 106 to the AND gate 130 and NAND gate 132 to reset the pause counter 140 which begins counting clock pulses through AND gate 99 and connector 174. The first counter unit 141, provides a first counter output, a HIGH to NAND gate 171, upon the first counter unit 141 counting a first predetermined number of pulses, for example 16 pulses whereas the second counter unit 142 provides a second counter output, a HIGH to NAND gate 172 upon counting a second predetermined number of pulses, for example 32 pulses. A second output 107 of the clock monostable 94 which second output is delayed in time from the first output 106 is applied to a clock latch circuit 111 which provides a HIGH output 112 along connector 175 to cause a HIGH output of AND gate 91 to enable the pause monostable 88. Since the pause monostable 88 is enabled by AND gate 91 after the pause counter 140 is reset, there is no chance that spurious outputs from the counter 140 will active monostable 88. The pause monostable 88 will activate upon the first HIGH output from the pause counter 140 through NAND gate 171 applying a LOW to the pause monostable output 88. The pause monostable 88 provides a first monostable output 89 which is connected by AND gate 177 to reset the transmitter 12A along connector 45. The transmitter 12A provides a signal on connector 50 through the inverters to apply a LOW to input 178 of AND gate 180. The transmitter 12B then counts 8 pulses before commencing transmission. The second output 90 from the pause monostable 88 is applied to the pause latch circuit 114 making output 115 HIGH. The HIGH output 115 is applied to NAND gates 125 and 126 to make the outputs thereof LOW. The HIGH output 115 is also applied to input 179 of AND gate 180 so that the next reset pulse from transmitter 12A along connector 50 to input 178 will toggle latch 116. The NAND gates 125 and 126 are connected to gate 46 shown in FIGS. 1 and 3 which connect the transmitter 12A to the communication line 10.
FIG. 3 is a schematic diagram of a portion of the transmitter terminator 12B shown in FIG. 1. NAND gate 125 in FIG. 2 is connected through inverter 128 and terminal 210 to the inputs of AND gates 181 and 182. NAND gate 126 is connected through terminal 211 to gates 183-186. Gates 181-186 interconnect connector 30 to the communication line 10. The gates 183-186 are tri-state gates wherein a LOW on terminal 211 enables gates 183-186 to pass a signal from the connector 30 to communication line 10. These tri-state gates are commercially available as National Semiconductor 8093. The combination of AND gates 181 and 182 and the tri-state 183-186 comprise gate 46 shown in FIG. 1.
After the transmitter 12A has been reset through line 45 and gates 181-186 have been enabled by latch 116, transmitter 12A waits 8 pulses before beginning transmission. The first transmitter 11A in FIG. 1 will disconnect four pulses prior to transmission by the second transmitter 12A or 20 pulses after the first transmitter 11A has completed transmission. This time period prevents unwanted transients on the communication line when gates 181-186 are connecting and disconnecting. The transmitter 12A now completes one transmission. Upon completing the transmission, transmitter 12A provides a signal through connector 50 indicating the transmission has been completed. The signal on conductor 50 applies a HIGH to input 178 of AND gate 180 to toggle latch 116 and make the output 117 LOW. This LOW output 117 is applied to the input of NAND gate 125 which has the remaining two inputs HIGH thereby causing the output of NAND gate 125 to go HIGH. The HIGH output of NAND gate 125 is inverted by inverter 128 to produce a low to AND gates 181 annd 182 in FIG. 3 thereby blocking any signal between the connector 30 and communication line 10. The LOW output 117 of latch 116 also resets counter 120 through connector 122 to enable counter 120 to count clock pulses through AND gate 99 and connector 123. The counter 120 begins to count a preselected number of counts, for example 20 pulses while the pause counter in transmitter terminator 13B is counting to reset transmitter 13A at the count of 16 pulses. When counter 120 counts 20 pulses, counter 120 applies a LOW to NAND gate 129 to activate latch 118 providing a LOW on output 119. The LOW on output 119 is applied to NAND gate 126 to provide a HIGH on terminal 211 causing gates 183-186 to disenable thereby disconnecting the connector 30 from the communication line 10. The third transmitter 13A will begin transmission 4 pulses later.
FIG. 3 illustrates the connectors 191 and 192 connecting the communication line 10 with two amplifiers 194 and 195 for amplifying the signal on the communication line 10 for transmitting the information through AND gates 197 and 198; NAND gates 199 and 200 and AND gate 201. Gates 197-201 form an OR gate to terminal 212 which is connected to the NAND gate 132 in FIG. 2. Connectors 191 and 192; amplifiers 194 and 195 and gates 197-201 form a part of the line receiver 32 shown in FIG. 1. A signal occuring on the transmission line 10 is amplified by either amplifier 194 or 195 and is passed by gates 197-201 through NAND gate 132 in FIG. 2 to reset the pause counter 140. Consequently, the pause counter 140 is constantly being reset during signal transfer on the communication line 10. If signal transfer terminates on the communication line 10, the pause counter 140 is no longer reset and the pause counter 14 0 is able to count the clock pulses through conductor 174 to generate oututs through gates 171 and 172. FIG. 3 includes a circuit comprising NAND gates 203-205 to a latch 206 for activating a light emitting diode 207 upon the transmitter 12A being connected to the communication line 10.
The signals transmitted by the third transmitter 13A on the communication line 10 are passed through amplifiers 194 and 195 and gate 197-201 and 132 to continually reset counter 140 during the transmission. After all transmitters 11A-14A have transmitted a silence will exist on a communication line 10 and the line receiver circuit 32 will not reset counter 140.
Upon counter 140 counting 32 clock pulses, the output of counter unit 142 goes HIGH providing a LOW output from NAND gate 172 to trigger monostable 95. The LOW output of monostable 95 is applied to the input of AND gate 108 to reset latches 111, 114, 116 and 118 and reset counter units 153-156 and 140 as described for the power-on circuit. The LOW from output 117 of latch 116 is applied to hold the output of NAND gates 125 and 126 HIGH masking any transitions that might occurr as the latches are reset simultaneously, all terminators will be reset. Upon completion of the output from monostable 95, the counter units 153-156 begins counting the clock pulses from transmitter 12B to await the 101 count to reactivate the transmitter 12B.
The receiver terminators 11C-14C operate in a manner similar to the transmitter terminators 11B-14B except that the receiver terminator must provide a signal for both enabling and disenabling the receiver. The transmitter terminator is disenabled by an output on connector 50 from the transmitter. The diagram and description of the receiver terminator may be found in my copending application which was filed concurrently with the instant application and is hereby incorporated by reference into this disclosure.
The invention has been described as a device for a multiplexer unit in a system 9 having a plurality of multiplexer units connected on a common communication line 10 wherein each multiplexer unit has a time period for operation relative to a time clock 25. The invention includes a counter circuit 40 connected to the multiplexer time clock 25 for providing a counter output on line 44 upon registering a preselected clock count which corresponds to the time period of the multiplexer unit. A line receiver 32 is connected by 35 for providing a line receiver output upon detecting a predetermined period of signal absence on the communication line 10. The line receiver 32 is connected by connector 37 for resetting the counter circuit 40 after the period of signal absence on line 10. The counter circuit is connected to the multiplexer unit 28 through gate 46 for enabling the multiplexer unit to transfer information through the communication line 10 only at the time period assigned to the multiplexer unit.
The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of the circuit and the combination and arrangement of circuit elements may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. | A multiplexer transmitter terminator is disclosed for connection to a multiplexer transmitter in a system having a plurality of multiplexer transmitters connected on a common communication line. Each of the multiplexer transmitters is assigned a time period for transmission relative to a multiplexer time clock. The improvement includes a counter circuit connected to the multiplexer time clock for providing a counter output upon counting a preselected number of clock pulses which output corresponds to the time period assigned for transmission of the multiplexer transmitter. A line receiver is connected to the communication line for providing an output upon detecting a predetermined period of signal absence on the communication line. The line receiver output is connected to the counter circuit to reset the counter after the predetermined period of signal absence. The counter circuit is connected to the multiplexer transmitter for enabling transmission through the communication line only at the time period assigned to the multiplexer transmitter. The foregoing abstract is merely a resume of one general application, is not a complete discussion of all principles of operation or applications, and is not to be construed as a limitation on the scope of the claimed subject matter. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns the production of glass in general from waste glass or glass batches. The three essential stations of the production process comprise melting, then refining and finally homogenizing.
2. Description of Related Art
The production of high-value special glasses requires the process step of refining after melting, in order to remove the residual bubbles from the melt. The prior art comprises the refining of glasses by addition of refining agents such as redox refining agents or evaporating refining agents. One speaks here of chemical refining, since the release of gases form the melt is utilized in order to inflate small bubbles that are present and thus to facilitate the rise of these bubbles.
Along with the methods of chemical refining, alternatively or additionally, physical effects are utilized, as described in the literature, for expelling bubbles and thus for refining, such as, for example, centrifugal force (U.S. Pat. No. 3,893,836) or the reduction of the bath depth and thus the rise of bubbles to the surface of the melt is facilitated (DE 197 10 351 C1).
It is known that refining is promoted by increasing the temperature of the melt. However, when refractory material is used for the refining tank, limits are imposed. If ceramics with high a zirconium content are used, then temperatures of a maximum 16,500° C. can be produced.
It is known also to conduct refining in an apparatus that operates according to the so-called skull pot principle. See EP 0 528,025 B1. Such a device comprises a crucible, the walls of which are formed from a ring or collar of metal pipes, which can be connected to a cooling medium, with slots between the metal pipes adjacent to one another. The device also contains an induction coil, which surrounds the walls of the crucible and by means of which high-frequency energy can be coupled into the contents of the crucible. This direct heating of the glass melt by means of irradiation of high-frequency energy is conducted at a power of 10 kHz to 5 MHz.
Such a crucible permits essentially higher temperatures than a vessel made of refractory material. The advantage of high-temperature refining in comparison to all other physical refining processes is that it is very effective and rapid due to the high temperatures. The processes take place clearly more rapidly at high temperatures, so that very small, rapid aggregate modules can be prepared for the process of refining.
DE 2,033,074A describes an arrangement for the continuous melting and refining of glass. A refining device is provided therein, which operates according to the skull pot principle. The melt from the bottom region of the melting vessel reaches the refining vessel via a connection channel. It enters in the bottom region of the latter. The glass flow in the refining vessel thus rises upward from the bottom. This has the advantage that the flow has the same direction as the lifting force of the bubbles. The bubbles to be removed reach the hot surface of the melt and are discharged from the latter.
A disadvantage of this embodiment consists of the fact that the connection channel between the melting-down basin and the high-frequency refining device is subject to intense wear and tear due to the high flow velocities.
SUMMARY OF THE INVENTION
The object of the invention is to develop a system in which the good refining results remain, based on an upward flow of the glass melt, but in which also the melt remains hot at the surface in the region where the bubbles are discharged, so that all bubbles can burst at the surface, and in which the problematic connection channel between the melting vat and the refining device can be omitted.
This object is solved by the independent claims.
The inventor has recognized the following: If the inlet as well as the outlet of the high-frequency crucible is arranged in the upper region and in fact in such a way that the two of these lie opposite one another, then a very good and effective refining results. One would have expected that with such a structure, an essential part of the melt would be unheated and unrefined and led along directly to the outlet in the short circuit from the inlet at the surface. However, this is not the case. Rather, a defined flow is set up based on the differences in density in different melt regions. If the expansion coefficient of the melt is sufficiently high and the heating of the melt in the crucible is assured appropriately, the laterally introduced cold glass does not directly reach the crucible outlet via short-circuit currents, but is first pulled to the bottom of the crucible and from here is led to the surface and to the outlet via convection rollers according to circular movements of variable length.
The inlet and outlet should essentially lie diametrically opposite each other. This is not absolutely necessary, however; certain deviations are admissible. Also, the crucible should be dimensioned correctly, but this is an optimizing problem, which can be solved by the person of average skill in the art.
The connection channel between the melting vat and the refining crucible, which is known from the prior art, will be avoided. Instead of this, the melt can overflow from the melting vat into an open channel to the refining crucible.
It may be appropriate to configure the refining crucible according to DE 2,033,074 A. The crucible comprises a lower part of relatively small diameter, and an upper part of relatively large diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail on the basis of the drawing. The following are shown individually therein:
FIG. 1 shows a set-up for the production of glass.
FIG. 2 shows a refining crucible according to the invention in a vertical section.
FIG. 3 shows another embodiment of a set-up for the production of glass.
FIG. 4 shows a cooled bridge barrier in the skull crucible, in schematic representation.
FIG. 5 illustrates the integration of the bridge barrier into a skull crucible.
FIG. 6 shows a set-up for the melting of glass with two refining stations.
DETAILED DESCRIPTION OF THE INVENTION
The set-up shown in FIG. 1 comprises a melting-down basin 1 with an introduction device 1 . 1 . The glass batch 1 . 2 which has been introduced is retained by a bridge barrier 1 . 3 to keep it from flowing further to the stations connected downstream.
An overflow channel 2 is connected to the melting-down basin 1 . This is open at the top. The crude melt reaches a refining device 3 via the overflow channel 2 . This refining device comprises a skull crucible and also a high-frequency coil, which is not shown here. The actual refining is conducted here at temperatures of 1,750 to 3,000° C., depending on the glass synthesized and the requirements for glass quality.
After the refining, the melt is free of bubbles. It reaches a homogenizing device 5 , which in turn comprises a stirring crucible and a stirrer, via a conventionally heated channel system 4 .
The structure of the skull crucible can be recognized in detail in FIG. 2 . This involves a so-called mushroom skull crucible according to DE 2,033,074 A. The skull crucible has a lower crucible part 3 . 1 of a relatively small diameter, and in addition an upper crucible part of a relatively large diameter. The upper crucible part also contains the inlet 3 . 2 and the outlet 3 . 3 for the melt. The arrows indicate the flow of the melt. As is seen, the cold glass introduced laterally through the inlet 3 . 2 first falls downward to the bottom of the crucible 3 . 4 , then rises again upward in order to once more flow downward and then upward again. As is seen, the lower part 3 . 1 of the skull crucible is surrounded by a high-frequency coil 3 . 5 .
The set-up shown in FIG. 3 is the refining device 3 equipped with an additional, cooled bridge barrier 3 . 6 . This has the following task: If the glass arriving in the skull refining aggregate is very foamy or the expansion coefficient of the melt as a function of temperature is very small, then the danger exists that a small portion of the melt is drawn over the surface. This can be prevented either by a clear increase in the temperature difference between the melt flowing in and the melt in the core of the crucible in the skull crucible module or by incorporating the bridge barrier 3 . 6 .
The bridge barrier 3 . 6 may be comprised of either a gas-cooled or liquid-cooled ceramic material or of a water-cooled metal material. Modifications of cooled metal components lined with ceramics are also conceivable. If the bridge barrier has metal components, which lie above the surface of the melt and come into contact with the burner atmosphere, then it may be helpful to coat the bridge barrier with a thin layer of Teflon (<150μ) in order to prevent a corrosion of the metal surface due to the aggressive burner atmosphere. The bridge barrier 3 . 6 can either be positioned centrally in the refining module or can be laterally displaced to inlet 3 . 2 . The latter modification has the advantage that the hot zone where the bubbles rise can be made as large as possible. If the bridge barrier is constructed of metal material, then it should be electrically connected to the metal skull crucible, so that no induced voltages build up between the metal corset and the barrier, since these can lead to arcing and thus to the disruption of the metal wall. If an electrical connection cannot be produced, then all components must be operated in an electrically free-floating manner—i.e., not grounded. This is particularly possible if the melt tends toward intense crystallization, since in this case a stable puncture proof intermediate layer is formed, which reliably stops the arcing.
An example of embodiment of such a bridge barrier 3 . 6 is shown in FIG. 4 . The incorporation of such a barrier 3 . 6 can be seen in FIG. 5 . Here, the barrier is positioned below the surface of the melt. This has the advantage that there are no cold metal components in the upper furnace space. The condensation of burner off-gases is particularly problematical on cold components. It is a disadvantage in this type of assembly that large fluctuations in the glass level cannot be allowed, since in order to assure that no liquid melt flows over the barrier, the immersion depth should be a maximum of 1 cm below the surface of the melt.
A barrier assembly can be made possible with the edge of the barrier above the upper edge of the glass bath by lining the metal barrier either with Teflon or ceramic materials or by raising the glass level first higher at the beginning of the process—and in fact raising it over the upper edge of the barrier—and then again lowering the glass level to the normal level in operation. In this case, a glazing of the barrier is achieved, which protects the barrier from attacks due to burner off-gases. In addition to the embodiment of the barrier that is shown here, simpler embodiments, for example, a simple ceramic stone barrier or even a cooled metal rod which runs crosswise over the crucible is conceivable.
An electrical connection 3 . 7 of the crucible 3 with the barrier 3 . 6 as well as a crucible short-circuit ring 3 . 8 can be seen in detail in FIG. 5 .
A cascade refining is provided in the set-up shown in FIG. 6 . The introduced glass batch 6 as well as a bridge barrier 7 can also be recognized again here. Several refining modules are connected one after the other and they connect with one another simply in the upper region. The connection sites can be heated conventionally, for example, with burners. In this case, complicated connection channels that are sensitive to disruption and consume a great deal of energy can be omitted. An example with two refining modules connected one after the other is shown in FIG. 6 . Of course, any number of refining modules connected one after the other is conceivable.
With respect to geometry—particularly diameter—, HF-frequency and HF voltage are adapted to the conductivity of the glass to be melted in each case. If different types of glass with clearly different electrical conductivities are to be melted in the same vat and are to be refined by means of HF heating, then this is not possible without retrofitting measures (connection of another generator with adapted frequency region, connection of an adapted coil, possible change of the melting diameter, adaptation of the capacities in the HF generator). Of course, as in FIG. 6 , two or more aggregates can be connected one after the other, and thus each individual module can be adapted to different electrical melting properties. The HF energy is only turned on in the HF refining module adapted to the respective melt, whereas the other modules are not heated with HF energy, but only with conventional energy—such as, for example, burners in the upper furnace space. The melt flows over the modules that are not turned on and is drawn into and heated only in the HF-heated module. In order to configure the exchange of glass in such an aggregate in a simpler and quicker manner, it is helpful if each module has an additional bottom outlet 9 , which is opened for a short time in the glass exchange phase. Such a bottom outlet can also be of use in the case of the simple structure with only one HF-module—particularly if exchanges of glass in the vat are considered—but also if bottom residues should deposit thereon.
Another advantage of the invention is the very good “emergency running properties” of the set-up if there are disruptions in the HF range. If the high-frequency heating apparatus fails for any reason whatever, then there exists the danger of a freezing up of the continuous flow in the case of the continuous-flow crucible with introduction from below, whereby the glass flow is interrupted. The danger does not exist in principle in the present invention, since the glass flow can be assured in each case by utilizing the upper heat of the burner. | A method for the refining of glass by means of high temperatures in a skull crucible is provided. The method includes introducing a glass melt in the skull crucible through an inlet disposed at an upper region of the skull crucible, heating the skull crucible by irradiation of high-frequency energy, and discharging the glass melt from the skull crucible through an outlet disposed at the upper region, the outlet being disposed at a place essentially lying opposite the inlet. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the production of fuel alcohol from cellulose. More specifically, this invention relates to the pretreatment of cellulose feedstocks for ethanol production. The pretreatment reaction of feedstocks chosen with a ratio of arabinan plus xylan to non-starch polysaccharides (AX/NSP) of greater than about 0.39 produces a superior substrate for enzymatic hydrolysis than other feedstocks. These pretreated feedstocks are uniquely suited to ethanol production. Examples of feedstocks that could be chosen in such a pretreatment process include some varieties of oat hulls and corn cobs, and feedstocks selectively bred for high AX/NSP.
2. Brief Description of the Prior Art
The possibility of producing ethanol from cellulose has received much attention due to the availability of large amounts of feedstock, the desirability of avoiding burning or landfilling the materials, and the cleanliness of the ethanol fuel. The advantages of such a process for society are described, for example in a cover story of the ATLANTIC MONTHLY, (April 1996).
The natural cellulosic feedstocks for such a process typically are referred to as "biomass`. Many types of biomass, including wood, agricultural residues, herbaceous crops, and municipal solid wastes, have been considered as feedstocks for ethanol production. These materials primarily consist of cellulose, hemicellulose, and lignin. This invention is concerned with converting the cellulose to ethanol. The familiar corn starch-to-ethanol process, in which the starch is converted to ethanol using sulfurous acid and amylase enzymes, lies outside the scope of this invention.
Cellulose is a polymer of the simple sugar glucose connected by beta 1,4 linkages. Cellulose is very resistant to degradation or depolymerization by acid, enzymes, or micro-organisms. Once the cellulose is converted to glucose, the resulting sugar is easily fermented to ethanol using yeast. The difficult challenge of the process is to convert the cellulose to glucose.
The oldest methods studied to convert cellulose to glucose are based on acid hydrolysis (review by Grethlein, Chemical Breakdown Of Cellulosic Materials, J.APPL.CHEM. BIOTECHNOL. 28:296-308 (1978)). This process can involve the use of concentrated or dilute acids. The concentrated acid process uses 72%, by weight, sulfuric acid or 42%, by weight, hydrochloric acid at room temperature to dissolve the cellulose, followed by dilution to 1% acid and heating to 100° C. to 120° C. for up to three hours to convert cellulose oligomers to glucose monomers. This process produces a high yield of glucose, but the recovery of the acid, the specialized materials of construction required, and the need to minimize water in the system are serious disadvantages of this process. Similar problems are encountered when concentrated organic solvents are used for cellulose conversion.
The dilute acid process uses 0.5% to 2%, by weight, sulfuric acid at 180° C. to 240° C. for several minutes to several hours. BRINK (U.S. Pat. Nos. 5,221,537 and 5,536,325) describes a two-step process for the acid hydrolysis of lignocellulosic material to glucose. The first (mild) step depolymerizes the hemicellulose to xylose and other sugars. The second step depolymerizes the cellulose to glucose. The low levels of acid overcome the need for chemical recovery. However, the maximum glucose yield is only about 55% of the cellulose, and a high degree of production of degradation products can inhibit the fermentation to ethanol by yeast. These problems have prevented the dilute acid hydrolysis process from reaching commercialization.
To overcome the problems of the acid hydrolysis process, cellulose conversion processes have been developed using two steps: (1) a pretreatment, and (2) a treatment comprising enzymatic hydrolysis. The purpose of pretreatment is not to hydrolyze the cellulose completely to glucose but, rather, to break down the integrity of the fiber structure and make the cellulose more accessible to attack by cellulase enzymes in the treatment phase. After a typical pretreatment of this type, the substrate has a muddy texture. Pretreated materials also look somewhat similar to paper pulp, but with shorter fibers and more apparent physical destruction of the feedstock.
The goal of most pretreatment methods is to deliver a sufficient combination of mechanical and chemical action, so as to disrupt the fiber structure and improve the accessibility of the feedstock to cellulase enzymes. Mechanical action typically includes the use of pressure, grinding, milling, agitation, shredding, compression/expansion, or other types of mechanical action. Chemical action typically includes the use of heat (often steam), acid, and solvents. Several known pretreatment devices will be discussed below, and with specific reference to extruders, pressurized vessels, and batch reactors.
A typical treatment by enzymatic hydrolysis is carried out by mixing the substrate and water to achieve a slurry of 5% to 12%, by weight of cellulose, and then adding cellulase enzymes. Typically, the hydrolysis is run for 24 to 150 hours at 50° C., pH 5. At the end of the hydrolysis, glucose, which is water soluble, is in the liquid while unconverted cellulose, lignin, and other insoluble portions of the substrate remain in suspension. The glucose syrup is recovered by filtering the hydrolysis slurry; some washing of the fiber solids is carried out to increase the yield of glucose. The glucose syrup is then fermented to ethanol by yeast, and the ethanol recovered by distillation or other means. The ethanol fermentation and recovery are by well-established processes used in the alcohol industry.
The two-step process of pretreatment plus enzyme hydrolysis overcomes many of the problems associated with a single harsh acid hydrolysis. The specific action of the enzymes decreases the amount of degradation products and increases the yield of glucose. In addition, the fact that the pretreatment for fiber destruction is milder than that for cellulose hydrolysis means that lower chemical loadings can be used, decreasing the need for chemical recovery, and a lower amount of degradation products are made, increasing the yield and decreasing the inhibition of fermentation to ethanol by yeast.
Unfortunately, to date the approach of a pretreatment and an enzyme hydrolysis treatment has not been able to produce glucose at a sufficiently low cost, so as to make a fermentation to ethanol commercially attractive. Even with the most efficient currently known pretreatment processes, the amount of cellulase enzyme required to convert the cellulose to glucose is so high as to be cost-prohibitive for ethanol production purposes.
Several approaches have been taken to attempt to decrease the amount of cellulase enzyme required.
The approach of simply adding less cellulase to the system decreases the amount of glucose produced to an unacceptable extent.
The approach of decreasing the amount of enzyme required by increasing the length of time that the enzyme acts on the feedstock leads to uneconomical process productivity, stemming from the high cost of hydrolysis tanks.
The approach of reducing the amount of cellulase enzyme required by carrying out cellulose hydrolysis simultaneously with fermentation of the glucose by yeast is also inefficient. The so-called simultaneous saccharification and fermentation (SSF) process is not yet commercially viable because the optimum operating temperature for yeast, 28° C., is too far below the optimum 50° C. conditions required by cellulase. Operating a SSF system at a compromise temperature of 37° C. is also inefficient, and invites microbial contamination.
The desire for a cost-effective ethanol production process has motivated a large amount of research into developing effective pretreatment systems. Such a pretreatment system would achieve all of the advantages of current pretreatments, including low production of degradation products and low requirements for chemical recovery, but with a sufficiently low requirement for cellulase enzymes so as to make the process economical.
The performance of a pretreatment system is characterized strictly by the amount of enzyme required to hydrolyze an amount of cellulose to glucose. Pretreatment A performs better than pretreatment B, if A requires less enzyme to produce a given yield of glucose than B.
The early work in pretreatment focused on the construction of a working device and determination of the conditions for the best performance.
One of the leading approaches to pretreatment is by steam explosion, using the process conditions described by FOODY (U.S. Pat. No. 4,461,648), which is incorporated herein by reference. In the FOODY process, biomass is loaded into a vessel known as a steam gun. Up to 1% acid is optionally added to the biomass in the steam gun or in a presoak. The steam gun is then filled very quickly with steam and held at high pressure for a set length of time, known as the cooking time. Once the cooking time elapses, the vessel is depressurized rapidly to expel the pretreated biomass, hence the terminology "steam explosion" and "steam gun".
In the FOODY process, the performance of the pretreatment depends on the cooking time, the cooking temperature, the concentration of acid used, and the particle size of the feedstock. The recommended pretreatment conditions in the FOODY process are similar for all the cellulosic feedstocks tested (hardwood, wheat straw, and bagasse) provided they are divided into fine particles. Furthermore, the cooking temperature is determined by the pressure of the saturated steam fed into the steam gun. Therefore, the practical operating variables that effect the performance of the pretreatment are the steam pressure, cooking time, and acid concentration. The FOODY process describes combinations of these variables for optimum performance; as one might expect, increasing the time decreases the temperature used, and vice versa. The range of steam pressure taught by FOODY is 250 psig to 1000 psig, which corresponds to temperatures of 208° C. to 285° C.
Another published study of steam explosion pretreatment parameters is Foody, et al, Final Report, Optimization of Steam Explosion Pretreatment, U.S. DEPARTMENT OF ENERGY REPORT ET230501 (April 1980). This study reported the effects of the pretreatment variables of temperature (steam pressure), particle size, moisture content, pre-conditioning, die configuration, and lignin content. The optimized steam explosion conditions were reported for three types of straws, five species of hardwood, and four crop residues.
The optimum pretreatment conditions as published by FOODY were subsequently confirmed by others using other feedstocks and different equipment. For example, GRETHLEIN (U.S. Pat. No. 4,237,226), describes pretreatment of oak, newsprint, poplar, and corn stover by a continuous plug-flow reactor, a device that is similar to an extruder. Rotating screws convey a feedstock slurry through a small orifice, where mechanical and chemical action break down the fibers.
GRETHLEIN specifies required orifice sizes, system pressures, temperatures (180° C. to 300 C.), residence times (up to 5 minutes), acid concentrations (up to 1% sulfuric acid) and particle sizes (preferred 60 mesh). GRETHLEIN obtained similar results for all of the specified substrates he identified (See Column 3, line 30). Even though the GRETHLEIN device is quite different from the steam gun of FOODY, the time, temperature, and acid concentration for optimum performance are similar.
More recent work has focused on understanding the means by which pretreatment improves the enzymatic hydrolysis of a given substrate. BRINK (U.S. Pat. No. 5,628,830) describes the pretreatment of lignocellulosic material by using a steam process to break down the hemicellulose and following with hydrolysis of the cellulose using cellulase enzymes.
The first explanation offered to characterize the advantage of a pretreatment was that a pretreatment should be evaluated on the amount of lignin removed, with better performance associated with higher degrees of delignification. See Fan, Gharpuray, and Lee, Evaluation Of Pretreatments For Enzymatic Conversion Of Agricultural Residues, PROCEEDINGS OF THE THIRD SYMPOSIUM ON BIOTECHNOLOGY IN ENERGY PRODUCTION AND CONSERVATION, (Gatlinburg, Tenn., May 12-15, 1981). The notion that delignification alone characterizes pretreatment was also reported by Cunningham, et al, PROCEEDINGS OF THE SEVENTH SYMPOSIUM ON BIOTECHNOLOGY FOR FUELS AND CHEMICALS, (Gatlinburg, Tenn., May 14-17, 1985).
Grethlein and Converse, Common Aspects of Acid Prehydrolysis and Steam Explosion for Pretreating Wood, BIORESOURCE TECHNOLOGY 36(2):77-82 (1991), put forth the proposition that the degree of delignification is important only for previously dried substrates and, therefore, not a relevant consideration to most pretreatment processes that use undried feedstocks.
Knappert, et al, A Partial Acid Hydrolysis of Cellulosic Materials as a Pretreatment for Enzymatic Hydrolysis, BIOTECHNOLOGY AND BIOENGINEERING 23:1449-1463 (1980) reported that the increased susceptibility to enzyme hydrolysis after pretreatment is caused by the creation of micropores by the removal of the hemicellulose, a change in crystallinity of the substrate, and a gross reduction in the degree of polymerization of the cellulose molecule.
Grohmann, et al, Optimization of Dilute Acid Pretreatment of Biomass, SEVENTH SYMPOSIUM ON BIOTECHNOLOGY FOR FUELS AND CHEMICALS (Gatlinburg, Tenn., May 14-17, 1985) specifically supported one of the hypotheses of Knappert, et al by showing that removal of hemicellulose in pretreatment results in improved enzymatic hydrolysis of the feedstock. (See p. 59-80). Grohmann, et al worked with wheat straw and aspen wood at temperatures of 95° C. to 160° C. and cooking times of up to 21 hours. For both feedstocks, about 80% of the cellulose was digested by cellulase enzymes after optimum pretreatments, in which 80% to 90% of the xylan was removed from the initial material.
Grohmann and Converse also reported that the crystallinity index of the cellulose was not changed significantly by pretreatment. They further reported that pretreatments can create a wide range of degrees of polymerization while resulting in similar susceptibility to enzymatic hydrolysis.
Another alternative explanation offered for the improvements in enzymatic hydrolysis due to pretreatment is the increase in surface area of the substrate. Grethlein and Converse refined this explanation by showing that the surface area that is relevant is that which is accessible to the cellulase enzyme, which has a size of about 51 angstroms. The total surface area, which is measured by the accessibility of small molecules such as nitrogen, does not correlate with the rate of enzymatic hydrolysis of the substrate, for the reason that small pores that do not allow the enzyme to penetrate do not influence the rate of hydrolysis.
In spite of a good understanding of devices and optimum conditions for pretreatment, and a large quantity of research into the mechanism of a pretreatment process, there still does not exist an adequate pretreatment for a commercially feasible process to convert cellulosic materials to ethanol. Such a pretreatment process would be of enormous benefit in bringing the cellulose-to-ethanol process to commercial viability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A graph of cellulose conversion for certain feedstocks after pretreatment reaction at 121 C., as a function of AX/NSP of the initial material, according to EXAMPLE 3.
FIG. 2 A graph of cellulose conversion for certain feedstocks after pretreatment reaction at 230 C., as a function of AX/NSP of the initial material, according to EXAMPLE 4.
SUMMARY OF THE INVENTION
The inventors have discovered that a critical property of a feedstock determines its relative cellulase enzyme requirement to convert the cellulose to glucose after the pretreatment reaction. That property is the ratio of arabinan plus xylan to total nonstarch polysaccharides, which we will refer to hereinafter as "AX/NSP." The inventors have discovered that the higher the AX/NSP, the less cellulase enzyme is required after the pretreatment reaction, and hence the more economical the production of ethanol. Feedstocks with AX/NSP over about 0.39 are particularly well suited for a cellulose-to-ethanol process. Examples of such feedstocks are certain varieties of oat hulls and corn cobs.
Based on this discovery, the inventors have developed improved pretreatment processes prior to enzyme treatment that converts a lignocellulosic feedstock to ethanol. One such process consists essentially of the steps:
1. Choosing a lignocellulosic feedstock with a ratio of arabinan plus xylan to total nonstarch polysaccharides (abbreviated AX/NSP) of greater than 0.39.
2. Reacting the chosen feedstock at conditions which disrupt the fiber structure and effect an hydrolysis upon portions of both cellulose and hemicellulose, so as to improve digestibility of the pretreated feedstock by a subsequent cellulase enzyme treatment.
A second such process consists essentially of the steps:
1. Choosing a lignocellulosic feedstock selectively bred to have a relatively increased ratio of arabinan plus xylan to total nonstarch polysaccharides (AX/NSP).
2. Reacting the chosen feedstock at conditions which disrupt the fiber structure and effect an hydrolysis upon portions of both cellulose and hemicellulose, so as to improve digestibility of the pretreated feedstock by a subsequent cellulase enzyme treatment.
Once a feedstock is chosen based on high AX/NSP, the pretreatment reactions can be carried out in a manner consistent with previous reports. This might include single stage or two stage reactions in steam guns, extruders, or other devices used previously.
By choosing the feedstock based on AX/NSP, the resulting cellulase enzyme requirement after the pretreatment reaction is significantly lower than otherwise required. This results in significant savings in the cost of producing ethanol from lignocellulosic materials.
There have been no previous reports of the superior performance after pretreatment of feedstocks specifically chosen because of any particular level of AX/NSP, let alone an AX/NSP level that is greater than 0.39, by weight.
The present invention is very surprising in view of the U.S. D.O.E. study by FOODY, et al, supra, which observed no correlation between xylan content of the feedstocks and glucose yield after steam explosion and hydrolysis by cellulase.
FOODY, et al was a study of thirteen feedstocks. The resulting conversion of cellulose to glucose varied widely among the pretreated feedstocks, between 46% to 50% for oak and sunflower stalks to 86% to 87% for barley straw and maple. The two best feedstocks of FOODY et al, barley straw and maple wood, had xylan contents of 31% and 19%, respectively, which were among the highest and lowest values reported. Oak and aspen both contained 21% xylan, yet they achieved widely differing glucose yields after hydrolysis by cellulase, 46% and 72%, respectively.
The present invention also is very surprising in view of the patent to GRETHLEIN, supra. GRETHLEIN described a device for the pretreatment of feedstocks using dilute sulfuric acid. All four of the GRETHLEIN feedstocks (oak, newsprint, poplar, and corn stover) performed similarly (Column 3, lines 25 to 32). This reported result is exactly contrary to the teachings of the present invention, who have found and identified a novel feedstock property, AX/NSP, that can reliably be used to predict the performance of the feedstocks after treatment.
The present invention also is very surprising in view of the publication by Knappert, et al., supra, which reviewed four feedstocks: Solka floc, newsprint, oak, and corn stover. Knappert, et al obtained optimum yields of glucose from cellulose after pretreatment reactions. One hundred percent yield was obtained from newsprint, corn stover, and oak, and 81% yield was obtained from Solka floc (Tables I and II, page 1453-1457). As the only feedstocks with cellulose and xylan content reported were newsprint and Solka floc, this study simply does not address the relationship between AX/NSP of the feedstock and the digestibility of the material by cellulase enzymes after pretreatment reaction.
The present invention actually suggests that the teachings of Knappert, et al are incorrect. At the very least, the teachings of Knappert, et al are at odds with the teachings of the present invention. Knappert et al taught that a low hemicellulose content of a material presages little improvement in cellulose digestibility during pretreatment. The present invention, at EXAMPLE 5, shows a large improvement in the digestibility of oat hulls with pretreatment reaction after the hemicellulose has been removed by a mild reaction.
SUMMARY OF TERMINOLOGY
The invention and preferred embodiments described hereafter are to be construed using certain terms as hereafter defined, for purposes of the present invention.
Lignocellulosic feedstock means any raw material that one might consider for a cellulose-to-ethanol process. Such a material has at least about 25% cellulose, and the cellulose is substantially converted to glucose and then ethanol in the process. Typical lignocellulosic feedstocks materials are wood, grains, and agricultural waste. For the present purposes there are no specifications on the lignin, starch, protein, or ash content. Examples of lignocellulosic feedstocks that have been considered for an ethanol process are wood, grasses, straws, and crop waste. Often, a lignocellulosic feedstock originates from one species of fiber. However, for present purposes the lignocellulosic feedstock can be a mixture that originates from a number of different species.
Conversion to fuel ethanol denotes the conversion of at least about 40% of the cellulose to glucose, and then fermentation of the glucose to ethanol. For the present purposes there are no specifications on the conversion products made from the lignin or the hemicellulose. In a preferred embodiment, at least 60% of the cellulose is converted to glucose and fermented to ethanol.
Xylan and xylan content are the terms used to express the quantity of anhydroxylose present in the feedstock. Much of the anhydroxylose is present as a linear beta 1,4-linked polysaccharide of xylose, but the designation xylan is not limited to anhydroxylose of this structure.
Arabinan and arabinan content are the terms used to express the quantity of anhydroarabinose present in the feedstock. Much of the anhydroarabinose is present as a branched alpha 1,3-linked polysaccharide of arabinose, but the designation arabinan is not limited to anhydroarabinose of this structure.
Arabinan plus xylan refers to the sum of the arabinan content and the xylan content of the feedstock. This is distinguished from the term arabinoxylan, which refers to an alpha 1,3-linked polymer of arabinose and xylose. Arabinoxylan is a specific example of arabinan and xylan, but does not comprise all possible forms of arabinan and xylan.
Hemicellulose is a general term that includes all natural polysaccharides except cellulose and starch. The term includes polymers of xylose, arabinose, galactose, mannose, etc. and mixtures thereof. In the present work, the primary constituents of the hemicellulose are arabinose and xylose.
AX/NSP is the ratio of arabinan plus xylan to non-starch polysaccharides and can be measured for any feedstock based on the analytical procedures described herein. AX/NSP is calculated from EQUATION (1):
AX/NSP=(xylan+arabinan)/(xylan+arabinan+cellulose) (1)
where the xylan, arabinan, and cellulose contents of the feedstocks are measured according to the procedures in EXAMPLE 1 and AX/NSP is calculated as shown in EXAMPLE 1.
AX/NSP is taught herein to characterize the performance of the pretreatment. The higher the AX/NSP, the less cellulase enzyme is required to hydrolyze the cellulose to glucose after a given pretreatment. The pretreatment performance is particularly good for feedstocks with AX/NSP of greater than about 0.39. This point is illustrated in EXAMPLES 3 and 4.
The AX/NSP content should be measured for each batch of a feedstock used, as it will no doubt vary seasonally and with the age, geographical location, and cultivar of the feedstock. Therefore, there are no absolute values of AX/NSP that are always valid for a given species. However, samples of oat hulls and corn cobs exhibited the highest AX/NSP in the data collected, as well as the highest performance in pretreatment. Oat hulls and corn cobs from the lots sampled would therefore be preferred feedstocks for an ethanol process.
The theoretical upper limit of AX/NSP is 0.75. This would be present in a material that was 25% cellulose and 75% arabinan plus xylan. The inventors know of no materials with this composition. The highest AX/NSP observed by the inventors is 0.422.
The hemicellulose, cellulose, arabinan, and xylan content of various materials have been widely published. However, the analytical methods used can greatly influence the apparent composition, and these publications are often based on widely varying methods. Therefore, these publications can be relied on only to give a general idea as to the approximate composition of these materials. For the purposes of practicing the invention, the same analytical methods must be applied to each candidate feedstock, and those of Example 1 are preferred for the absolute values being claimed.
In practicing the invention, feedstocks with high AX/NSP can be identified by two generic methods: (1) by screening of natural fibers and grains, and (2) by screening of varieties selectively bred for higher AX/NSP levels.
Reaction or Pretreatment reaction refers to a chemical process used to modify a lignocellulosic feedstock to make it more amenable to hydrolysis by cellulase enzymes. In the absence of pretreatment, the amount of cellulase enzyme required to produce glucose is impractical.
Improve digestibility by cellulase enzymes by disrupting the fiber structure and effecting the hydrolysis of a portion of the hemicellulose and the cellulose. This terminology refers to the physical and chemical changes to the feedstock caused by the pretreatment reaction. At a minimum, pretreatment increases the amount of glucose hydrolyzed from the feedstock by cellulase, disrupts the fibers, and hydrolyzes some fraction of the cellulose and hemicellulose.
The pretreatment process of the invention preferably is part of an integrated process to convert a lignocellulosic feedstock to ethanol. Such a process includes, after pretreatment, enzymatic hydrolysis of cellulose to glucose, fermentation of the glucose to ethanol, and recovery of the ethanol.
Cellulose hydrolysis refers to the use of cellulase enzymes to convert the pretreated cellulose to glucose. In the present invention, a minority of the cellulose is hydrolyzed during the pretreatment, and the majority survives pretreatment and is subjected to hydrolysis by cellulase enzymes. The manner in which the enzymatic hydrolysis is carried out is not constrained by the invention, but preferred conditions are as follows. The hydrolysis is carried out in a slurry with water that is initially 5% to 12% cellulose and is maintained at pH 4.5 to 5.0 and 50° C. The cellulase enzymes used might be any of the commercial cellulases available, which are manufactured by IOGEN CORPORATION, Novo NORDISK, GENENCOR INTERNATIONAL, PRIMALCO, and other companies. The cellulase enzymes might be supplemented with beta-glucosidase to complete the conversion of cellobiose to glucose. A commercial beta-glucosidase enzyme is NOVOZYM 188, sold by Novo NORDISK.
The skilled practitioner will realize that the amount of cellulase enzyme used in the hydrolysis is determined by the cost of the enzyme and the desired hydrolysis time, glucose yield, and glucose concentration, all of which are influenced by the process economics and will vary as each of the relevant technologies is evaluated. The typical enzyme dosage range is 1 to 50 Filter Paper Units (FPU) cellulase per gram cellulose for 12 to 128 hours. In a preferred embodiment the cellulase enzyme dosage is 1 to 10 FPU per gram cellulose. EXAMPLES 2 and 3 describe cellulose hydrolysis in more detail.
In a preferred embodiment, cellulose hydrolysis and ethanol fermentation are carried out simultaneously, using those techniques generally employed in an SSF process, as discussed previously herein.
Ethanol fermentation and recovery are carried out by conventional processes that are well known, such as yeast fermentation and distillation. The invention is not constrained by the manner in which these operations are carried out.
DESCRIPTION OF PREFERRED EMBODIMENTS
In practicing the invention, any type of feedstock, including but not limited to naturally occurring and selectively bred feedstock, can be employed. As emphasized above, the novelty of the present invention relates to the use of a high AX/NSP ratio, heretofore unrecognized as a critical standard for choosing optimum feedstocks for glucose and ethanol production; the origin of the feedstock is of secondary importance.
In one embodiment, the feedstock is naturally occurring. In this case, the AX/NSP of the feedstock is measured by the method of Example 1. Feedstocks with AX/NSP of greater than about 0.39 are preferred for a cellulose-to-ethanol process.
The AX/NSP content should be measured for each batch of a feedstock used, as it will no doubt vary seasonally and with age, geographic location, and cultivar of the feedstock. As experience with a given feedstock accumulates, the frequency of testing AX/NSP will lessen.
In another preferred embodiment, the feedstock has already been selectively bred. In this case, the AX/NSP of the bred feedstock is measured by the method of Example 1 and compared with that of the natural feedstock. If the AX/NSP has been increased by breeding, the feedstock is more suitable for cellulose conversion than the natural or starting feedstock material.
Such breeding can, in principle, be carried out by any of the common methods used to select for desired traits in plant breeding. These methods are summarized by H. B. Tukey, "Horticulture is a Great Green Carpet that Covers the Earth" in American Journal of Botany 44(3):279-289 (1957) and Ann M. Thayer, "Betting the Transgenic Farm" in Chemical and Engineering News, Apr. 28, 1997, p. 15-19. The methods include:
1. Scientific Breeding. Screen varieties of a species for a high level of AX/NSP and repeatedly grow those varieties which exhibit the trait.
2. Chimaeras. Graft two or more species and screen the resulting species for the level of AX/NSP.
3. Pollination breeding. Combine two or more species by cross pollination and screen for AX/NSP level.
4. Chemical thinning. Expose plants to chemical toxins such that only the fittest survive. Requires a toxin that is resisted by arabinan or xylan.
5. Induction. Expose species to conditions that induce higher levels of AX/NSP.
6. Environmental distress. Expose species to conditions that induce death unless protested by high levels of AX/NSP.
7. Nutrition and fertilizers. Develop nutritional regimen to increase AX/NSP.
8. Genetic engineering. Genetically modify a species so as to increase its level of AX/NSP.
In one preferred embodiment, the selectively bred lignocellulosic feedstock has an AX/NSP level that is greater than about 0.39, and such a selectively bred feedstock then is reacted to increase its digestibility by cellulase enzymes and converted to ethanol by hydrolyzing the cellulose to glucose with cellulase enzymes, fermenting the glucose, and recovering the ethanol.
In another preferred embodiment, the selectively bred lignocellulosic feedstock has an increased AX/NSP level over a starting feedstock material, but still below 0.39. Such a selectively bred feedstock is then reacted to increase its digestibility to cellulase enzymes and converted to ethanol. The reason that increasing the AX/NSP content of a feedstock is beneficial, even if the level remains below 0.39, is that in certain geographical areas the climate supports the growth of only a narrow range of feedstocks. For example, corn does not grow in climates where the annual number of degree days above 40 F. is less than 240. In these cooler areas, the choice of feedstocks is limited, and there might not be any feedstocks available with AX/NSP close to 0.39. In these climates, improving such a feedstock by selectively breeding to increase its AX/NSP over a starting feedstock material would improve the efficiency of a cellulose-to-ethanol plant significantly, even if the AX/NSP still remained below 0.39. In these situations, the present invention would provide a novel standard against which such selectively bred feedstocks could be measured and compared.
The desired extent of pretreatment might be achieved by any means available, including but not limited to those discussed in the preferred embodiments or examples contained herein. Any combination of mechanical and chemical treatments that results in the chemical changes noted lies within the scope of practicing the invention. This includes any reactors, chemicals added, temperature, time, particle size, moisture, and other parameters that result in the changes to the feedstock.
In a first preferred embodiment, the pretreatment reaction is carried out at the broad conditions described by GRETHLEIN for acid pretreatments. This is done by subjecting the chosen feedstock to a temperature of about 180° C. to about 270° C., for a period of 5 seconds to 60 minutes. It is understood by those skilled in the art that the feedstock temperature is that of the feedstock itself, which might differ from the temperature measured outside the reaction chamber. It is also understood by those skilled in the art that a temperature range specified over a time period is the average temperature for that period, taking into account the effect of temperature on the rate of reaction. For example, the reaction chamber might require a short period to heat from ambient conditions up to 180° C. Based on knowledge of reaction kinetics (for example, within limited temperature ranges for a given substance, the rate approximately doubles over a 10° C. increase in temperature), the effect of the temperature increase on the overall reaction can be calculated and thereby the average temperature determined.
The pretreatment reaction is typically run with 0.1% to 2% sulfuric acid present in the hydrolysis slurry. However, those skilled in the art are aware that alkali or acid present in some feedstocks can alter the acid requirement to be outside of the typical range. The degree of acidity present is better expressed by the target pH range, which is 0.5 to 2.5 regardless of the acid or concentration used. EXAMPLE 8 illustrates pretreatment reactions at this range of conditions.
A second preferred embodiment uses the narrower set of conditions identified by FOODY as optimal for steam explosion pretreatment. This is illustrated in EXAMPLE 4 with pretreatment consisting of a cooking step at a temperature between 220° C. to 270° C. at pH 0.5 to 2.5 for 5 seconds to 120 seconds. Devices used to carry out this pretreatment preferably include sealed batch reactors and continuous extruders. Large scale examples of these pretreatment conditions are described in EXAMPLES 6 and 7.
A third preferred embodiment uses a two-stage pretreatment, whereby the first stage improves the cellulose hydrolysis somewhat while solubilizing primarily the hemicellulose but little cellulose. The second stage then completes a full pretreatment. In this embodiment, the first stage reaction is run at a temperature of less than 180° C. while the second stage reaction is run at a temperature of greater than 180° C. An advantage of a two-stage pretreatment, as shown hereafter in EXAMPLE 5, is that a separate recovery of the hemicellulose for downstream processing is facilitated.
In the third preferred embodiment, the first stage of reaction is carried out at a temperature of about 60° C. to about 140° C. for 0.25 to 24 hours at pH 0.5 to 2.5. More preferably, the first stage of pretreatment is carried out at a temperature of 100° C. to 130° C. for 0.5 to 3 hours at pH 0.5 to 2.5.
In the fourth preferred embodiment, the second stage of reaction is carried out at a temperature of 180° C. to 270° C., at pH 0.5 to 2.5 for a period of 5 seconds to 120 seconds. The feedstock also can be dry (free from added moisture) or in a slurry with water.
In a preferred embodiment, the selectively bred feedstock is a woody fiber. W ood is the most prevalent lignocellulosic material in cooler climates.
Another aspect to successful practice of the present invention is to integrate the pretreatment process within a process that hydrolyzes the pretreated feedstock with cellulase enzymes to produce glucose. In a preferred embodiment, at least 40% of the cellulose in the pretreated feedstock is hydrolyzed by cellulase enzymes to produce glucose. The glucose produced can be purified, crystallized, and packaged as solid sugar. Alternatively, it can be left dissolved in a liquid slurry for further processing or use.
EXAMPLE 1
Measurement of AX/NSP in Feedstocks
The ratio of arabinan plus xylan to total non-starch polysaccharides of a given feedstock was determined based on a composition al analysis of the feeds tocks. This analysis was performed, as follows.
Feedstocks examined were barley straw, wheat straw, wheat chaff, oat hulls, switch grass, corn stover, maple wood, pine wood, and three varieties of corn cobs. All were obtained locally in Ottawa, Ontario except the oat hulls, which were from Quaker Oats in Peterborough, Ontario. The feedstocks were coarsely ground in a Waring blender and then milled through a #20 gauge screen using a Wiley mill. The feedstocks were stored at ambient temperature in sealed bags until the time of use. The moisture content of small samples was 5% to 10% and was determined by drying at 100° C.
Approximately 0.3 grams of sample was weighed into test tubes, ea ch containing 5 ml of 70% sulfuric acid. The tubes were vortex mixed, capped, and placed in a 50° C. water bath for one hour, with vigorous vortex mixing every 10 minutes. After the one hour incubation, the tube contents were transferred into preweighed 250 ml flasks containing 195 ml deionized water, which reduced the ac id content to 1.75%. The contents were mixed, and then 10 gram aliquots were transferred into test tubes. The tubes were vortex mixed and then transferred to a steam autoclave, where they were maintained for 1 hour at 121° C. After autoclaving, the solution contents were neutralized using a small amount of barium carbonate, and then vacuum-filtered over glass microfiber filter paper.
The concentrations of glucose, xylose, and arabinose present in the filtrates were measured by using a Dionex Pulse-Amperometric HPLC. These measurements were then related to the weight of the initial sample of feedstock present and expressed as glucan, xylan, and arabinan contents, respectively, of the feedstock, with small adjustments to take into account (1) the water of hydration to make the monomers from polymers and (2) the amount of material destroyed by the concentrated acid, which was measured by taking pure cellulose, xylose, and arabinose controls through the procedure. The determination was performed in triplicate and the average value is reported.
The cellulose content was determined by subtracting the starch content from the total glucan. The starch content was determined by adding 1 gram of Wiley-milled feedstock to a 250 ml flask containing 20 ml of deionized water, 0.2 ml of 91.7 g/L CaCl 2 .2H 2 O stock solution, and 50 microliters of a 1:100 solution of Sigma Alpha Amylase #A3403 in deionized water. Each flask was adjusted to pH 6.4 to 6.6 using dilute sodium hydroxide, then incubated in a boiling water bath for one hour. The flasks were incubated for 30 minutes in a steam autoclave at 121° C. after the addition of a second 50 ml dose of amylase. Finally, the flask was incubated for another 60 minutes in the boiling water bath with a third 50 ml dose of amylase. The flasks were then cooled to ambient temperature and adjusted to pH 4.2 to 4.4 using dilute hydrochloric acid. A 0.5 ml aliquot of Novo Spritamylase stock solution was added; the stock solution consisted of 3 grams of enzyme in 100 ml deionized water. The flasks were shaken at 50° C. for 20 hours with 150 RPM agitation. The flasks were then cooled and the contents were filtered over glass microfiber filter paper. The glucose concentration was then measured on a Yellow Springs Instrument (YSI) glucose analyzer and used to determine the starch concentration of the feedstock, taking into account the water necessary to hydrolize the starch.
The protein and ash content of the feedstocks were determined by standard Kjeldahl nitrogen and ash oven methods.
The lignin content of the samples was determined by measuring the amount of insoluble solids remaining after the sulfuric acid treatment of the feedstocks, then subtracting the amount of ash present.
The results of these measurements are shown in TABLE 1. The material recovered was between 842 and 1019 mg per gram of original solids (mg/g). This corresponds to 84.2%, by weight, to 101.9% of the starting material, which is typical mass balance closure in these systems.
TABLE 1__________________________________________________________________________COMPOSITION OF THE FEEDSTOCKSMeasured composition (mg/g)FeedstockGlucan Starch Xylan Arabinan Lignin Ash Protein Total__________________________________________________________________________Barley426 19.6 161 28 168 82 64 929StrawWheat464 8.6 165 25 204 83 64 1005StrawWheat405 14.4 200 36 160 121 33 955chaffSwitch403 3.4 184 38 183 48 54 910grassCorn 411 3.2 128 35 127 60 81 842stoverMaple504 4.0 150 5 276 6 6 947woodPine 649 1.0 33 14 320 0 2 1018woodCorn cobs436 34 253 38 .sup. ND.sup.(2) ND ND ND(red)Corn cobs439 28 250 38 ND ND ND ND(white)Corn cobs438 8.5 240 36 ND ND ND ND(Indian)Oat Hulls481 89 247 39 170 44 38 1019__________________________________________________________________________ .sup.(1) Total = Glucan + Xylan + Arabinan + Lignin + Ash + Protein .sup.(2) ND = Not determined
The AX/NSP content of the feedstocks is shown in TABLE 2. Of the 11 feedstocks analyzed, four have AX/NSP of greater than about 0.39. These include the samples of oat hulls and corn. The other seven feedstocks have AX/NSP content below about 0.39.
TABLE 2______________________________________AX/NSP COMPOSITION OF THE FEEDSTOCKS Cellulose NSPFeed-stock (mg/g).sup.(1) AX (mg/g).sup.(2) (mg/g).sup.(3) AX/NSP______________________________________Barley 407 189 596 0.317StrawWheat 455 190 645 0.295StrawWheat 391 236 627 0.376chaffSwitch 399 222 621 0.357grassCorn 408 163 571 0.285stoverMaple 500 155 655 0.237woodPine 648 47 695 0.068woodCorn cobs 402 291 693 0.420(red)Corn cobs 411 288 699 0.412(white)Corn cobs 429 276 705 0.391(Indian)Oat Hulls 392 286 678 0.422______________________________________ .sup.(1) Cellulose = Glucan Starch .sup.(2) AX = Xylan + Arabinan .sup.(3) NSP = Xylan + Arabinan + Cellulose
EXAMPLE 2
Measurement of Cellulase Activity of an Enzyme
The cellulase activity of an enzyme is measured using the procedures of Ghose, PURE AND APPL. CIIEM., 59:257-268 (1987), as follows. A 50 mg piece of Whatman #1 filter paper is placed in each test tube with 1 ml of 50 mM sodium citrate buffer, pH 4.8. The filter paper is rolled up and the test tube is vortex mixed to immerse the filter paper in the liquid. A dilution series of the enzyme is prepared with concentrations ranging between 1:200 and 1:1600 of the initial strength in 50 mM sodium citrate buffer, pH 4.8. The dilute enzyme stocks and the substrates are separately preheated to 50° C., then a 0.5 ml aliquot of each dilute enzyme stock is placed in a test tube with substrate. The test tubes are incubated for 60 minutes at 50° C. The reaction is terminated by adding 3 ml of dinitrosalicylic acid (DNS) reagent to each tube and then boiling for 10 minutes. Rochelle salts and deionized water were added to each tube to develop the color characteristic of the reaction between reducing sugars and DNS reagent. The amount of sugar produced by each sample of enzyme is measured, taking into account the small background from the enzyme and the filter paper, by comparing the amount of sugar in each tube with that of known sugar standards brought through the reaction.
A unit of filter paper activity is defined as the number of micromoles of sugar produced per minute. The activity is calculated using the amount of enzyme required to produce 2 mg of sugar. A sample of Iogen Cellulase was found to have 140 filter paper units per ml, as shown in TABLE 3.
TABLE 3______________________________________FILTER PAPER ACTIVITY OF IOGEN CELLULASEAmount of enzyme (ml)to make 2 mg sugar Enzyme activity (FPU/ml)______________________________________0.00264 140.0______________________________________
EXAMPLE 3
Mild Pretreatment Reaction with the Feedstocks
This example illustrates the comparative performance of the feedstocks after a mild pretreatment reaction that primarily dissolves the hemicellulose. This pretreatment reaction by itself is not optimal, although it could be the first stage of a two-stage pretreatment reaction. This mild reaction illustrates the use of AX/NSP to characterize the suitability of a feedstock for ethanol production. Optimized pretreatment reactions are described in later examples.
Samples of 4 grams of Wiley-milled feedstocks from EXAMPLE 1 were placed in 96 grams of 1% sulfuric acid (pH 0.6 to 0.9) in a 250 ml flask. The contents of the flasks were gently mixed, and then the flasks were placed in a steam autoclave at 121° C. for 1 hour. The flasks were then cooled and vacuum-filtered over glass microfiber filter paper. The glucose, xylose, and arabinose concentrations of selected filtrates were determined by neutralizing with barium carbonate and analyzing the samples using a Dionex Pulsed-Amperometric HPLC. The filter cakes were washed with tap water and air dried. The cellulose, xylan, and arabinan concentrations in the solids were determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1.
The effect of the reaction on the cellulose and hemicellulose levels in the selected feedstocks is shown in TABLE 4. In all cases, small amounts (less than 8%) of the cellulose is hydrolyzed, while more than 70% of the hemicellulose is hydrolyzed.
TABLE 4______________________________________EFFECT OF 121° C. PRETREATMENT REACTION ONDIFFERENT FEFDSTOCKSDissolution (%) Hemi-Feedstock Cellulose cellulose______________________________________Barley 3.2 85strawWheat 3.6 72strawWheat <2 75chaffSwitch 5.7 80grassCorn 4.3 82stoverMaple <2 80woodOat hulls 7.9 85______________________________________
All 11 pretreated feedstocks were subjected to cellulase enzyme hydrolysis as follows. A sample of the pretreated solids corresponding to 0.2 grams of cellulose was added to a 250 ml flask with 19.8 grams of 0.05 M sodium citrate buffer, pH 5.0. Iogen Cellulase (standardized to 140 FPU/ml) and Novozym 188 beta-glucosidase (1440 BGU/ml) were added to the flask in an amount corresponding to 9 FPU/gram cellulose and 125 BGU/gram cellulose. The small amount of glucose carried into the flask with the beta-glucosidase was taken into account.
Each flask was placed on a New Brunswick gyrotory shaker at 50° C. and shaken for 20 hours at 250 RPM. At the end of this period, the flask contents were filtered over glass micro fiber filter paper, and the glucose concentration in the filtrate was measured by a YSI glucose analyzer. The glucose concentration was related to the cellulose concentration of the pretreated feedstock to determine the cellulose conversion.
FIG. 1 is a graph of cellulose conversion for certain feedstocks, as a function of AX/NSP, at an average temperature of 121° C., according to EXAMPLE 3.
Surprisingly, as shown in FIG. 1, for this particular pretreatment reaction the cellulose conversion increases linearly with the AX/NSP of the initial feedstock. The four feedstocks with the highest AX/NSP (oat hulls and the three corn cobs) had the highest conversion to glucose.
These results indicate that the higher the AX/NSP of the feedstock, the more suitable the feedstock will be for ethanol production after a given pretreatment.
EXAMPLE 4
High Performance Pretreatment Reaction with the Feedstocks
This example illustrates the comparative performance of the feedstocks after a pretreatment reaction. This pretreatment reaction is at conditions that optimize performance in the subsequent cellulose hydrolysis.
Samples of 0.28 grams of Wiley-milled feedstocks from EXAMPLE 1 were placed in 7 grams of 1% sulfuric acid (pH 0.6 to 0.9) in a sealed stainless steel "bomb" reactor. The capacity of the bomb reactor is 9 ml. For any one experiment, five bombs of identical contents were set up and the reaction products were combined to produce a pool of adequate quantity with which to work. The bombs were placed in a preheated 290° C. oil bath for 50 seconds, then removed and cooled by placing them in tap water. Thermocouple measurements showed that the temperature in the interior of the bomb reached 260° C. by the end of the heating period. The average equivalent temperature was 235° C.
The contents of the bombs were removed by rinsing with tap water, and then vacuum-filtered over glass microfiber filter paper. The filter cakes were washed with tap water and air dried. The cellulose concentration in the solids was determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1.
The reacted feedstocks were subjected to hydrolysis by cellulase as follows. A sample of the reacted solids corresponding to 0.05 grams of cellulose was added to a 25 ml flask with 4.9 grams of 0.05 M sodium citrate buffer, pH 4.8. Iogen Cellulase (140 FPU/ml) and Novozym 188 beta-glucosidase (1440 BGU/ml) were added to the flask in an amount corresponding to 9 FPU/gram cellulose and 125 BGU/gram cellulose. The small amount of glucose carried into the flask with the beta-glucosidase was taken into account.
Each flask was placed on an Orbit gyrotory shaker at 50° C. and shaken for 20 hours at 250 RPM. At the end of this period, the contents of the flasks were filtered over glass microfiber filter paper, and the glucose concentration in the filtrate was measured by a Dionex Pulsed-Amperometric HPLC. The glucose concentration was related to the cellulose concentration in the pretreated feedstock to determine the cellulose conversion.
FIG. 2 is a graph of cellulose conversion for certain feedstocks, as a function of AX/NSP, at an average temperature of 235° C., according to EXAMPLE 4.
As with the 121° C. reaction, FIG. 2 shows a cellulose conversion that also increases linearly with the AX/NSP of the initial feedstock. The four feedstocks with the highest AX/NSP (oat hulls and the three corn cobs) had the highest level of cellulose conversion observed, with more than 65% of the cellulose hydrolyzed to glucose.
These results demonstrate that the higher the AX/NSP of the feedstock, the more suitable the feedstock will be for ethanol production after a high performance pretreatment.
TABLE 5 shows the amount of cellulase enzyme required to reach 80% conversion to glucose. The amount of enzyme required is a key factor in determining the feasibility of an ethanol production process. The data in TABLE 5 are derived from the results shown in FIG. 2 plus other data describing cellulose conversion as a function of cellulase dosage.
The top four feedstocks, including oat hulls and corn cobs, require 23% to 68% less cellulase enzyme to convert to cellulose to glucose than the next best feedstock, wheat chaff. The top four feedstocks have a great performance advantage over the other feedstocks tested.
The top four feedstocks have AX/NSP greater than 0.39, while the other feedstocks have AX/NSP below this value. This data demonstrates that significantly less cellulase enzyme is required for feedstocks with AX/NSP above about 0.39. This lower enzyme requirement is a significant advantage in an ethanol production process.
TABLE 5______________________________________CELLULASE ENZYME REQUIREMENTS Cellulase dosage (FPU/g)Feedstock for 80% conversion in 20 hr AX/NSP______________________________________Corn Cobs 6.6 0.420(Red)Corn cobs 8.7 0.412(White)Corn cobs 15.6 0.391(Indian)Oat hulls 16.3 0.422Wheat chaff 21.0 0.376Switch grass 27.1 0.357Barley straw 28.3 0.317Wheat straw 44.5 0.295Maple wood 45.5 0.237Corn stover 63.4 0.285______________________________________
EXAMPLE 5
Two-stage Pretreatment Reaction of Oat Hulls
This example demonstrates the use of a two-stage pretreatment reaction of oat hulls, the first mild stage followed by a second harsher stage.
For the first stage, samples of 4 grams of Wiley-milled feedstocks from EXAMPLE 1 were placed in 96 grams of 1% sulfuric acid (pH 0.6 to 0.9) in a 250 ml flask. The contents of the flasks were gently mixed, and then the flasks were placed in a steam autoclave at 121° C. for 40 minutes. The flasks were then cooled and vacuum-filtered over glass microfiber filter paper. The glucose, xylose, and arabinose concentrations of the filtrates were determined by neutralizing with barium carbonate and analyzing the samples by using a Dionex Pulsed-Amperometric HPLC. The filter cakes were washed with tap water and air dried. The cellulose, xylan, and arabinan concentrations in the solids were determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1. The effect of the mild reaction on the cellulose and hemicellulose (arabinan+xylan) levels in the feedstock is shown in TABLE 6. Almost all of the hemicellulose is dissolved, which enriches the concentration of cellulose.
TABLE 6______________________________________COMPOSITION OF OAT HULLS AFTER MILDPRETREATMENT REACTIONFeedstock: Oat hulls Cellulose (%) Hemicellulose (%)______________________________________Before Pretreatment 27.9 22.0After Pretreatment 39.5 3.0______________________________________
Samples of 0.28 grams of feedstocks reacted under mild conditions were placed in 7 grams of 1% sulfuric acid (pH 0.6 to 0.9) in a sealed stainless steel "bomb" reactor as described in EXAMPLE 4. Five bombs of identical contents were set up and the reaction products werecombined to produce a pool of adequate quantity with which to work. The bombs were placed in a preheated 290° C. oil bath for 50 seconds, then removed and cooled by placing them in tap water.
The contents of the bombs were removed by rinsing with tap water, and then vacuum-filtered over glass microfiber filter paper. The filter cakes were washed with tap water and air dried. The cellulose concentration in the solids was determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1.
After one or two stages of pretreatment reaction, various feedstocks were subjected to hydrolysis by cellulase, as follows. A sample of the pretreated solids corresponding to 0.05 grams of cellulose was added to a 25 ml flask with 4.9 grams of 0.05 M sodium citrate buffer, pH 4.8. Iogen Cellulase (140 FPU/ml) and Novozym 188 beta-glucosidase (1440 BGU/ml) were added to the flask in an amount corresponding to 10 FPU/gram cellulose and 125 BGU per gram cellulose. The small amount of glucose carried into the flask with the beta-glucosidase was taken into account.
Each flask was placed on an Orbit gyrotory shaker at 50° C. and shaken for 20 hours at 250 RPM. At the end of this period, the contents of the flasks were filtered over glass microfiber filter paper, and the glucose concentration in the filtrate was measured by a Dionex Pulsed-Amperometric HPLC. The glucose concentration was related to the cellulose concentration in the pretreated feedstock to determine the glucose yield.
The results are summarized in TABLE 7.
After the first stage of reaction, little hemicellulose remained in the oat hulls. The glucose yield after the cellulose was hydrolyzed by cellulase was only 340 mg/g.
After the second stage of pretreatment reaction, the glucose yield is over 85% higher than that of the first stage. The second stage pretreatment reaction therefore provided a significant enhancement of the hydrolysis performance. The two stage pretreatment results in a glucose yield within 6% of that after the single stage reaction of oat hulls described in EXAMPLE 4.
These results ran exactly opposite to the teachings of Knappert, et al, who concluded that a material with low hemicellulose content does not have an improved digestibility by cellulase enzymes after pretreatment reaction. In the present example, after the first stage of reaction, very little hemicellulose remained in the oat hulls, yet the second stage reaction increased the digestibility significantly. Knappert et al taught that such a low-hemicellulose material should not respond well to pretreatment reaction. The present invention teaches the opposite.
TABLE 7______________________________________TWO STAGE PRETREATMENT REACTION OF OAT HULLS HemicellulosePretreatment content before this Glucose yieldreaction stage (%) (mg/g cellulose)______________________________________Two stage 3.0 645First stage 22.0 340Single stage 22.0 685(EXAMPLE 4)______________________________________
EXAMPLE 6
Large Scale Pretreatment Reaction with Oat Hulls
A large scale pretreatment of oat hulls was carried out using a Werner-Pflederer twin-screw extruder (Ramsey, N.J.). After milling in a Wiley mill, the oat hulls were slurried to a 30% solids concentration in 1% sulfuric acid (pH 0.7 to 1.2). The slurry was fed to the extruder at a rate of 10 pounds per hour and the pressure was 500 psig. The extruder was maintained at 230° C. with live steam injection. At the average feed rate, the material passed through the extruder within 30 seconds. The extruded oat hulls were collected and washed with water to remove dissolved material, then filtered over glass microfiber filter paper.
The cellulose content of the extruded oat hulls was measured using the methods of EXAMPLE 1.
The extruded oat hulls were subjected to hydrolysis by cellulase as follows. A sample of the extruded oat hulls corresponding to 0.05 grams of cellulose was added to a 25 ml flask with 4.9 grams of 0.05 M sodium citrate buffer, pH 4.8. Iogen Cellulase (140 FPU/ml) and Novozym 188 beta-glucosidase (1440 BGU/ml) were added to the flask in an amount corresponding to 9 FPU/gram cellulose and 125 BGU/gram cellulose. The small amount of glucose carried into the flask with the beta-glucosidase was taken into account.
Each flask was placed on an Orbit gyrotory shaker at 50° C. and shaken for 20 hours at 250 RPM. At the end of this period, the contents of the flask were filtered over glass microfiber filter paper, and the glucose concentration in the filtrate was measured by a Dionex Pulse-Amperometric HPLC. The glucose concentration was related to the cellulose concentration of the extruded oat hulls to determine the glucose yield.
The results are listed in TABLE 8. The glucose yield from the large scale pretreatment reaction of oat hulls was slightly (8%) less than that from the laboratory scale pretreatment in EXAMPLE 4. This indicates that the oat hull pretreatment reaction can be run on a large scale, as optimization of the extrusion operation will no doubt overcome the 8% advantage of the laboratory pretreatment reaction.
TABLE 8______________________________________GLUCOSE YIELD FROM PRETREATED OAT HULLSPretreatment Glucose (mg/g cellulose)______________________________________Extruder 630Bomb (EXAMPLE 4) 685______________________________________
EXAMPLE 7
Large Scale Pretreatment of Hardwood
A sample of aspen wood was pretreated using the steam explosion device and technique described by FOODY, U.S. Pat. No. 4,461,648. The resulting pretreated material was washed with water and is denoted as "Steam exploded hardwood". The cellulose content of the steam exploded hardwood was measured using the methods of EXAMPLE 1.
The steam exploded hardwood was subjected to hydrolysis by cellulase enzyme as follows. A sample of the steam exploded hardwood corresponding to 0.05 grams of cellulose was added to a 25 ml flask with 4.9 grams of 0.05 molar sodium citrate buffer, pH 4.8. Iogen Cellulase (140 FPU/ml) and Novozym 188 beta-glucosidase (1440 BGU/ml) were added to the flask in an amount corresponding to 9 FPU/gram cellulose and 125 BGU/gram cellulose. The small amount of glucose carried into the flask with the beta-glucosidase was taken into account.
Each flask was placed on an Orbit gyrotory shaker at 50° C. and shaken for 20 hours at 250 RPM. At the end of this period, the contents of the flask were filtered over glass microfiber filter paper, and the glucose concentration in the filtrate was measured by a Dionex Pulsed-Amperometric HPLC. The glucose concentration was related to the cellulose concentration of the steam exploded hardwood to determine the glucose yield.
The results are listed in TABLE 9. The performance of the hardwood reacted using the large scale device is within 2% by weight, of that using the laboratory device. In this case, the large scale use of steam explosion has been extensively optimized and can match the laboratory results.
TABLE 9______________________________________PRETREATMENT REACTION OF HARDWOODDevice Glucose yield (mg/g cellulose)______________________________________Steam explosion 415Laboratory (EXAMPLE 4) 425______________________________________
EXAMPLE 8
Effect of Temperature on Single-stage and Two-stage Pretreatment Reaction of Oat Hulls
This example demonstrates the use of a range of temperatures with both single stage and two-stage pretreatment reactions of oat hulls.
For the single stage reactions, samples of 0.28 grams of oat hulls were placed in 7 grams of 1% sulfuric acid (pH 0.6) in a sealed stainless steel "bomb" reactor as described in EXAMPLE 4. Five bombs of identical contents were set up and the reaction products combined to produce a pool of adequate quantity with which to work. The bombs were placed in a preheated oil bath, then removed and cooled by placing them in tap water.
The temperatures and times in the oil bath were, as follows:
(1) 235° C., 50 seconds; (2) 180° C., 6 minutes; (3) 170° C., 8 minutes.
The contents of the bombs were removed by rinsing with tap water, and then vacuum-filtered over glass microfiber filter paper. The filter cakes were washed with tap water and air dried. The cellulose concentration in the solids was determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1.
For the two stage reactions, the first stage was carried out by placing samples of 4 grams of Wiley-milled oat hulls in 96 grams of 1% sulfuric acid (pH 0.6) in a 250 ml flask. The contents of the flasks were gently mixed, and then the flasks were placed in a steam autoclave at 121° C. for 40 minutes. The flasks were then cooled and the contents were vacuum-filtered over glass microfiber filter paper. The filter cakes were washed with tap water and air dried. The cellulose, xylan, and arabinan concentrations in the solids were determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1.
The second stage was carried out by placing samples of 0.28 grams of material from the first stage in 7 grams of 1% sulfuric acid (pH 0.6) in a sealed stainless steel "bomb" reactor as described in EXAMPLE 4. Five bombs of identical contents were set up and the reaction products combined to produce a pool of adequate quantity to work with. The bombs were placed in a preheated oil bath, then removed and cooled by placing them in tap water.
The temperatures and times in the oil bath matched those for the single stage reaction: (1) 235° C., 50 seconds; (2) 180° C., 6 minutes; (3)170° C., 8 minutes.
The contents of the bombs were removed by rinsing with tap water, and then vacuum-filtered over glass microfiber filter paper. The filter cakes were washed with tap water and air dried. The cellulose concentration in the solids was determined by dissolution of aliquots in 70% sulfuric acid, as described in EXAMPLE 1.
Feedstocks after one or two stages of reaction were subjected to cellulase enzyme hydrolysis as follows. A sample of the reacted solids corresponding to 0.05 grams of cellulose was added to a 25 ml flask with 4.9 grams of 0.05 molar sodium citrate buffer, pH 4.8. IOGEN Cellulase (140 FPU/ml) and NOVOZYM 188 beta-glucosidase (1440 BGU/ml) were added to the flask in an amount corresponding to 9 FPU/gram cellulose and 125 BGU per gram cellulose. The small amount of glucose carried into the flask with the beta-glucosidase was taken into account.
Each flask was placed on an Orbit gyrotory shaker at 50° C. and shaken for 20 hours at 250 RPM. At the end of this period, the contents of the flasks were filtered over glass microfiber filter paper, and the glucose concentration in the filtrate was measured by a Dionex Pulsed-Amperometric HPLC. The glucose concentration was related to the cellulose concentration in the pretreated feedstock to determine the glucose yield.
The results are summarized in TABLE 10.
Using a single stage reaction, the glucose yield is almost as high at 180° C. as at the optimum temperature. The glucose yield drops as the temperature is decreased from 180° C. to 170 C.
The two stage reaction has the same temperature profile as the single stage pretreatment reaction, with a similar performance at 180° C. and the optimum temperature, and a drop in performance below 180° C. Glucose yields in the two-stage reaction were 15% below those with the single stage reaction.
TABLE 10______________________________________EFFECT OF TEMPERATURE ON GLUCOSE YIELD FROMOAT HULLS Relative Reaction Reaction Glucose yield GlucosePretreatment Temperature (C.) Time (sec) (mg/g cellulose) yield______________________________________Single stage 235 50 685 100Single stage 180 360 660 96Single stage 170 480 555 81Two stages 235* 50 575 84Two stages 180* 360 560 82Two stages 170* 480 485 71______________________________________ *Following a first stage at 121 C.
While preferred embodiments of our invention have been shown and described, the invention is to be defined solely by the scope of the appended claims, including any equivalent for each recited claim element that would occur to one of ordinary skill and would not be precluded by prior art considerations. | An improved pretreatment of cellulosic feedstocks, to enable economical ethanol production by enzyme treatment. The improved pretreatment comprises choosing either a feedstock with a ratio of arabinoxylan to total nonstarch polysaccharides (AX/NSP) of greater than about 0.39, or a selectively bred feedstock on the basis of an increased ratio of AX/NSP over a starting feedstock material, and reacting at conditions that disrupt the fiber structure and hydrolyze a portion of the cellulose and hemicellulose. This pretreatment produces a superior substrate for enzymatic hydrolysis, by enabling the production of more glucose with less cellulase enzyme than any known procedures. This pretreatment is uniquely suited to ethanol production. Preferred feedstocks with an AX/NSP level greater than about 0.39 include varieties of oat hulls and corn cobs. | 8 |
BACKGROUND--FIELD OF INVENTION
This invention relates to an automatic dog and cat feeder that improves the delivery of dry particular matter feed desired at predetermined time intervals.
BACKGROUND--DESCRIPTION OF PRIOR ART
Many of the prior art category of animal feeders were primarily made to provide feeders for dogs and cats. They were designed to feed pets when owners were away from home. Their design was to automatically accomplish this task reliably and not bother neighbors, friends, or family to do this task daily. These pet feeders have many designs and various ways of approaching this objective. Besides being very expensive and complicated mechanically such as motors, pulleys, augers, gears and so many features, few have been marketable. Notably, only a few plastic and one metal battery operated which spread the food in a radius are available or you can order from a pet store. These are not suitable or strong enough to withstand the abuse from dogs, raccoons, skunks, etc. or being toppled over; only one plastic model with 5-meal rotary dish for 120 volt AC, the rest all battery operated.
SUMMARY OF THE INVENTION
The dog and cat feeder includes an elongated vertical housing enclosing a hopper in the upper portion thereof. The lower end is the funnel end connected to fittings. The dry feed material from the hopper is gravity-fed into a feed dish outside the housing. Tipping the housing and installing feed dish under outlet pipe will prevent dish from being moved after cabinet is returned to floor. The means to deliver the feed described above is by a slide valve installed into a fitting that is modified. The valve movement is solenoid operated with timers. One timer selects the time of day for feeding and the other timer the amount of feed delivered. This is regulated by a predetermined setting; the valve remains open for large or small pets' needs.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the feeder may be had by reference to the following detailed described drawings in which:
FIG. 1 is a perspective view of the feeder;
FIG. 2 is a view of all the parts inside the feeder;
FIG. 3 is a view of the base support for the hopper and fitting;
FIG. 4 is a view of the hopper vertical side spacer supports;
FIG. 5 is a view of the template which is formed in the hopper for its lower funnel;
FIG. 6 is a view of the cabinet and pipe fittings to the exterior feed dish;
FIG. 7 is a view of the fittings, modification and slide valve assembly parts;
FIG. 7A is a view of the slide valve assembly parts;
FIG. 7B is a view of the opening from above showing the closed and open operational position of slide valve and solenoid;
FIG. 8 is a schematic of the electrical circuit of invention; and
FIG. 9 is a view of the protective cover for outdoor use of the feeder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The automatic dog and cat feeder as best seen in FIG. 1, includes an elongated vertical square housing of sheet metal material of light-weight metal.
FIG. 2 comprises all of the components inside the housing. The frame item 24 of feeder item 10 is a one-piece square metal tubing welded together of the various pieces. The height is capable of enclosing all the components required.
FIG. 3 item 32 a piece of plywood is the base support for a hopper item 26 and item 36 a closet and hub fitting. The hopper item 26 is a 5-gallon plastic water bottle that has to be modified. A hole is cut in the bottle base for filling the hopper with feed. The cover item 34A and 34B for the hole is made from plywood pieces; one the hole diameter and the other a little larger diameter bolted together with a hole in the center of each piece provides a cover for the hopper hole. Item 26 plastic bottle neck is cut off square across leaving a 3" hole. The hopper is then installed into the frame to item 36 a closet flange and hub which mounts in hole of base item 32 and accommodate each other.
A funnel FIG. 5 item 28 is manufactured from a template using the formula to get the correct slope for dry feed to dispense from the hopper. It was made from surplus copper clad mica material flexible with a hole punched in each end. The funnel was then installed through the feed hole and formed inside the hopper; a small bolt and nut keep the two ends together.
Item 38 a spigot and hub with a slot cut into it is installed into item 36 a closet and hub. The following procedure is required to modify the spigot and hub with the correct slot cut.
Referring to FIG. 7, you will notice the side opposite the bend is where the slot is to be cut. First mount the bracket item 64 to the frame item 24 in the center of control panel frame support of the hopper base item 32 as depicted in FIG. 2. This is determined with the solenoid mounted to the bracket and the shaft item 54 inserted in the solenoid armature core hole. Extending the shaft to the maximum will provide the best position for the slot to be cut in the hub. FIG. 7 and FIG. 7B show the horizontal cut parallel to hub and in line to solenoid core hole is necessary, making sure the hub item 38 is fully pressed into item 36 a closet and hub and item 40 a pipe is installed into item 38. It should exit opposite side of solenoid centered between the frame item 24 vertical supports. Then mark and remove the hub.
Item 60 a slide valve was made from a piece of flat aluminum material. After the hub is modified with the slot, reinstall it back into item 36 fully with item 40 pipe inserted and centered between frame members. When feeder is completed, item 40 pipe will exit sheet metal side item 12B of FIG. 1 into the feed dish item 76. Tipping item 10 will allow the feed dish to be installed and held in place by item 40 pipe. The feed dish will have some holes in bottom to allow for any water drainage.
Item 18 (FIG. 6) is a sheet metal cover that fits over top of feeder item 10. Item 20 angle iron brackets are bolted to frame left and right side as shown in FIG. 1. They can be used to anchor feeder to concrete with studs or using 9" metal stakes, garden or tent type, into ground.
Because of space limitation and simplicity, it is easier to install the parts items 54 to 62 assembled together as shown in FIG. 7 and 7B. Holding the assembled parts and compressing spring with your fingers insert assembled parts into 52 solenoid core hole. Then install slide valve 60 into item 38 and mount assembly to bracket item 64 with bolts item 66. With everything secured, pulling the slide back by hand should work smoothly and return with spring pressure to the closed position. Minor adjustment could provide trouble free operation if needed. It is noted here that all ABS fittings are pressed together and not cemented together. There isn't any liquid to leak out and the fittings function are to provide a conduit to gravity feed dry particulate material feed. Also, it takes considerable effort to install or remove apart after pressed together.
The electrical controls are next installed on item 74 base. Item 48 receptacle with a single 3-prong socket, ground pin facing front, is installed on left side of cabinet to item 70 bracket. Item 42 Timer-1 is plugged into socket of item 48 and the timer's socket will be on the right side for accessibility. The adjustment dial will also face front. Next item 44B bracket is mounted to item 74 base support. Item 44A socket 11 pin mounts to item 44B bracket. Item 46 plug and wires are connected to item 44A socket terminals as depicted in FIG. 8 with the plug into T-1 socket and wires of 52 solenoid to 44A terminals.
Item 44 T-2 timer plugs into item 44A after completion of wiring. Item 44 T-2 timer is a solid state timer model T2K-30-461 range, 0.3-30 seconds, Mfg. NCC (National Control) 11 pin. It has an adjustable dial knob. Item 48A 120 volt power cord and plug connects to item 48 receptacle through item 12B sheet metal left side of control panel cabinet. Item 42 T-1 timer is an Intermatic Time All Model SB711C. It has two (2) on/off settings a day. This timer was selected because it could be set for 1/4 hour minimum, the lowest setting which power would be on to its outlet socket because the requirements for feeding a dog or cat is controlled in seconds. The T-2 timer is set for only 1 to 2 seconds, for example, for 4 ounces of feed for a cat.
The T-2 timer makes only one cycle and will reset after T-1 timer trips the power off to its socket outlet. The cycle will repeat one or two times a day as required. As mentioned for animal feeding, it is recommended daylight settings be used to prevent raccoons or other animals that forage at night from eating pet's feed. Functional testing of about 50 cycles should be done before feed is put in the hopper. This is accomplished by turning T-1 timer clockwise until an audible click is heard, then set T-2 timer, for example, 5 seconds. Then plug item 48A into power. The solenoid item 52 will energize opening slide valve for 5 seconds then return to closed position. Doing this for 5 to 10 minutes plugging and unplugging to power will provide enough functional testing. Then putting feed in the hopper and trying different settings of T-2 timer will give the correct amount of feed desired. Then adjusting T-1 timer to the correct time will put the feeder in automatic operation.
Another problem relates to various feeding devices that combine the delivery of feed and water. There are many disadvantages to feeders with this feature. Several are listed here and will be made apparent. First of all, it is not a problem for pet owners to supply pets with water:--buckets of water, watering devices to spigot's drip type methods, pet store devices, float devices, etc. Feeders with water and feed are electrically controlled and can make them inoperable. The problem of mold, algae, humidity in an enclosed cabinet could affect dry particulate feed material getting soggy and not dispensing properly. The condition of the cabinet would be a health problem for pets and difficult to clean or control. Pet owners already know what a problem it is to keep dish and water containers clean. Humidity also would affect electrical controls and cause rust. Basically, it would be better and simpler without getting into the mechanics of it.
Consideration must be taken to provide protection to feeder in inclement weather. A vinyl cover or plastic square container which is locally purchased would provide this protection. The container as down in FIG. 9 item 10A with a slot cut out would fit over feeder FIG. 6 item 10 to the ground over pipe to feed dish. As depicted in FIG. 9 a plastic hood riveted to container would provide some umbrella protection also over feed dish. This invention is constructed as well as other feeders but the problem has not been addressed in prior art reviewed. For example, covers are made for barbecues and many outdoor items. Any animal feeder should be protected from inclement weather. For very little cost it would provide complete protection from inclement weather.
I have described and made some references that may or may not be apparent. The feed conduit fittings for example are 3" inside diameter. This allows feed to freely dispense without the problem of feed bridging, a common occurrence in feed devices. Also, item 60 shown in FIG. 7A a slide valve is wide enough and when installed is supported on each side of slot item 38. This guides and prevents slide from rotating because core 54 is round and free floating in core hole of solenoid item 52. Also in FIG. 7B in the open position you will notice the valve item 60 of FIG. 7A does not open fully. It does open enough because its oval curviture provides a large area for feed to fall through. The rating of solenoids have pull in ounces and pounds versus length of stroke. The solenoid item 52 in FIG. 7B has a maximum 11/4" length of stroke and combined with 3" fittings provides very good feed delivery.
SUMMARY, RAMIFICATIONS AND SCOPE
Thus, the reader will see that the Automatic Dog and Cat Feeder is simple, easy to operate and reliable. It has the least mechanical parts to function as stated. Further improvement would be possible with the manufacture of similar parts but also to facilitate assembly. A molded square hopper with a funnel end, threaded end, and the other fittings all threaded male and female, the hopper being square would hold more feed and with a feed hole cover, the fitting with the slot could be made during production. The frame made of angle iron, square to support hopper, with legs, sheet metal sides, electrical controls are all easily assembled with bolts and sheet metal screws. Some of the parts in the first embodiment could be eliminated. In a kit form it would not be difficult to assemble with some parts off the shelf items used in the present invention. The cover as seen in FIG. 9 item 10A could be made an accessory for outside use of feeder for protection in inclement weather.
This invention has been described with references to its illustrated preferred embodiment. Persons skilled in the art of constructing feeding apparatus may upon exposure to the teaching herein conceive variations in the mechanical development of the components therein. Such variations ere deemed to be encompassed by the disclosure, the invention being delimited only by the appended claims.
Drawing Reference Numerals Worksheet
10 Feeder
10A outdoor cover
12A sheet metal right side
12B left side
16 sheet metal door front
16A knobs 4 ea. 3 prong
18 feeder top cover, sheet metal
20 angle iron brackets 2 ea.
22 handles sides and top cover
24 frame welded sq. stock steel
26 hopper
28 internal funnel (in hopper)
30 hopper support spacers, plywood 2 ea.
32 hopper base, plywood (with hole in center)
34A A hopper feed hole cover
34B hopper feed hole cover plywood
36 3" closet and hub
38 3"1/6" bend spigot and hub (with slot cut in it)
40 3"×12" ABS feed pipe to feed dish
42 Timer 1 intermatic Time All MD.SB711C
44 Timer 2
44A timer socket 11 pin
44B timer mount bracket
46 elec. plug and wiring for Timer 2 (to T-1 and 44A terminals)
48 120 volt recepticle
48A power cord and plug with connector to 12B
52 solenoid part no. 281-001-001 Argdon Corp., Forest Park, Ill.
54 solenoid shaft (core or plunger) with yoke end
56 washers 2 ea.
58 compression spring
60 slide valve (with hole for cotter pin)
62 cotter pin
Drawing Reference Numerals Worksheet
64 solenoid mount bracket (to frame)
66 solenoid mount bolts 2 ea.
68 solenoid bracket bolt to frame
70 Timer 1 support bracket
74 base support for elec. controls
76 feed dish | An elongated vertically extended housing enclosing a hopper. Its lower end funnel connects to fittings extending to the exterior of housing into a feed dish. The pipe holds the dish in place. Dry feed material is controlled electrically by a solenoid operated valve incorporated into the lower fitting to hopper. Two timers control when and how much feed should be released. The first timer activates time of day, the second timer dispenses a feed portion. The second timer being adjustable in seconds per minute. The feed valve solenoid remains open releasing the feed material. The automatic dog and cat feeder can be used indoors and outdoors. Its exterior cabinet as well as the frame is sheet metal. The feeder as well as other feeders are to a degree fairly waterproof, but for outdoor use an inexpensive plastic cover as an accessory provides inclement weather protection. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to washing machines, and more particularly, to methods and apparatus for controlling wash temperatures.
Washing machines typically include a cabinet that houses an outer tub for containing wash and rinse water, a perforated clothes basket within the tub, and an agitator within the basket. A drive and motor assembly is mounted underneath the stationary outer tub to rotate the basket and the agitator relative to one another, and a pump assembly pumps water from the tub to a drain to execute a wash cycle.
At least some known washing machines provide that an operator can select from three wash temperatures. Such machines have valve systems including hot and cold water valves. For a hot wash operation, for example, the hot water valve is turned on, i.e., opened, and for a cold wash operation, the cold valve is opened. For a warm wash, both the hot valve and cold valve are opened. The flow rates of water through the valves is selected so that the desired warm temperature is achieved using hot and cold water.
The use of a pressure sensor to measure water level allows for more accurate control of multiple water levels compared to the use of a pressure switch. Unfortunately, this provides an opportunity for a single point error in the microprocessor hardware, or software to generate an over fill condition. At least one known system externally monitors the pressure sensor signal and generates a signal that opens a relay that breaks the line voltage to the water valve. The use of a relay adds a cost to the circuit.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, a circuit is provided. The circuit includes a processor programmed to prevent overfilling of a cabinet with a fluid, and a backup circuit having fixed logic. The backup circuit is electrically coupled to the processor to redundantly prevent overfilling the cabinet with the fluid.
In another aspect, a washer overfill protection system is provided. The washer overfill protection system includes a pressure sensor configured to generate a variable frequency signal that is proportional to the fluid level of the washer, a converter electrically coupled to the pressure sensor, the converter is configured to generate an voltage that is proportional to the frequency of the output of the pressure sensor, and a microprocessor electrically coupled to the converter. The microprocessor is configured to calculate the fluid level from the voltage of the converter, and the microprocessor is electrically coupled to a fluid valve. The washer overfill protection system further includes a backup circuit having fixed logic. The backup circuit is electrically coupled to the converter and the fluid valve. The backup circuit is configured to at least one of turn on the fluid valve and turn off the fluid valve when the microprocessor fails.
In a further aspect, a washing machine is provided. The washing machine includes a cabinet, a tub and basket mounted within the cabinet, a cold water valve for controlling flow of cold water to the tub, a hot water valve for controlling flow of hot water to the tub, and a circuit coupled to at least one of the hot water valve and the cold water valve to control opening and closing of the hot and cold water valves. The circuit includes a processor programmed to prevent overfilling of the cabinet and a backup circuit having fixed logic. The backup circuit is electrically coupled to the processor to redundantly prevent overfilling the cabinet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective cutaway view of an exemplary washing machine.
FIG. 2 is front elevational schematic view of the washing machine shown in FIG. 1 .
FIG. 3 is a schematic block diagram of a control system for the washing machine shown in FIGS. 1 and 2 .
FIG. 4 is a schematic diagram of a over fill protection circuit for the washing machine shown in FIGS. 1 and 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view partially broken away of an exemplary washing machine 50 including a cabinet 52 and a cover 54 . A backsplash 56 extends from cover 54 , and a control panel 58 including a plurality of input selectors 60 is coupled to backsplash 56 . Control panel 58 and input selectors 60 collectively form a user interface input for operator selection of machine cycles and features, and in one embodiment a display 61 indicates selected features, a countdown timer, and other items of interest to machine users. A lid 62 is mounted to cover 54 and is rotatable about a hinge (not shown) between an open position (not shown) facilitating access to a wash tub 64 located within cabinet 52 , and a closed position (shown in FIG. 1 ) forming a substantially sealed enclosure over wash tub 64 . As illustrated in FIG. 1 , machine 50 is a vertical axis washing machine.
Tub 64 includes a bottom wall 66 and a sidewall 68 , and a basket 70 is rotatably mounted within wash tub 64 . A pump assembly 72 is located beneath tub 64 and basket 70 for gravity assisted flow when draining tub 64 . Pump assembly 72 includes a pump 74 and a motor 76 . A pump inlet hose 80 extends from a wash tub outlet 82 in tub bottom wall 66 to a pump inlet 84 , and a pump outlet hose 86 extends from a pump outlet 88 to an appliance washing machine water outlet 90 and ultimately to a building plumbing system discharge line (not shown) in flow communication with outlet 90 .
FIG. 2 is a front elevational schematic view of washing machine 50 including wash basket 70 movably disposed and rotatably mounted in wash tub 64 in a spaced apart relationship from tub side wall 64 and tub bottom 66 . Basket 70 includes a plurality of perforations therein to facilitate fluid communication between an interior of basket 70 and wash tub 64 .
A hot liquid valve 102 and a cold liquid valve 104 deliver fluid, such as water, to basket 70 and wash tub 64 through a respective hot liquid hose 106 and a cold liquid hose 108 . Liquid valves 102 , 104 and liquid hoses 106 , 108 together form a liquid supply connection for washing machine 50 and, when connected to a building plumbing system (not shown), provide a fresh water supply for use in washing machine 50 . Liquid valves 102 , 104 and liquid hoses 106 , 108 are connected to a basket inlet tube 110 , and fluid is dispersed from inlet tube 110 through a known nozzle assembly 112 having a number of openings therein to direct washing liquid into basket 70 at a given trajectory and velocity. A known dispenser (not shown in FIG. 2 ), may also be provided to produce a wash solution by mixing fresh water with a known detergent or other composition for cleansing of articles in basket 70 .
In an alternative embodiment, a known spray fill conduit 114 (shown in phantom in FIG. 2 ) may be employed in lieu of nozzle assembly 112 . Along the length of the spray fill conduit 114 are a plurality of openings arranged in a predetermined pattern to direct incoming streams of water in a downward tangential manner towards articles in basket 70 . The openings in spray fill conduit 114 are located a predetermined distance apart from one another to produce an overlapping coverage of liquid streams into basket 70 . Articles in basket 70 may therefore be uniformly wetted even when basket 70 is maintained in a stationary position.
A known agitation element 116 , such as a vane agitator, impeller, auger, or oscillatory basket mechanism, or some combination thereof is disposed in basket 70 to impart an oscillatory motion to articles and liquid in basket 70 . In different embodiments, agitation element 116 may be a single action element (i.e., oscillatory only), double action (oscillatory movement at one end, single direction rotation at the other end) or triple action (oscillatory movement plus single direction rotation at one end, singe direction rotation at the other end). As illustrated in FIG. 2 , agitation element 116 is oriented to rotate about a vertical axis 118 .
Basket 70 and agitator 116 are driven by motor 120 through a transmission and clutch system 122 . A transmission belt 124 is coupled to respective pulleys of a motor output shaft 126 and a transmission input shaft 128 . Thus, as motor output shaft 126 is rotated, transmission input shaft 128 is also rotated. Clutch system 122 facilitates driving engagement of basket 70 and agitation element 116 for rotatable movement within wash tub 64 , and clutch system 122 facilitates relative rotation of basket 70 and agitation element 116 for selected portions of wash cycles. Motor 120 , transmission and clutch system 122 and belt 124 collectively are referred herein as a machine drive system.
Washing machine 50 also includes a brake assembly (not shown) selectively applied or released for respectively maintaining basket 70 in a stationary position within tub 64 or for allowing basket 70 to spin within tub 64 . Pump assembly 72 is selectively activated, in the example embodiment, to remove liquid from basket 70 and tub 64 through drain outlet 90 and a drain valve 130 during appropriate points in washing cycles as machine 50 is used. In an exemplary embodiment, machine 50 also includes a reservoir 132 , a tube 134 and a pressure sensor 136 . As fluid levels rise in wash tub 64 , air is trapped in reservoir 132 creating a pressure in tube 134 that pressure sensor 136 monitors. Liquid levels, and more specifically, changes in liquid levels in wash tub 64 may therefore be sensed, for example, to indicate laundry loads and to facilitate associated control decisions. In further and alternative embodiments, load size and cycle effectiveness may be determined or evaluated using other known indicia, such as motor spin, torque, load weight, motor current, and voltage or current phase shifts.
Operation of machine 50 is controlled by a controller 138 which is operatively coupled to the user interface input located on washing machine backsplash 56 (shown in FIG. 1 ) for user manipulation to select washing machine cycles and features. In response to user manipulation of the user interface input, controller 138 operates the various components of machine 50 to execute selected machine cycles and features.
In an illustrative embodiment, clothes are loaded into basket 70 , and washing operation is initiated through operator manipulation of control input selectors 60 (shown in FIG. 1 ). Tub 64 is filled with water and mixed with detergent to form a wash fluid, and basket 70 is agitated with agitation element 116 for cleansing of clothes in basket 70 . That is, agitation element is moved back and forth in an oscillatory back and forth motion. In the illustrated embodiment, agitation element 116 is rotated clockwise a specified amount about the vertical axis of the machine, and then rotated counterclockwise by a specified amount. The clockwise/counterclockwise reciprocating motion is sometimes referred to as a stroke, and the agitation phase of the wash cycle constitutes a number of strokes in sequence. Acceleration and deceleration of agitation element 116 during the strokes imparts mechanical energy to articles in basket 70 for cleansing action. The strokes may be obtained in different embodiments with a reversing motor, a reversible clutch, or other known reciprocating mechanism.
After the agitation phase of the wash cycle is completed, tub 64 is drained with pump assembly 72 . Clothes are then rinsed and portions of the cycle repeated, including the agitation phase, depending on the particulars of the wash cycle selected by a user.
FIG. 3 is a schematic block diagram of an exemplary washing machine control system 150 for use with washing machine 50 (shown in FIGS. 1 and 2 ). Control system 150 includes controller 138 which may, for example, be a microcomputer 140 coupled to a user interface input 141 . An operator may enter instructions or select desired washing machine cycles and features via user interface input 141 , such as through input selectors 60 (shown in FIG. 1 ) and a display or indicator 61 coupled to microcomputer 140 displays appropriate messages and/or indicators, such as a timer, and other known items of interest to washing machine users. A memory 142 is also coupled to microcomputer 140 and stores instructions, calibration constants, and other information as required to satisfactorily complete a selected wash cycle. Memory 142 may, for example, be a random access memory (RAM). In alternative embodiments, other forms of memory could be used in conjunction with RAM memory, including but not limited to flash memory (FLASH), programmable read only memory (PROM), and electronically erasable programmable read only memory (EEPROM).
Power to control system 150 is supplied to controller 138 by a power supply 146 configured to be coupled to a power line L. Analog to digital and digital to analog converters (not shown) are coupled to controller 138 to implement controller inputs and executable instructions to generate controller output to washing machine components such as those described above in relation to FIGS. 1 and 2 . More specifically, controller 138 is operatively coupled to machine drive system 148 (e.g., motor 120 , clutch system 122 , and agitation element 116 shown in FIG. 2 ), a brake assembly 151 associated with basket 70 (shown in FIG. 2 ), machine water valves 152 (e.g., valves 102 , 104 shown in FIG. 2 ) and machine drain system 154 (e.g., drain pump assembly 72 and/or drain valve 130 shown in FIG. 2 ). In a further embodiment, water valves 152 are in flow communication with a dispenser 153 (shown in phantom in FIG. 3 ) so that water may be mixed with detergent or other composition of benefit to washing of garments in wash basket 70 .
In response to manipulation of user interface input 141 controller 138 monitors various operational factors of washing machine 50 with one or more sensors or transducers 156 , and controller 138 executes operator selected functions and features according to known methods. Of course, controller 138 may be used to control washing machine system elements and to execute functions beyond those specifically described herein. Controller 138 operates the various components of washing machine 50 in a designated wash cycle familiar to those in the art of washing machines.
FIG. 4 is a schematic of a washer overfill protection circuit 200 . Washer overfill protection circuit 200 includes a pressure sensor 210 electrically coupled to a frequency to voltage converter 215 . The output of frequency to voltage converter 215 is electrically coupled to at least a first circuit 220 and a second circuit 225 . In the exemplary embodiment, first circuit 220 is a back up circuit 220 and includes a first operational amplifier (op amp) 230 and a second op amp 235 . In one embodiment, first op amp 230 is a overfill comparator 230 and second op amp 235 is a sensor error comparator 235 . Overfill comparator 230 and sensor error comparator 235 are electrically coupled to a first gate 240 . First gate 240 is electrically coupled to a second gate 245 and a third gate 248 . Second gate 245 is electrically coupled to a first transistor 250 , such as a bipolar junction transistor. First transistor 250 is electrically coupled to a first relay driver 255 . First relay driver 255 is electrically coupled to a fluid valve coil 260 , such as a hot water valve coil 260 .
Second circuit 225 includes a microprocessor 270 . Microprocessor 270 is electrically coupled to second gate 245 of back up circuit 220 and a third gate 248 . Third gate 248 is electrically coupled to a second transistor 285 , such as a bipolar junction transistor. Second transistor 285 is electrically coupled to a second relay driver 290 . Second relay driver 290 is electrically coupled to a fluid valve coil 300 , such as a cold water valve coil 300 .
Microprocessor 270 is programmed to perform functions described herein, and as used herein, the term microprocessor is not limited to just those integrated circuits referred to in the art as microprocessor, but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein.
Pressure sensor 210 generates a variable frequency signal that is proportional to the water level in washer tub 64 . Frequency to voltage converter 215 generates an analog voltage that is proportional to the frequency from the output of pressure sensor 210 . The analog voltage is then input to microprocessor 270 . Microprocessor 270 uses the analog voltage to calculate the water level and sends, for example, a hot water valve command signal to turn on and off hot water valve coil 260 . The hot water valve command and pressure sensor check signal are sent to the input of second gate 245 . If hot water command is high and the pressure sensor check signal is high, the output of second gate 245 is high, turning on first transistor 250 . If first transistor 250 is on, first relay driver 255 is energized, closing the normally closed contact for first relay driver 255 energizing hot water valve coil 260 . Energizing hot water valve coil 260 opens the hot water valve (not shown), allowing hot water to flow into washer tub 64 . If the hot water valve command and/or the pressure sensor check signal is low, the output of second gate 245 is low, turning off first transistor 250 . If first transistor 250 is off, first relay driver 255 is de-energized, opening the normally open contacts of first relay driver 255 , de-energizing hot water valve coil 260 . De-energizing hot water valve coil 260 shuts off the hot water valve, blocking hot water from entering the washer tub 64 .
The output of the frequency to voltage converter 215 is input into overfill comparator 230 and compared with an over fill reference voltage. If the frequency to voltage converter 215 output is less than the over fill reference voltage, the overfill comparator 230 output is high, indicating a normal tub water level. If the frequency to voltage converter 215 output is greater than the over fill reference voltage, the overfill comparator 230 output is low, indicating an over fill condition.
The output of the frequency to voltage converter 215 is also an input into sensor error comparator 235 and compared with a sensor error voltage. If the frequency to voltage converter 215 output is greater than the sensor error voltage, the sensor error comparator 235 output is high indicating a valid pressure sensor signal. If the frequency to voltage converter 215 output is less than the sensor error voltage, the sensor error comparator 235 output is low indicating an invalid pressure sensor signal.
Overfill comparator 230 output and sensor error comparator 235 output are connected to the input of first gate 240 . If overfill comparator 230 output and/or sensor error comparator 235 output is low, first gate 240 output is low. If the output of first gate 240 is low, second gate 245 and third gate 248 outputs are low, de-energizing first transistor 250 and second transistor 285 . De-energizing first transistor 250 and second transistor 285 de-energizes first relay driver 255 and second relay driver 290 , respectfully, de-energizing hot and cold water valve coils 260 and 300 , respectfully. De-energizing hot and cold water valve coils 260 and 300 , blocks the hot and cold water from entering washer tub 64 .
In one embodiment, pressure sensor 210 may output an analog voltage instead of a frequency signal, thereby removing frequency to voltage converter 215 from circuit 200 . In another embodiment, the logic performed by first, second, and third gates 240 , 245 , and 248 may be performed by other logic that generates the same operation. In addition, the water valve driver circuits may be generated by any other switching device. In a further embodiment, hot and cold water valve coils 260 and 300 may be replaced by dc water valves, using a dc drive circuit instead of first and second relay drivers 255 and 290 .
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | A circuit is provided. The circuit includes a processor programmed to prevent overfilling of a cabinet with a fluid and a backup circuit having fixed logic. The backup circuit is electrically coupled to the processor to redundantly prevent overfilling the cabinet with the fluid. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/049,230 filed Mar. 16, 2011, now U.S. Pat. No. 8,781,689, the disclosure of which is incorporated in its entirety by reference herein.
TECHNICAL FIELD
Various embodiments relate to systems for controlling a vehicle seat assembly.
BACKGROUND
A vehicle seat assembly may be provided with a movable seat component. An example of the movable seat component is a movable head restraint. Examples of movable head restraints are disclosed in U.S. Pat. Nos. 4,674,797, 5,699,668, 6,983,995, and 7,267,407.
SUMMARY
According to an embodiment, a vehicle seat adjustment assembly is provided with at least one actuator adapted to move a component of the vehicle seat assembly along a path, and a generally planar sensor array accessible from an outer surface of the vehicle seat assembly. The sensor array has a plurality of adjoining sensors arranged in at least one column and at least two rows. The vehicle seat assembly has a controller in communication with the at least one actuator for controlling the at least one actuator and in communication with the sensor array. The controller is configured to control the at least one actuator to move the component along the path in response to receiving a signal indicative of a touch input by a user when a pattern of adjacent sensors in the array are activated by the user, the pattern corresponding with the path.
According to another embodiment, a vehicle seat adjustment assembly is provided with an actuator adapted to move a component of the vehicle seat assembly, and a generally planar sensor array in communication with the controller and accessible from an outer surface of the vehicle seat assembly. The sensor array has a plurality of contiguous sensors positioned on an outer surface of the vehicle seat assembly. A controller is in communication with the actuator for controlling the actuator and in communication with the sensor array. The controller is configured to control the actuator to move the component in response to receiving a signal indicative of a touch input of the sensor array by a user such that the movement of the component correlates with the input to the sensor array.
According to yet another embodiment, a vehicle seat assembly is provided with a support structure and a seat assembly component supported by the support structure that is movable relative to the support structure between a first position and a second position. An actuator is connected to the component for moving the component between the first position and the second position. A controller is in communication with the actuator for controlling the actuator. A generally planar sensor array is in communication with the controller and is positioned on an outer surface of the vehicle seat assembly. The sensor array has a first region and a second region adjoining the first region. The sensor array is configured to sense a tactile input of the first region and second region being sequentially activated by a user. The controller is configured to receive a signal indicative of the tactile input from the sensor array and command the actuator to move the component in response to the tactile input by the user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a vehicle seat assembly according to an embodiment of the disclosure;
FIG. 2 is another schematic of a vehicle seat assembly;
FIG. 3 is yet another schematic of a vehicle seat assembly;
FIG. 4 is a schematic of the sensor array of FIG. 1 showing various inputs to the array according to various embodiments of the disclosure; and
FIG. 5 is a schematic of an electronics diagram for use with the vehicle seat assembly of FIG. 3 .
DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
FIG. 1 illustrates a vehicle seat assembly 10 . The vehicle seat assembly 10 may be a front seat, such as a driver seat assembly or a front passenger seat assembly, or may be a rear seat assembly, such as a second row or a third row seating of a vehicle. The seat assembly 10 has a support structure 12 , such as a seatback. The support structure 12 supports a head restraint 16 . The head restraint 16 has adjustment features, which allow the head restraint 16 to move in various directions to provide ergonomic support for a cross section of different users, for example, by adjusting the height, backset and tilt, and to be able to fold and stow the head restraint when not in use, to improve driver visibility or seat stowage, or the like. The head restraint 16 is shown in the design position, and in a tilted forward or folded/stowed position shown in phantom.
FIG. 2 illustrates two degrees of adjustment and freedom for the head restraint 16 . A height 13 of the head restraint may be adjusted as well as an amount of backset 15 of the head restraint 16 .
The head restraint 16 , as shown in FIG. 3 , contains power mechanisms as are known in the art to translate or rotate the head restraint 16 . For example, an actuator 18 , such as an electric motor, solenoid, or the like, is connected to various rack and pinions systems, lever systems, gears, cams, cranks, linkages, etc. to provide the motion of the head restraint 16 . The actuator 18 is connected to a power source 20 , such as a vehicle battery or an alternator. The actuator 18 is also connected to a controller 22 , such as a microcontroller or integrated circuit, or the like, which controls the actuator 18 . The controller 22 may turn the actuator on and off, control the direction of motion provided by the actuator 18 , and control the duration of time that the actuator 18 is operated, which may correspond to the amount of movement of the head restraint 16 .
For example, the head restraint 16 is configured to move in several directions, such as along a first axis 24 , along a second axis 26 , and in rotation about a third axis 28 . Of course, translation or rotation about any axis is contemplated, and the head restraint may move or translate about any number of axes, including a single axis or more than three axes. The first axis 24 is shown as being in an upright orientation, or aligned with the longitudinal axis of the vehicle seat assembly 10 or seatback 12 . The head restraint 16 travels along this axis 24 to change the height 13 of the head restraint 16 with respect to the vehicle seat assembly 10 or to the head of an occupant of the seat 10 . The second axis 26 is shown as being in line with the fore/aft direction of the head restraint 16 or the vehicle seat assembly 10 , which generally corresponds with the fore/aft direction of a vehicle that the seat assembly 10 is installed in. The head restraint 16 travels along this axis 26 to adjust the amount of backset 15 of the head restraint 16 with respect to the vehicle seat assembly 10 . The third axis 28 is shown as being in a lateral or transverse direction of the head restraint 16 or the vehicle seat assembly 10 . The head restraint 16 rotates or pivots about this axis 28 to fold or tilt the head restraint with respect to the vehicle seat assembly 10 . The head restraint 16 has an angular motion about the axis 28 to rotate between a design position and tilted or folded position as shown in FIG. 1 . The head restraint 16 may be placed in the folded position when the vehicle seat assembly 10 is unoccupied. If the vehicle seat 10 is occupied or is going to be occupied, the amount of tilt of the head restraint 16 may be adjusted by rotating the head restraint 16 about axis 28 to better fit the head position of an occupant, for example, by tilting the head restraint 16 forward or rearwards within a range of thirty degrees, sixty degrees, or some other amount.
A sensor array 34 is supported by the head restraint 16 as shown, or alternatively, may be located elsewhere on the vehicle seat assembly 10 , such as on the seatback 12 , a vehicle door, an armrest, a console, or the like. The sensor array 34 is electrically connected to the controller 22 and is powered by the power source 20 . The sensor array 34 contains a plurality of capacitive sensors 36 , which may be arranged, for example, into columns and rows. Alternatively, the sensor array 34 contains a plurality of any other positional sensors as are known in the art.
Each capacitive sensor 36 operates through capacitive touch sensing, using for example, the concept of a variable capacitor. In some embodiments, a printed circuit board (PCB) based capacitor is formed and an electric field is allowed to leak into the area above the capacitor, which includes the outer surface of the sensor array 34 . A user interacts with this outer layer. The sensor pad and a surrounding ground pour (or ground plane underneath) create a baseline capacitance that can be measured.
When a conductor, e.g., a finger of a user, is near to or touches the outer surface of the sensor array 34 above an open capacitor 36 , the electric field is interfered with and causes the resulting capacitance to change. The sensitivity of the sensor 36 may be adjusted through the connected detector integrated circuit or controller 22 such that the outer surface of the sensor array 34 needs to be touched to activate the sensor 36 . The outer surface may act as an insulating layer and to provide separation between the sensor 36 and the user. The coupling of the conductive finger with the capacitive sensor 36 increases the capacitance of the structure beyond the baseline capacitance, or the capacitance of the sensor 36 with no touch.
In some embodiments, a ground plane underneath the sensor 36 aids in shielding it from potential interference generated by other electronics and helps to maintain a more constant baseline capacitance.
Referring to FIGS. 3 and 4 , the head restraint 16 may be movable relative to the support structure 12 along one of the axes 24 , 26 , 28 between a first position and a second position. The first position and second position may be the locations of the head restraint 16 at its maximum travel along that respective axis, i.e. maximum and minimum heights, maximum and minimum backset, and design and tilted or folded positions. The actuator 18 moves the head restraint 16 along or about one or more of the axes 24 , 26 , 28 . The sensor array 34 has a first region 38 and a second region 40 . The regions 38 , 40 are illustrated in FIG. 4 , although any size or oriented region is contemplated. The regions 38 , 40 are such that the user activates at least two sensors 36 in the array 34 . The user typically slides a finger along the array 34 , and activates sensors 36 . If the user activates two sensors 36 , the first sensor 36 activated would be in the first region 38 , and the second sensor 36 activated would be in the second region 40 . The path of sensors 36 activated defines the motion of the head restraint 16 . The first region 38 and second region 40 may be adjacent to one another or spaced apart from one another on the sensor array 34 . Each region 38 , 40 contains one or more capacitive sensors 36 or other positional sensors. For example, a user interacts with the first region 38 by activating the capacitive sensors within it, and then slides their finger or otherwise activates sensors in the second region 40 immediately after interacting with the first region 38 . A time limit may be programmed into the controller 22 such that the signal from sensors 36 in the second region 40 need to be received within a predetermined time after the signal from sensor 36 in the first region 38 to be considered an input. The controller 22 receives and processes the signals from the sensor array 34 and commands the actuator to move the head restraint based on the input.
For example, if the first position and second position of the head restraint are spaced apart along a longitudinal or upright axis of the vehicle seat assembly, the first and second regions of the sensor array are similarly oriented on the sensor array 34 . When the user activates the first region 38 followed by the second region 40 (bottom to top motion 42 on FIG. 4 ), the head restraint 16 moves or translates away from the support structure 12 along the longitudinal axis 24 . Based on the magnitude of the sliding motion, i.e. number of sensors 36 activated, and/or length of sensor array 34 activated, etc., the head restraint 16 may translate anywhere from an incremental amount between the first and second positions, to the complete distance between the first and second positions. Similarly, the head restraint 16 may be moved or translated from the second position to the first position by activating the second region 40 followed by the first region 38 of the sensor array 34 (top to bottom motion 42 on FIG. 4 ).
If the first position and second position of the head restraint 16 are spaced apart along a fore/aft axis 26 of the vehicle seat assembly 10 , the first and second region of the sensor array 38 , 40 are similarly oriented on the sensor array 34 . When the user activates the first region 38 followed by the second region 40 (left to right motion 44 on FIG. 4 ), the head restraint 16 moves or translates rearward along the fore/aft axis 26 . Based on the magnitude of the sliding motion, i.e. number of sensors 36 activated, and/or length of sensor array 34 activated, etc., the head restraint 16 may translate anywhere from an incremental amount between the first and second positions, to the complete distance between the first and second positions. Similarly, the head restraint 16 may be moved or translated from the second position to the first position by activating the second region 40 followed by the first region 38 of the sensor array 34 (right to left motion 44 on FIG. 4 ).
If the first position and second position are spaced apart about a lateral axis 28 of the vehicle seat assembly 10 , such that they are at different angular positions about the axis 28 , the first and second region of the sensor array 38 , 40 are similarly oriented on the sensor array 34 . When the user activates the first region 38 followed by the second region 40 (clockwise motion 46 on FIG. 4 ), the head restraint 16 moves towards a design position about the lateral axis 28 . The head restraint 16 will move along an arcuate path as it is tilted by rotating about the lateral axis 28 . Varying degrees of forward and backward tilt of the head restraint 16 are contemplated, including but not limited to thirty degrees, sixty degrees, to a forward folded position, or any other amount. If the head restraint 16 is capable of tilting forward or backwards through thirty degrees, the head restraint may be positioned at any position as limited by that thirty degree value, i.e. forward ten degrees, backward fifteen degrees, forward twenty degrees, etc. Based on the magnitude of the sliding motion, i.e. number of sensors 36 activated, length of sensor array 34 activated, etc., the head restraint 16 may move anywhere from an incremental amount between the first and second positions, to the complete distance between these positions. Similarly, the head restraint 16 may be moved from the second position to the first position by activating the second region 40 followed by the first region 38 of the sensor array 34 (counter clockwise motion 46 on FIG. 4 ).
The head restraint 16 may include a substrate (not shown) that is covered with a foam cushion or other padding material, which in turn may be covered with trim 32 such as a fabric, leather, or other similar material. In some embodiments, the sensor array 34 is connected to the substrate, and the trim cover 32 is placed over the sensor array 34 to cover it. The trim cover 32 may have demarcation such as stitching, different material, or the like, to show the location of the sensor array 34 to a user. In other embodiments, the sensor array 34 is integrated into the trim cover 32 , and the trim cover 32 containing the sensor array 34 is affixed to the substrate of the head restraint 16 . The sensor array 34 may be made from a flexible material to have properties similar to that of the trim cover 32 .
For a head restraint 16 with a conventional adjustment system, such as a mechanical button or lever, the system is limited by design constraints, i.e. only one location for the button or lever and over a relatively small surface area of the head restraint 16 even if there is more than one location may be desired for the user interface. With embodiments of the present disclosure, the sensor array 34 may cover more than one of these preferred locations for user access to adjust the head restraint 16 because the array 34 is not as limited in size as the mechanical mechanisms, or more than one array 34 may be used at more than one location, i.e. an array 34 on the head restraint 16 and an array 34 on the support structure 12 or seatback is possible with the use of the controller 22 .
In some embodiments, shown in FIGS. 3-4 , the vehicle seat assembly 10 has a head restraint 16 supported by the support structure 12 where the head restraint 16 is movable relative to the support structure for translation along a first axis 24 , translation along a second axis 26 , and rotation about a third axis 28 . Therefore the head restraint 16 has six degrees of freedom, although any number of degrees of freedom is contemplated, such as less than or more than six.
An actuator 18 is connected to the head restraint 16 to move the head restraint 16 . The actuator 18 may contain more than one motor and/or more than one mechanical system to provide required motion of the head restraint 16 . For example, three motors may be provided, with one for each of the translation movements, and one for the rotational movement of the head restraint 16 . Also, a separate rack and pinion, lever, gear, or other mechanical mechanism may be provided for each movement.
A sensor array 34 may contain a plurality of capacitive sensors 36 or other positional sensors and is electrically connected to the controller 22 . The capacitive sensors 36 are activated by the user, and the pattern or path of the activated sensors during an input determines the corresponding movement of the head restraint 16 . Sample paths or patterns which correspond with movement of the head restraint 16 for translation along a first axis 24 , translation along a second axis 26 , and rotation about a third axis 28 are shown in FIG. 4 . An input to the sensor array 36 includes the activation of at least two adjacent sensors 36 , and to be considered an input by the controller 22 , the adjacent sensors may need to be activated within a predetermined time limit, such that there is a maximum time delay between sensor 36 activations. When at least two adjacent sensors 36 are activated in a direction on the sensor array 34 which corresponds with one of the axes 24 , 26 , 28 , the controller 22 commands the actuator 18 to move the head restraint 16 along that axis. As the number of adjacent sensors 36 activated for an input increases, the head restraint 16 may travel along a correspondingly longer distance along that axis.
Alternately, at the first position or the second position of the head restraint 16 , at least one input from a user is required, such as the use of two fingers to activate the head restraint 16 to translate or rotate about an axis. This would activate at least two sensors 36 of the sensor array 34 in either the first or second region 38 , 40 , and may prevent an inadvertent activation of the head restraint 16 .
Alternatively, after sensors 36 are activated in either the first or second region 38 , 40 and indicate the direction of motion of the head restraint 16 , if the finger remains in the same region 38 , 40 and does not cross into the other region 40 , 38 , the motion of the head restraint 16 continues in that direction until the input from a user to the sensor array 34 ends.
The first, second, and third axes 24 , 26 , 28 may be nonparallel to one another, such that they converge at a point or origin. In some embodiments, the first, second, and third axes 24 , 26 , 28 are orthogonal to one another.
FIG. 5 illustrates an electrical component schematic for use with the head restraint 16 . Capacitive sensors 36 in the array 34 are connected to the controller 22 . A ground may also be connected to the controller 22 . The controller 22 may be an integrated circuit or other microcontroller. The controller 22 is connected to the various motors or actuators 18 for the head restraint 16 using power driver circuits 48 . Each actuator 18 controls one of the movements of the head restraint 16 , i.e. translation along axis 24 , translation along axis 26 , or rotation along axis 28 . Alternatively, the controller 22 may command two or more actuators 18 to act in concert to provide one of the movements, such as rotation of the head restraint 16 . Optional features may be available through additional driver circuits and actuators such as movable comfort wings, head restraint monitors, anti-whiplash protection, and the like.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | A vehicle seat adjustment assembly has an actuator adapted to move a component of the vehicle seat assembly, and a generally planar sensor array in communication with the controller and accessible from an outer surface of the vehicle seat assembly. The sensor array has a plurality of adjacent sensors accessible from an outer surface of the vehicle seat assembly. A controller is in communication with the actuator for controlling the actuator and in communication with the sensor array. The controller is configured to control the actuator to move the component in response to receiving a signal indicative of a touch input of the sensor array by a user such that the movement of the component correlates with the input to the sensor array. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of United States Ser. No. 285,033 filed July 20, 1981, now U.S. Pat. No. 4,374,877.
BACKGROUND OF THE INVENTION
The present invention relates to decorations for use in gift-wrapping a package and, more particularly, to such a decoration including an ornament which automatically expands or "pops up" upon application of the decoration to the package.
Decorative ornaments for use in gift-wrapping packages are well known in the art. Decorative ornaments which stand up from the top surface of the package being gift-wrapped add a highly desirable touch of three dimensional class and elegance to the gift-wrapping. U.S. Pat. No. 4,293,601, issued Oct. 6, 1981, describes such an ornament affording a spray- or fountain-like appearance. Strong deterrents to the use of such stand-up ornaments are, first, the fact that they typically require ample storage space so as not to be crushed or damaged prior to use, and second, frequently must be manually positioned in a vertical orientation to insure that the ornament will stand upright on the package. The first of these deterrents is overcome by the use of expandable ornaments of the type disclosed in U.S. Pat. No. 3,174,894, which ornament, in its unexpanded state, is substantially flat and compact, suitable for storage, and manually openable to provide, in its expanded state, a circular wreath or semi-circular half-wreath (like a fan).
The patent describes its expansible structure as being "a honeycomb structure constituted of a plurality of sheets of tissue paper, each sheet superposed upon another, the sheets being joined together along parallel adhesive lines, staggered on alternate sheets of paper, and progressively built up until an appropriate desired thickness is obtained. In die-cutting the resulting honeycomb blanket in the design of a half profile of a holly-leaf, provision is made for disposing the adhesive lines inwardly from the leaf edge and a second adhesive line disposed at the edges of the simulated leaf adapted to secure the edges of one leaf with its adjacent member. When the tissue sheets forming the simulated leaf are parted in a continuous pull-out form, the resulting leaf will be comprised of a back of one sheet and the front of another, with the inwardly disposed adhesive line forming a central vein in simulation of a natural leaf. The adhesive line securing the tips or edges of the leaf accordingly acts to spread its adjacent member".
While the patent does not suggest use of the half-wreath for gift-wrapping purposes, clearly the same could be adapted for such use simply by manually spreading the ends thereof to form the half-wreath, suitably positioning the expanded half-wreath vertically on the package, and then affixing the half-wreath ends to the package by means of adhesive, stapling or the like. The second deterrent is not, however, alleviated.
Accordingly, it is an object of the present invention to provide an expandable pop-up decoration including an ornament which automatically expands and pops up upon application thereof to a package as part of the gift-wrapping of the package.
Another object is to provide such a decoration which is simple and inexpensive to manufacture, easily and rapidly applied to the package, and securely attachable thereto.
SUMMARY OF THE INVENTION
It has now been found that the above and related objects of the present invention are obtained in an automatically expanding pop-up decoration for use in gift-wrapping a package, such decoration comprising an ornament and an elasticized cord. The ornament has a pair of opposed end members and an expansible structure pivotally joining the end members together. The end members are capable of pivoting between a substantially face-to-face relationship and a substantially edge-to-edge relationship, the ornament being substantially flat when the end members are in the substantially face-to-face relationship, and having a substantially upstanding portion when the end members are in a substantially edge-to-edge relationship. The cord operatively engages the ornament end members, whereby application of the cord about a package so as to tension the cord automatically causes the ornament end members to pivot into the substantially edge-to-edge relationship.
In a preferred embodiment, the cord has the opposite ends thereof secured to the ornament end members, respectively, whereby application of the cord about a package so as to tension the cord ends automatically causes the ornament end members to pivot into the substantially edge-to-edge relationship. Preferably one edge of the expansible structure defines a spine about which the end members pivot. At least one cord end (and preferably each) is secured to at least one ornament end member at a point substantially spaced from the spine. Thus, the cord ends are spaced from one another when the ornament end members are in a substantially edge-to-edge relationship. The cord is secured to the ornament so that application of the cord about a package under tension both secures the ornament to the package and causes a portion thereof to become substantially upstanding.
In another preferred embodiment, one edge of the expansible structure defines the spine and the ornament end members are pivotable with respect to each other about the spine. Each of the ornament end members defines an aperture therethrough, and the cord is in the form of a continuous loop and passes through each of the apertures and behind the spine so that it traverses at one point the structure-facing surface of one ornament end member and at another point the opposite surface of the one end member, whereby the cord traverses the width of the one ornament end member partially on one surface thereof and partially on the other surface thereof. Preferably the cord traverses in turn the structure-facing surface of one of the ornament end members, the opposite surface thereof, the spine, the opposite surface of the other ornament end member, and the structure-facing surface thereof. The aperture defined by the one ornament end member (and preferably both apertures) is disposed at a point substantially spaced from the spine. Where the cord is in the form of a continuous loop containing a knot formed by the opposite ends of the cord, the knot is best disposed in a recess defined by the back of the spine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a decoration according to the present invention, taken from the spine and one side thereof, and showing the ornament in its collapsed orientation;
FIG. 2 is a top elevation view of the decoration, showing the ornament in a partially expanded orientation;
FIG. 3 is an isometric view of the decoration applied to a package, showing the ornament in its expanded orientation;
FIG. 4 is an elevation view, partially in section, taken along line 4--4 of FIG. 3;
FIG. 5 is an isometric view of a decoration according to a second embodiment of the present invention; and
FIG. 6 is a fragmentary section of the decoration of FIG. 5 applied to a package, showing the ornament in its expanded orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and, in particular, to FIGS. 1 and 2 thereof, the decoration of the present invention is suitable for use in gift-wrapping a package, generally designated by the letter A (shown in FIGS. 3 and 4), and comprises an ornament, generally designated by the numeral 10, and an elasticized cord, generally designated by the numeral 12. The accordian-like ornament 10 comprises a pair of opposed end members 14 and an expansible structure 16, joining the end members together.
The precise nature of the expansible structure 16 is not a part of the present invention, and many of the expansible structures described in the prior art are useful in the present invention. For example, an expansible structure of the type described in the aforementioned U.S. Pat. No. 3,174,894 may be used.
The ornament of the present invention, as shown in FIGS. 1-4, is in the shape of a half-bell (rather than a holly-leaf) and consists primarily of a plurality of spokes 18, with each pair of adjacent spokes being interconnected by means of folded connectors 20. While it is possible for the spokes 18 at each end of the expansible structure 16 to constitute the ornament end members 14, preferably, there are separate end members 14 secured to the outer spokes 18, the end members 14 being of a strengthening material stronger than the spokes 18 and, thus, less likely to tear. The end members 14 may be of the same size and configuration as the spokes 18, but, if desired, may be smaller (as shown). The end members 14 may be secured to the outer spokes 18 by any conventional fastening techniques, including adhesive means, stapling, and the like.
When the ornament 10 is in its collapsed state or orientation, it lies substantially flat and occupies a minimum of storage space. In this orientation, the end members 14 are in a substantially face-to-face relationship (with the expansible structure 16 therebetween). While the drawing illustrates the use of two separate and distinct, unjoined end members 14, it is also possible to utilize a single relatively large sheet of strengthening material, suitably folded at the spine 19, so as to form a pair of connected end members 14. In such an instance, the ornament 10, in its collapsed orientation, still has the end members 14 in substantially face-to-face relationship, but generally such end members 14 would not be capable of assuming the substantially parallel relationship illustrated in FIG. 1.
The shape of the ornament 10 is selected for the particular aesthetic value desired and may be, for example, a half-wreath, a half-tree, or the like, as found suitable for particular gift-giving occasions. Furthermore, the materials from which the ornament is constructed can be varied to achieve desired effects, the expansible structure 16 typically being foil, cardboard, piece goods or the like, and the end member 14 being cardboard, plastic or other somewhat stronger material than that used for the expansible structure.
The elasticized cord 12 is in the form of a loop with the opposite ends 22 thereof secured to the opposed ornament end members 14 by any conventional means, such as, for example, staples 24. While it is preferable that the end members 14 be secured to the expansible structure 16 over a large area, if only a point connection is to be utilized, the same staple 24 may be used both to secure an end member 14 to both a cord end 22 and to the expansible structure 16. Obviously, adhesives or other fasteners may be used instead of the staples 24 and, in some cases, it is even possible to merely pass the cord ends 22 through suitably provided apertures in the end members 14, each cord end 22 then being individually knotted to prevent withdrawal of the cord end 22 through its associated end member aperture.
Each of the cord ends 22 is secured to its respective ornament end member 14 at a point substantially spaced from the spine 19, so that when the decoration is applied to a package A, the tensed cord ends 22 apply to ornament end members 14, turning a moment about the spine 19, and each end member 14 flips over and pivots until it rests on its side on the package A.
Whereas FIG. 1 illustrates the decoration in its storage orientation, and FIG. 2 illustrates the decoration in only a partially expanded orientation, FIGS. 3 and 4 illustrate the decoration in its open, fully expanded orientation, as it would be found when applied to a package A. Referring now, in particular, to FIGS. 3 and 4, the cord 12 may be applied to the package A in the normal "fancy" wrapping style shown in FIG. 3, or it may be simply slipped over the package A in more mundane fashion. In any case, as the cord 12 is applied about the package A so as to tense the cord ends 22, the ornament end members 14 automatically pivot and assume a substantially edge-to-edge relationship--that is, the end members 14 lie in substantially the same plane. As the end members 14 assume the substantially edge-to-edge relationship, the expansible portion 16 of the ornament 10 expands and forms a substantially upstanding portion which projects upwardly from the plane containing the end members 14 and, hence, from the top surface of the package A.
As most clearly shown in FIG. 4, when the end members 14 are separate and distinct from each other (as shown), after the decoration is applied to the package, a portion of the expansible structure 16 is, in effect, along with the cord 12 and end members 14, acting to secure the ornament 10 to the package A. Hence, the expansible structure 16 must be sufficiently strong to resist the tension applied thereto by the cord 12 and by any expected handling of the package A. Thus, when the tension to be applied by the cord 12 is high or there is anticipated considerable rough handling of the package A, it is preferred that the end members 14 be portions of a single suitably folded strengthening material so that the ornament is secured to the package A only by means of the cord 12 and end members 14.
Referring now to FIG. 5, therein illustrated is another preferred embodiment of the present invention. The ornament, generally designated by the numeral 10', is similar to the ornament 10 of the first embodiment except that the ornament end members 14' are devoid of staples 24 and contain instead apertures 30 extending therethrough. The apertures 30 are large enough to enable relatively free passage therethrough of the cord, the apertures 30 preferably being disposed at points substantially spaced from the spine 19.
The cord, generally designated by the numeral 12', is similar to the cord 12 of the first embodiment except that it is in the form of a continuous loop passing through each of the apertures 30 and behind the spine 19. The cord 12' traverses at one point the structure-facing surface 32 of one ornament end member 14' and at another point the opposite surface 34 of that ornament end member 14', whereby the cord 12' traverses the width of the ornament end member 14' partially on one surface thereof and partially on an opposite surface thereof. Preferably the cord 12' traverses in turn the structure-facing surface 32 of one of the ornament end members, the opposite surface 34 thereof, the spine 19, the opposite surface 34 of the other ornament end member, and the structure-facing surface 32 thereof. While the cord 12' may be in the form of a continuous loop without any visible knot or enlarged portion thereof, it is conveniently made in the form of a continuous loop containing a knot 36 (for example, one formed by interlocking the opposite ends of the cord). The knot 36 is best disposed in a recess 38 defined by the back of the spine 19 so that it remains invisible from above the ornament, does not prevent the ornament end members 14' from lying flat on the surface of the package A, and does not damage the expansible structure thereabove.
Several advantages result from use of the cord in a continuous loop engaging the ornament as described hereinabove for the second embodiment. First, there is a more reliable engagement between the cord and the oranement end members, with less likelihood of the ornament end members becoming torn by the cord and less need for reinforcement of the ornament end members. Second, there is enhanced ease of connection between the ornament and the cord as one need only thread the cord through the appropriate apertures and form a single knot with the ends thereof, without the need for staples, adhesive means or a separate knot for each cord end. Third, the second embodiment enables the use of more delicate and fragile (and hence more aesthetic) expansible structures because the expansible structures are primarily ornamental in the second embodiment and need not have any great structural strength. It will be appreciated that in the first embodiment using two separate ornament end members, when the ornament was applied to a package, the cord ends pulled the end members away from each other; it was therefore necessary that the expansible structure provide sufficient structural strength to withstand the applied stress and maintain a connection between the ornament end members. However in the second embodiment there is no force exerted by the cord on the ornament end members pulling them apart, and hence there is no requirement that the expansible structure have a structural strength sufficient to withstand such force. (Nonetheless the two ornament end members may be portions of a single suitably folded strengthening material as described hereinabove in connection with the first embodiment.)
It will be appreciated that conventional application of the cord about a package under tension automatically performs two separate and distinct functions. First, it secures the ornament to the package. Second, it causes the expansible portion of the ornament to become substantially upstanding. Thus, the decoration automatically stands and pops-up upon application thereof to the package as part of the gift-wrapping of the package and requires no special operation on the part of the wrapper to especially position the ornament or open same. In addition, the decoration is simple and inexpensive to manufacture, easily and rapidly applied to the package, and securely attachable thereto.
Now that the preferred embodiments of the present invention have been shown and described, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is to be limited only by the appended claims, and not by the foregoing disclosure. | An automatically expanding pop-up decoration for use in gift-wrapping a package is capable of assuming a compact folded orientation suitable for storage in a limited area, yet expands automatically upon application to a package so as to create a substantially upstanding portion. The decoration comprises an ornament having a pair of opposed end members and an expansible structure pivotally joining the end members together. It further comprises an elastic cord operatively engaging the opposed ornament end members so that application of the cord about a package so as to tension the cord automatically causes the ornament end members to pivot into a substantially edge-to-edge relationship with the expansible structure standing substantially upright from the package. | 6 |
TECHNICAL FIELD
This disclosure pertains to smelting of iron or ferro-alloy ores. More specifically, it pertains to an improvement in the equipment and methods utilized in preparing such ores for introduction into bath smelting systems.
BACKGROUND OF THE INVENTION
The present disclosure pertains to a new apparatus and method for partial pre-reduction of iron or ferro-alloy ores, using fine particulate ores and fuel gas or coal-based producer gas in a hot cyclone reactor. The producer gas is preferably derived from the off gas resulting from operation of a bath smelting process. The melted and partially reduced iron that exits the hot cyclone reactor can then be gravity-coupled to a bath smelting process for complete reduction of ore to liquid iron or steel.
The disclosed apparatus and process obviates the need for indurated iron or ferro-alloy ore pellets. It also eliminates the need for coking of the coal used in the disclosed processes.
Both environmental and economic considerations have led to renewed efforts to develop effective iron smelting processes and equipment utilizing coal, rather than coke. Among the current coal-based systems under consideration are bath smelting processes. The background of bath smelting processes and their perceived shortcomings are described in a paper titled "Flash Melting and Partial Reduction of Iron Ore Concentrates" by Robert W. Bartlett, published in Salt Lake City, Utah in 1988 at the Center for Pyrometallurgy Symposium. That paper is hereby incorporated into this application by reference.
The referenced paper describes efforts to evaluate improvements in bath smelting processes for iron ores by flash melting particulate ores as they are descending to the bath. To do this, the ore particles are injected with a carrier gas and allowed to react with the bath off-gases as they rise between the bath and injector.
Partial reduction of iron oxide particles is initiated as the ore particles are delivered to the bath. This occurs in a quasi-counter current system in which the rising reducing gases flow by the descending ore particles. The difficulties perceived in this system revolved about the very short free flight residence time of the particles, which particularly limited pre-smelting reduction of larger ore particles.
The principle of cyclone firing entered practical boiler construction in the nineteen forties. The appeal of the cyclone configuration is that it gives flash combustion efficiency through turbulence enhanced mass and heat transfer and reaction rates. Pyrometallurgical processes using cyclones were first suggested in the mid-1950's, when a plant was built in Sardina to treat antimony concentrates. Another early use was developed in the USSR for copper concentrates.
As mentioned in the referenced paper, high temperature entrained flow smelting (e.g. cyclone smelting) has been suggested as an alternative to bath smelting to use pulverized coal and dry iron ore concentrate. The application of cyclones to iron ore reduction was first attempted in 1955. The research was not successful and was terminated in 1966.
The ability to produce iron through the use of fine particulate ores and coal as starting materials is significant due to: the phase-out of coke ovens and the environmental costs associated with coking, the need for a coal-based iron process, the existence of a large amounts of fine taconite, and the fact that a process based upon treating fine particles would be more economic because pelletizing and pellet induration would not be required.
The presently-described use of a cyclone reactor to partially reduce iron ore fines pores a number of advantages, for example: utilization of waste producer gas from the primary smelting furnace, high throughout being possible in a small reactor, enhanced heat and mass transfer rates, increased mixing of particles and gases due to high turbulence, use of high reaction temperatures, rapid reaction times available when dealing with small particles, elimination of induration, the use of coal in place of coke, and rapid separation of liquids and gases.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention is illustrated in the accompanying drawings, in which:
FIG. 1 is a diagrammatic view of the present system;
FIG. 2 is an equilibrium diagram plotting iron content as a function of temperature and CO 2 content in the exiting mixture;
FIG. 3 is a prior art depiction of a plot of time for complete reaction as a function of particle size;
FIG. 4 is a plot of time for complete reaction as a function of the ratio of CO to CO 2 ;
FIG. 5 is a plot of time for heating and melting as a function of particle size;
FIG. 6 is a plot of time for heating and melting as a function of gas temperature for 160 micron particles;
FIG. 7 is a plot of energy balance estimations assuming constant wall temperatures of 1370° C.; and
FIG. 8 is a schematic representation of the experimental system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following disclosure of the invention is submitted in furtherance with the constitutional purpose of the Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).
The disclosed cyclone reactor according to this disclosure is lined with non-reactive refractory material. It can be effectively operated at temperatures in excess of 1400° C. (typically 1500° C.) and encompasses a reducing atmosphere. Fine particulate ores, such as a taconite concentrate or a ferro-alloy ore, and either a fuel gas or a producer gas (mostly carbon monoxide and carbon dioxide), or both, are fed tangentially into the cyclone. When desired, a stream of particulate coal might also be used as the primary or supplementary fuel for the reactor.
Fine particulate ore, such as taconite, can be melted and reduced to iron, wustite and some iron carbides during its residence time in the cyclone reactor. The resulting molten product is discharged from the bottom of the cyclone, where it can flow directly into an iron smelting bath. If desired the reactor can be uncoupled from and operated independently of the bath smelter.
The production process that occurs within the cyclone reactor preferably burns oxygen or oxygen-enriched air with excess quantities of CO rich producer gas to provide the required reaction heat while maintaining an adequately reducing chemical potential in the combustion gases. The producer gas used within the cyclone reactor will typically be the off-gas from the bath smelting furnace associated with the reactor.
The apparatus and method are generally illustrated in FIG. 1. A conventional bath smelter is shown at 10. Coal and oxygen are injected into the molten metal reaction zone for direct-reduction purposes. Slag and hot metal are separated as shown to the left in FIG. 1, and the resulting off-gases are typically discharged for heat-recovery or cogeneration purposes.
In most bath smelting processes, the incoming ores are formed into pellets fed continuously into the bath smelter 10. The production of such ores initially requires that they be ground to a fine state prior to the pelletizing step. One object of this disclosure is to utilize the finely ground particulate ores without the costs and energy requirements of pelletizing.
In the present apparatus, the particulate iron or ferro-alloy ores are melted and partially reduced prior to introduction into the bath smelter 10. This is accomplished within a cyclone reactor 11. Feed means 12 is provided for directing a stream of fine ore particles into the cyclone reactor 11.
An external burner 13 can be used to direct a tangential stream of burning gases into the upper end of the cyclone reactor 11. These gases will normally comprise oxygen or oxygen-enriched air and waste producer gas from the bath smelter 10. Fuel gases, such as methane or natural gas, can be used in place of all or part of the producer gas when desired. The waste producer gas must first be cooled within a boiler 14 or other heat exchanger to lower its temperature to the handling temperature required for introduction into the cyclone reactor 11. Excess off-gas can be directed to a boiler 15 for combustion or for cogeneration purposes.
It is to be understood that the reducing gas or fuel material and the oxygen/air supply can be separately introduced into the cyclone reactor 11 in tangential streams by use of two or more injector nozzles (not shown) for this purpose. Additionally, an ignitor (not shown) must be provided to initiate burning when the cyclone reactor is being brought up to an equilibrium operating temperature. Once burning has been achieve, the system will be continuously operated and the gases will combust as they are introduced.
As diagrammatically shown in FIG. 1 the preferable location of the cyclone reactor 11 is immediately above the reaction zone within the bath smelter 10. The cyclone reactor is shown as a closed-top reactor having an open conical exit 16 positioned above the smelting bath within the bath smelter 10. The melted and partially reduced ore will collect about the conical walls of the cyclone reactor 11 and fall by gravity into the bath. At the preferred reaction temperatures, the melted ore will be preheated to the bath temperatures within the bath smelter 10, thereby contributing to higher efficiency of bath smelter operation.
Testing and calculations to date have shown that partial reduction of fine particulate iron or ferro-alloy ores is practical for a full scale refractory-lined cyclone reactor that is gravity-coupled to a bath smelter system. Typical particle residence times in the cyclone can range up to 10 seconds. Equilibrium temperatures within it can range between 1300°-1650° C. The system can effectively handle particle sizes below 150 microns.
THERMODYNAMIC ANALYSIS
The ability to reduce iron-based ores at high temperatures depends upon the equilibrium partial pressure ratio of carbon monoxide to carbon dioxide at the exit end of the cyclone reactor 11. This relationship for iron ores, such as taconite, is shown in FIG. 2. It shows equilibria between iron, wustite, magnetite and carbon monoxide, carbon dioxide and carbon at P CO +P CO .sbsb.2 =1 bar. As one example, at an average reactor temperature of 1500° C. (1773° K.) and an exit carbon monoxide to carbon dioxide partial pressure ratio of 1 (50% CO 2 , the product would be mostly molten wustite (melting point=1378° C. (1651° K.)). The volume ratio of CO 2 to CO and the equilibrium temperature at the exit end of the reactor can be chosen at any combination of values encompassing the wustite regions shown in FIG. 2 or those iron regions to the left of them.
The molten wustite and/or iron produced in the cyclone reactor 11 will collect certain impurities, such as: sulfur, carbon, etc. The solubilities of these impurities in the molten phases have been evaluated preliminarily. Experiments have confirmed that such impurities might be contained in the molten product leaving the cyclone reactor.
KINETIC CONSIDERATIONS
The rates at which suspended ore particles are reacted, heated, and melted may be estimated using transport models for the individual particles, assuming average gas compositions and temperatures.
The rate of the reduction reaction is assumed to be controlled by either fluid film mass transfer or pore diffusion of the carbon monoxide. The time required for complete reaction of the magnetite particles, as a function of their size is shown in FIG. 3. The time values for fluid film mass transfer are illustrated by plotted line 20. The time values for pore diffusion control are illustrated by plotted line 21.
Similarly, the time for complete reaction is shown in FIG. 4 as a function of the carbon monoxide to carbon dioxide partial pressure ratio. Values for fluid film control are plotted along line 22, while values for pore diffusion control are plotted along line 23.
The rates of heating and melting of iron ore particles can also be calculated as functions of temperature and particle size. The heat loss to the cyclone reactor walls can also be estimated, using basic energy transport equations. The rate of heat loss depends primarily upon the wall heat transfer coefficient, wall emissivity, available surface area, and the wall temperature. Predicted rates are shown in FIGS. 5 and 6, as functions of temperature and size, respectively. In these plots, line 24 shows time to heat, line 25 shows time to melt, and line 26 shows total time.
The heat loss to the cyclone reactor walls can also be estimated, using basic energy transport equations. The rate of heat loss depends primarily upon the wall heat transfer coefficient, wall emissivity, available surface area, and the wall temperature. These effects are shown in FIG. 7.
REACTOR DESIGN CONSIDERATIONS
Among the reactor design considerations that were evaluated in the development of the cyclone system, were: methods to heat the reactor to high temperatures, reactor size, plasma gas requirements, residence time calculations, time to react, heat and melt, energy requirements, energy and material balances, wall construction, and insulation. A clear plastic model was used in measuring particle flow patterns within the cyclone reactor 11.
REACTOR HEAT UP
Because large amounts of plasma gases are required to heat the cyclone reactor to 1500° C. (1773° K.), a natural gas burner system was designed to provide initial heat up of the reactor system. The burner was shut and plugged and the plasma torch started after heat up. The reactor may also be heated using the plasma system alone.
REACTOR SIZE
The reactor size was chosen based upon the residence time requirements that were calculated for individual particles, the overall energy balance, and the amount of plasma gas required (6-8 scfm) to provide the heat to the system. The test cyclone reactor, diagrammatically shown in FIG. 8, has an inside diameter of 9 inches and an axial length of 2 feet. The lower conical section has an axial length of 4 inches and narrows to an exit diameter of 3 inches. Typical residence times for iron ore particles in the operational reactor were about 11/2 seconds.
Once it was determined that it was possible to extend the residence time (through the clear plastic model studies) and that it was possible to use nitrogen in place of helium in plasma torch (2-3 scfm); it was determined that the initial hot cyclone reactor was oversized. The residence time was determined to be one and one half times greater than that calculated to be necessary.
PLASMA GAS REQUIREMENTS
The non-transferred plasma arc torch used in this study (PT50 from Plasma Energy Corporation) requires fixed flow rates of the plasma gases in order to generate the required energy. The flow rates required to achieve 50 kw (50 kj/sec) of power were 2.0 ft 3 /min (0.05664 m 3 /min) of argon and 1.0 ft 3 /min (0.02832 m 3 /min) of nitrogen.
RESIDENCE TIME CALCULATIONS
All of the preliminary residence time calculations assumed plug flow. These estimates were improved by the clear plastic model study. Due to the formation of a liquid wustite phase in the reactor, the residence time may approach that of a falling film reactor, which would extend the residence time; but the host and mass transfer rates may be decreased drastically.
ENERGY AND MATERIAL BALANCES
Detailed energy and material balance calculations have been performed and the energy balance calculations have been compared to those obtained from the experiments. Energy losses in the various sections of the cyclone reactor 11 have been within expected ranges.
WALL CONSTRUCTION AND INSULATION
The original design called for the formation of wustite skull on the reactor wall to protect it from interaction with the liquid product. This would have required maintaining the inner wall temperature somewhat below 1378° C. (1651° K.), using a thin refractory, water cooled wall. Energy losses through the walls, under these conditions, are too large and an inhibitively large taconite flow rate would be required to obtain a skull of any appreciable thickness. The current graphite wall design in an experimental cyclone reactor allows the walls to reach temperatures near the gas temperature. The graphite inner wall is insulated with graphite felt. The reactor has a water cooled shell. However, graphite is reactive with iron. A suitable non-reactive refractory material should be selected for more permanent installations.
CLEAR MODEL STUDIES
The flow patterns in conventional open gas-solid cyclones have been studied and modeled in detail. These cyclones have a gas discharge at the top that may carry out some of the fine particles. The cyclone used in this study is closed and all of the material discharges out of the bottom. There have been very few fundamental flow studies performed on closed cyclones. The clear model studies were performed to provide fundamental information on the flow of the gases and solids in a closed cyclone of the same size and shape as planned for the hot cyclone.
The clear plastic model was used to measure the gas velocity and pressure profiles using a hot wire anemometer. The measured tangential, radial, and axial velocities were recorded and then used to plot the flow fields in the cyclone. The clear model was also used to study the flow pattern of the ore particles using a time frame video camera.
GAS VELOCITY DISTRIBUTIONS
The measured tangential gas velocity distribution along the radial coordinate, at several axial positions within the cyclone, was observed to have low velocities near the wall and the center line, with a maximum velocity that shifted, slightly, from the outside-in down the length of the reactor. The maximum tangential velocity was measured near the wall at the top of the cyclone, but then shifted towards the center through much of the length. The minimum tangential velocity was always near the center line.
The axial velocity, at any axial position, increases from the wall towards the center line. The minimum was always near the wall and the maximum near the center. The center line axial velocity increases down the length of the reactor and may provide a short circuit for some of the particles.
GAS FLOW PATTERN
The gas flow pattern in the cyclone is a changing radial spiral pattern with a short circuit in the center of the cyclone. A high velocity spiral surrounds the center line and the low velocity flow region is near the walls.
SOLID FLOW PATTERN
The solids flow pattern has been observed experimentally and an attempt is being made to model the behavior of the solids as they travel down the reactor. The particles enter a turbulent region near the top, but are quickly thrown out towards the walls. The particles travel down the cyclone walls in spirals as they melt. The distance between each spiral is independent of the gas flow rate, but the particles appear to travel faster at higher gas flow rates. The location of the spirals also depends upon the geometry of the discharge cone.
PARTICLE RESIDENCE TIME
The particle residence time, using taconite fines as commercially produced, was measured using a time frame video camera. This value varied almost linearly, ranging from about 1.2 seconds at an air flow rate of 30 CFPM to about 0.6 seconds at an air flow rate of 90 CFPM.
CYCLONE EXPERIMENTS
A schematic of a test hot cyclone system is shown in FIG. 8. The system used a non-transferred arc plasma torch 30 for a heat source. The torch 30 was operated under the standard conditions for the cyclone reactor 11 as given in Table I.
TABLE I______________________________________STANDARD OPERATING CONDITIONS______________________________________240-250-VOLTS, 19-200 AMPS2.0 FT.sup.3 /MIN ARGON, 1.0 FT.sup.3 /MIN NITROGEN20 VOLUME % CARBON MONOXIDE,5 VOLUME % CARBON DIOXIDE(Incoming Gaseous Mixture)50 GRAMS/MINUTE TACONITEPOWER: 45-50 KILOWATTS______________________________________
Plasma gases were injected tangentially into the cyclone reactor 11. The taconite concentrate powder tested was primarily magnetite, as is shown in Table II.
TABLE II______________________________________LTV STEEL TACONITE SAMPLE ANALYSIS______________________________________67.04% Fe4.50% Silica0.20% p(67.68% Fe.sub.3 O.sub.4 & 25.94% Fe.sub.2 O.sub.3 calculated)______________________________________
The taconite powder was fed axially with a powder feeder 31 using carbon dioxide and argon as the carrier gases. Carbon monoxide was fed, also axially, at the rate determined to allow the development of a known discharge ratio of the partial pressures of carbon monoxide and carbon dioxide. The gas composition was sampled at the discharge and analyzed with a gas chromatograph 32.
Temperatures were measured at three locations inside the reactor. Temperatures and water flow rates were monitored for all the cooling lines. All of the data were collected on a data acquisition system with a computer 33.
The experiments were performed by: (1) Heating the cyclone reactor 11 to a uniform discharge temperature (typically 1500° C. (1773° K.)), (2) Feeding the taconite particles, carbon monoxide, and carbon dioxide into the heated cyclone reactor 11, and (3) Collecting gas, liquid and solid samples from the exit or discharge end of the cyclone reactor 11 for analysis.
Samples collected during study state operation were of primary interest. After cooling, solid samples were collected and subjected to chemical and physical characterization.
An example of our preliminary experimental results is given in Table III.
TABLE III______________________________________OPERATING CONDITIONS AND RESULTS______________________________________OPERATING CONDITIONS:CURRENT: 195-197 AMPS. VOLTAGE: 235-250 VOLTSPOWER: 45.8-49.3 KILOWATTSAr TORCH FLOW RATE: 2.1 SCFM.N.sub.2 TORCH FLOW RATE: 0.9 SCFMCO FLOW RATE: 0.7 SCRF.Ar CARRIER FLOW RATE: 0.35 SCFMTACONITE FEED RATE: 50 GRAMS/MINUTETOP WALL TEMP: 1550 C. CENTER TEMP: 1675 C.EXIT TEMP: 1425° C.IRON ANALYSIS:INGOT IRON CONTENT: 90.4% FeFEED IRON CONTENT: 68.4% Fe______________________________________
In compliance with the statute, the invention has been described in language more or less specific as to structural features. It is to be understood, however, that the invention is not limited to the specific features shown, since the means and construction herein disclosed comprise a preferred form of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | A closed-cover hot cyclone reactor is used to melt and partially reduce particulate iron or ferro-alloy ores fed to it in a stream. Tangential streams of fuel gas or, preferably, producer gas supplied by an associated bath smelter, interact with the spiralling particles as they pass through the reactor. The molten metal travels downwardly along the reactor walls and can be discharged by gravity onto the receiving bath. The system eliminates the need for pelletizing ore and coking coal in smelting of iron products. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a Continuation application which claims the benefit of priority from U.S. non-provisional application Ser. No. 12/804,685, filed on Jul. 26, 2010, and said non-provisional application being incorporated herein by reference. This application further claims priority from U.S. Provisional Application, Ser. No. 61/271,842, filed on Jul. 27, 2009, said provisional application being incorporated herein by reference.
FEDERALLY-SPONSORED RESEARCH & DEVELOPMENT
There is no federally sponsored research or development in connection with this inventive concept.
NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
There is no joint research agreement applicable to this inventive concept.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present inventive concept, among other uses and applications, primarily relates to an improved surgical instrument and a method which will enable a physician to perform laparoscopic or endoscopic surgery with a minimum amount of bodily incisions to a patient's body. The device under consideration is an improvement on what is known in the medical profession as a grasper.
Graspers come in a wide of variety of functional designs, which are intended for specific purposes. Various types of graspers include tissue, claw, sharp tooth, endo-clinch, alligator, aggressive, cobra tooth, spoon, cup, babcock, DeBakey, and Allis graspers.
(2) Description of the Related Art
Graspers are used to clasp bodily tissue or an internal organ and, often to reposition the tissue or organ for better utilization of other instruments which may be required during a laparoscopic surgical process. The grasper is typically inserted into the abdominal cavity by means of insertion through the inner channel of a trocar, said trocar having been initially used to pierce the abdominal wall in the vicinity of the subject organ or tissue. Usually, a second trocar is also required as a means of inserting other surgical instruments to perform operations on the organ or tissue being held by the grasper.
Over the years, various surgical instruments and complex trocar designs have been devised to perform separate multiple functions during laparoscopic surgery. A recent patent, U.S. Pat. No. 7,318,802 (Suzuki, 2008), discloses a combination of an endoscope and a grasping, device which, when used together, are suited for operationally treating gastro esophageal reflux disease. The grasping device is specially designed for holding tissue formed at the junction the stomach and esophagus.
U.S. patent application publication #2005/0149066 (Stafford, 2005) presents a device for laparoscopally suturing tissue, comprising an elongated shall which, upon being inserted through the abdominal wall, deploys two mechanical arms, each arm having a means of receiving a needle and its respective suture.
U.S. patent application publication #2009/0062816 (Weber, 2009), discloses an apparatus comprising a manually operated handle attached to the proximal end of a lengthy shaft. The handle further comprises two separate mechanical operating devices, one being attached to a pair of grasping jaws at the distal end of the shaft and the other device serving to advance suture to two needles, also at the distal end of the shaft. The handle may mechanically advance the suture.
U.S. patent application publication #2007/0123914 (Lizardi et al, 2007) presents a needle passer instrument which has a needle engaging cartridge in the upper jaw and a surgical needle with attached suture mounted in the lower jaw. A needle actuation rod engages the surgical needle and pushes the needle through tissue contained between the jaws of the device.
BRIEF SUMMARY OF THE INVENTION
The present inventive concept, among other uses and applications, relates to an apparatus and method by which a physician may perform laparoscopic or endoscopic surgery within the abdominal cavity of a patient. The device gives the physician/surgeon a unique capability to reposition a body organ or tissue during the surgical procedure. An important object of the disclosed apparatus and method is to minimize the number of incisions and/or trocar placements into the abdominal wall during the course of a surgical procedure, while providing enhanced tissue positioning and retraction capability to the physician.
The primary components of the apparatus include a detachable grasping device comprising a detachable head, a grasper handle removably fixed to the detachable head, at least two needles on suture, which needles may be removably attached to the detachable head, and a storage handle, referred to as a “puppet handle,” said handle maintained exteriorly to the abdominal wall. The detachable head may be separated from the grasper handle either exteriorly to the patient or after insertion into a patient proximate the actual operation situs.
Initiation of the surgical process is begun with the placement of a trocar through the abdominal wall of the patient. The grasping device is inserted through the channel of the trocar and positioned proximate the organ or tissue to be operated upon. For illustrative and ease of reference purposes only, the object of the surgical manipulations may be interchangeably referred to as “organ” or “tissue.” Once the tissue is grasped by the detachable head of the grasping device, the grasper handle is removed from the detachable head. A secondary grasper is then inserted through the trocar for the purpose of removing the first of the two needles on suture from its retention means on the detachable head. The respective suture remains within its retention mechanism on the detachable head. The secondary grasper is then manipulated to a desired location or exit point on the interior of the abdominal wall, at which exit point the first needle and suture is impelled outwardly through the abdominal wall.
The foregoing procedure is repeated with the second needle and suture. Once outside the abdominal wall, the two needles and sutures are inserted into opposite ends of the puppet handle. The storage handle then becomes the means by which the operator may retract or reposition the organ as required for better vision and assessment during the surgical procedure. The puppet/storage handle may move either of the two stored needles/sutures, thereby directly re-positioning the organ at the point where the detachable head is grasping the tissue.
The reader is advised that, for the sake of convenience and clarity, the operation of this device has been described primarily with respect to the human body. However, the inventive concept is also suitable for use by veterinarians and other professionals where anatomical procedures internal to a vertebrate body are necessary. Therefore, the descriptions rendered herein are not considered to be restrictive or limiting of the operation of the device.
BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS
A more thorough understanding of the present invention and fabrication system may be had by reference to the drawings herein, of which a brief summation of each drawing follows:
FIG. 1 is an overall view of the general positioning, functions, and maneuvering methods utilized with the basic inventive concept.
FIG. 2 depicts a stylized concept of a universal grasper device with a detachable head, the device also referred to as a separable grasping device
FIG. 3 illustrates a partial cutaway view of an embodiment of the distal end of a separable grasping device and the detachable grasper head.
FIG. 3 a depicts the proximal end of a separable grasping device, its grasper head detaching means, and its jaws locking means.
FIG. 4 presents the open position of the grasper jaws of an embodiment of the detachable head.
FIG. 4 a and FIG. 4 b combined illustrate the clutch and clutch housing of a particular embodiment of detaching means of a separable grasping device.
FIG. 4 c depicts the union of the clutch and clutch housing of an embodiment of the separable grasping device.
FIG. 5 illustrates a cutaway view of the threaded locking rod, which enables operation of the jaws of an embodiment of a detachable grasper head.
FIG. 5 a presents an end view looking interiorly at the clutch of an embodiment of the separable grasping device.
FIG. 5 b presents a view of the clutch housing.
FIG. 6 depicts the method of positioning of two detachable heads onto a bodily organ during a surgical procedure.
FIG. 7 is a plan view illustration of an embodiment of a dual puppet handle, as seen from the perspective of the physician holding the instrument.
FIG. 7A is a left (or right) side end view of the dual puppet handle, of FIG. 7 , above.
FIG. 8 illustrates a triple-stem puppet handle.
FIG. 9 depicts the stowage of a separable grasper handle onto the upper surface of a dual puppet handle.
FIGS. 10 a through 10 c present a different embodiment of the separable grasper device wherein the internal operating mechanism is two interconnecting drive shafts.
Numerical Index to Nomenclature of Invention
1.
Separable grasping device
2.
Grasping handle
3.
(a) Grasping handle proximal end
(b) Grasping handle distal end
4.
Endoscope
5.
Detachable head
(a) Second detachable head
6.
Upper jaw
7.
Lower jaw
8.
Jaws locking means
(a) Jaws locking mechanism
(b) Locking rod control
9.
Head detaching means
9(a) Head detaching mechanism
10.
Upper jaw motion linkage
11.
Lower jaw motion linkage
12.
Needle one fastening means
13.
Needle two fastening means
14.
Needle one
15.
Needle two
16.
Suture one
17.
Suture two
18.
Suture one harnessing means
19.
Suture two harnessing means
20.
Dual puppet handle
(a) Left handle stem
(b) Right handle stem
(c) Extra handle stem
21.
Triple-stem puppet handle
22.
Multiple-stemmed puppet handle
23.
Puppet handle connector means
24.
Exit point one
25.
Exit point two
(a) Exit point three
26.
Secondary grasping device
27.
Inner abdominal wall
28.
Outer abdominal wall
29.
Body organ
30.
n/a
31.
Needle three
32.
Needle four
33.
Third Suture
34.
Fourth Suture
35.
Working port
36.
Needle driver
37.
Compressible material
38.
Universal grasper device
39.
Release mechanism
40.
Needle one retainer
41.
Needle two retainer
42.
Pins: a), b), c), d)
41.-49,
n/a
50.
Square drive shaft (hollow)
51.
Driven shaft (square)
52.
Sleeve
53.
Circumferential groove
54.
Spring-loaded ball
55.
U-joint
56.
Locking ring
57.
Control wheel
58.
Gripping handle
59.
Grasper head housing
60.
Housing for detachable head
(a) Stator
61.
Threaded receptor
61
(a) Spring-loaded ball
(b) Recessed seat
62.
n/a
63.
Clutch
63.
(b) Clutch housing
64.
Threaded locking rod
65.
Handle shaft
DETAILED DESCRIPTION OF THE INVENTION
The description of this inventive concept will begin with reference to FIG. 1 , where it can be seen that the general objective of the inventive concept is to attach the distal ends of suture one 16 and suture two 17 to the surgical object, which for illustrative and descriptive purposes only, will be assumed to be a body organ 29 , by means of a detachable grasper head 5 . The proximal ends of the sutures 16 , 17 , having been attached to needles 14 , 15 , are removed from the abdominal cavity by piercing, from inside to outside, the abdominal wall 28 . For the sake of convenience and easy reference, said needles 14 and 15 shall be referred to as Keith needles, although any other surgical needle suitable for the purposes herein may also function in this inventive concept.
Exterior to the patient's body, the Keith needles 14 , 15 are then inserted into the respective stems 20 a , 20 b or ends of a dual- or multiple-tube storage handle, referred to as a “puppet handle” 20 . The stems 20 a , 20 b of the puppet handles presented may be constructed with a variety of means for retention of the abdominally exiting needles, 14 , 15 . As shown in FIGS. 7 and 7A , the preferred embodiment comprises a compressible material 37 firmly compacted into the interior of each stem 20 a , 20 b to securely retain the needles 14 , 15 after exiting the abdominal cavity 28 The dual puppet handle 20 may then be manipulated by the physician, at a variety of gentle pulling angles, to retract or reposition the body organ 29 . An elementary puppet handle 20 is illustrated in FIG. 1 , FIG. 7 , and FIG. 9 . A multiple-stem puppet handle 21 is shown in FIG. 8 .
Any surgical procedure requiring piercing of a patient's abdominal cavity may be initiated by the placement of an initial trocar device through the outer and inner abdominal walls 28 , 27 , respectively. The penetration point of the initial trocar becomes the working port 35 for the surgery. Utilizing the initial trocar, an endoscope 4 may be inserted into the channel of the trocar or through the working port 35 created by the initial trocar. The endoscope 4 is then maneuvered to position the instrument proximate the body organ 29 which is the subject of the surgical procedure. The trocar may need to be gradually pressed to a greater depth, since immediately afterwards, the separable grasping device 1 is inserted, parallel to the tube of the endoscope 4 , through the channel of the initial trocar or through the working port 35 .
By turning the attention to FIG. 6 , it is observed that greater capability for surgical adaptation is provided, with the insertion of a second detachable head 5 a attached to a different location on the body organ 29 . Thus, the physician may make more accurate, or differently-oriented, placements of the body organ 29 for better access. The second detachable head 5 a may be manipulated via its own third suture 33 , which will likely be affixed to a third stem of the puppet handle 21 (as depicted in FIG. 8 ). Either or both the primary detachable head 5 or the second detachable head 5 a may be constructed with wing clamps so as to remove the detachable heads 5 , 5 a , as necessary.
FIG. 2 depicts a general drawing of a generic universal grasper device 38 which is typical of embodiments of the inventive concept. The device may operate by several differing combinations of means for, and methods of connection. Once the device 38 is inserted through the initial trocar, the grasper's upper jaw 6 and lower jaw 7 are placed at the desired site on the subject tissue or body organ 29 . The jaws 6 , 7 must comprise non-traumatic teeth or Babcock type heads. Upper jaw 6 and lower jaw 7 motion control means 10 , 11 are then operated through a connective means to gently close the grasper's upper jaw 6 and lower jaw 7 at the selected location. A jaws locking means 8 may be operated, through a jaws locking mechanism 8 a , to securely attach the grasper head 5 to the body organ 29 . The jaws locking means 8 may be an industry-common slide lock ratchet system, a rotary-type mechanism, or other means of securing the jaws 6 , 7 of the grasper in a locked position.
Generally, the detachable grasper head 5 can be separated from its grasping handle 2 by a head detaching mechanism 9 a which transmits control inputs through linkage to a head detaching means 9 . At the time of separation, the needle one retainer 40 and needle two retainer 41 are also activated so as to release needle one 14 and needle two 15 . Suture-harnessing means 18 , 19 hold the respective sutures for needle one 14 and needle two 15 . The suture-harnessing means 18 , 19 may be small eyelets or hook-type retainers with inner diameters somewhat larger than the gauge of suture utilized. The two needles remain close to the grasper head 5 for the ensuing capture by a needle driver which is used to execute a piercing-type exit of each needle 14 , 15 and its respective suture through the abdominal wall 28 .
In turning the attention to a different embodiment, FIG. 3 and FIG. 3 a show a separable grasping device 1 which is observed to be a combination of a grasping handle 2 , disconnected from its detachable grasper head 5 . The detachable grasper head 5 further comprises an upper jaw 6 , lower jaw 7 , an upper jaw motion linkage 10 , a lower jaw motion linkage 11 , a threaded receptor 61 , and a head detaching means 9 . In viewing FIGS. 3 and 3 a , another embodiment of the inventive concept depicts a jaws locking means accomplished by a threaded locking rod 64 , handle shaft 65 , a locking, rod control 8 b , and two suture harnessing means 18 , 19 . Provisions may also be made for needle retention mechanisms proximate, or on, the detachable grasper head 5 .
At the proximal end of the separable grasping device 1 , as shown in FIG. 3 , the upper and lower jaw motion control linkages 10 , 11 are operated by the threaded locking rod 64 so as to open the upper and lower jaws 6 , 7 of the detachable head 5 . While viewing the operational site through a laparoscope 4 , the upper and lower jaws 6 , 7 , being in the closed position, are maneuvered into a desired location adjacent to a body organ 29 . The jaws are thereupon opened and then closed upon the organ 29 . Appropriately placed pins 42 a - d , connecting the threaded locking rod 64 and the upper and lower jaw motion linkages 10 and 11 effectuate the opening and closing of both jaws 6 , 7 .
A dual-component threaded receptor 61 consisting of a clutch 63 having internally-embedded spring-loaded balls 61 a , is integral to the grasping handle 2 . The threaded receptor 61 further comprises a coaxial fitting having recessed seats 61 b corresponding to the circumference of the spring-loaded bails 61 a . A handle shaft 65 culminates in a threaded locking rod 64 . The threads of the locking rod 64 engage compatible threads on the interior surface of a stator 60 a . The stator 60 a is permanently affixed to a detachable head housing 60 .
The threaded receptor 61 , comprising a spring-loaded ball 61 ( a ) and a recessed seat 61 ( b ), prevents further movement of the threaded locking rod 64 at certain rotated extensions of the locking rod control 8 b and the handle shaft 65 , thereby locking the jaws 6 , 7 and securely maintaining the body organ 29 within the grasp of the detachable head 5 . If necessary, a second separable grasping device 1 ( a ) may be inserted into the initial trocar with another detachable grasper head 5 ( a ), as shown in FIG. 6 , and a separate length of a third suture 33 for additional retraction capability.
Referring to FIG. 3 a , at the grasping handle proximal end the head detaching means 9 is activated to disengage the spring-loaded balls 61 ( a ) from their respective recessed seats 61 ( b ), thereby separating the detachable head 5 from the grasping handle 2 . The grasping handle 2 is then removed from the initial trocar and placed in temporary storage within the puppet handle 20 connector means 23 . Suture one 16 and suture two 17 , being previously attached to needle one 14 and needle two 15 , are now prepared for being drawn through suture one harnessing means 18 and suture two harnessing means 19 , respectively. To accomplish this, a specialized grasper or needle driver 36 is inserted into the channel of the initial trocar and maneuvered into position to grasp each needle 14 , 15 , in sequence. Each needle is then positioned upward toward desired respective abdominal exit point one 24 and exit point two 25 , as illustrated in FIG. 1 .
Again referring to FIG. 1 , at the exterior of each exit point 24 and 25 , each of the two surgical needles 14 , 15 , along with their respective sutures 16 , 17 , are pulled through the outer abdominal wall 28 . The needles 14 , 15 are then firmly pushed into the compressible material 37 compacted into the respective stems 20 ( a ), ( b ) of the dual puppet handle 20 . After completion of extraction of the needles, the needle driver 36 is then withdrawn upwards through the initial trocar and properly stored. At this point, the operator may place other surgical instruments into the immediate vicinity of the body organ 29 . The respective exteriorly-exposed sutures 16 , 17 are secured at the dual puppet handle 20 so as to enable a physician, with reference to the endoscope 4 previously inserted, to position and/or retract the body organ 29 as necessary, by well-planned incremental movements of the puppet handle 20 .
FIG. 9 demonstrates the manner in which the handle 2 of the separable grasping device 1 is attached for storage to the upper surface of a dual puppet handle 20 while the associated detachable head 5 is in use during the surgical procedure.
FIGS. 10 a through 10 c illustrate the basic workings of another embodiment of the inventive concept. FIG. 10 a depicts an embodiment of the detachable head 5 of a separable grasping device with the upper and lower jaws 6 , 7 in the closed position. Internal to the detachable head 5 , and coaxially centered with the detachable head 5 , is a driven shaft 51 of square cross-section which, when rotated clockwise along its axis, expands or contracts a tensionally-loaded locking ring 56 . The locking ring 56 , comprised of at least one winding, is affixed at one of its ends to a grasper head housing 59 , and at its opposite end to the driven shaft 51 . FIG. 10 a shows the locking ring 56 having been expanded to near its limit, thereby causing the upper and lower jaws 6 , 7 to close. FIG. 10 c depicts the locking ring 56 having been tensionally released by reason of the driven shah 51 having been rotated in the counter-clockwise direction, thereby allowing the upper and lower jaws 6 , 7 to open.
In FIG. 10 b , the handle 2 of a separable grasping device is seen to comprise a longitudinal sleeve 52 , which expands at its distal end into a circular u-joint 55 . The u-joint 55 contains integral spring-loaded balls 54 symmetrically spaced around the inner perimeter of the u-joint 55 . Contained within the sleeve 52 is a drive shaft 50 , comprising a hollow, square cross-section which runs from the distal end of the sleeve 52 to its juncture, at the proximal end of the sleeve 52 , with a control wheel 57 . The hollow drive shaft 50 is of precise inner cross-sectional dimensions so as to allow a snug fit over the outer walls of the driven shaft 51 . In this manner, when the detachable head 5 and the handle 2 are conjoined via the u-joint 55 and the groove 53 of the detachable head 5 , the drive shaft 50 , by means of the control wheel 57 , can incrementally turn the driven shaft 51 .
Also connected at the proximal end of the handle 2 is a gripping handle 58 which, by longitudinal connection means, operates to release the spring-loaded balls 53 from the circumferential groove 53 , thereby disengaging the detachable head 5 .
Variations of Equipment and Methods
By the nature of the surgical procedures presented herein, it is evident that other variations of the devices and the methods may be utilized, according to the medical requirements of a particular surgical procedure. As an alternative structure or embodiment of the disclosed device, a quadruple stem, or larger, puppet handle may also be utilized. As shown in the accompanying FIG. 8 , the abdominally exiting needles, needle one 14 and needle two 15 may be stored in a similar compressible material 37 as shown in the triple puppet handle 21 . To improve the versatility of operational use of the puppet handle, the stems may be joined at a common pivoting junction, serving to vary the relative angles between stems during surgery.
All embodiments of the puppet handles presented thus far may be constructed with a variety of means for retention of the abdominally exiting needles, 14 , 15 , said means including, but not limited to, latching, clamping, grasping, hooking, constricting, and clutching. In other words, the compressible material 37 is not the sole means of securely retaining the abdominally exiting needles 14 , 15 in, or proximate to, the stem of a particular puppet handle.
It is recognized that one knowledgeable in the medical industry and skilled in the art, has the capability to design or produce similar, or other embodiments of this inventive concept. However all such variations, alterations, or modifications are entirely conceivable as being within the intent and scope of the present inventive concept. In particular, the essence of the inventive concept is the utilization of at least two surgical graspers comprising a detachable grasper head containing at least one length of suture, combined with the method of performing surgical manipulations with sutures attached to said grasper head and controlled exteriorly of the abdominal wall. Any number of connections, disconnecting methods, operational linkages, functions, and combinations thereof may be used to effectuate the engagement and disengagement of the detachable grasper head from its handle component. | A surgical device and method for the retracting, maneuvering, and re-positioning of tissue and/or a body organ during endoscopic and laparoscopic procedures. The surgical apparatus comprises at least one separable grasping device with a detachable head, and an exteriorly-operated handle mechanism, or puppet handle. The disclosed device enables a physician, using a plurality of lengths of sutures simultaneously connected to (a) stems of the exteriorly exposed puppet handle and (b) the detachable head, positioned at clasping points on the organ, to rearrange the orientation of tissue or the organ for better accessibility, analysis, and/or exposure to accompanying surgical instruments in situ. The method presented minimizes the number of bodily incisions required to perform surgery by means of endoscope or laparoscopic equipment. | 0 |
BACKGROUND OF THE INVENTION
The invention is directed to a method for the control of a weaving machine and a weaving machine for implementing the method.
Methods and weaving machines of the type mentioned in the beginning are known, for example, from CH-PS No. 590 358. In this method and this weaving machine, after the weaving machine is stopped because of the breaking of a warp yarn, the shafts are moved back into the shedding crossing point by means of the motor of a pick finder via the shedding device, from which shedding crossing point the weaving machine starts on a starting signal in phase balance with the weaving machine and triggers the continuation of the normal weaving process. This weaving machine contains no control device for controlling the shedding device in accordance with a weaving program. Possibly, a determined, simple weaving program with small repeat can be adjusted at the shedding device so as to be fixed. However, an accurate warp yarn coordination cannot be achieved then, since certain yarn guiding eyelets remain in the upper shed or in the lower shed in the shedding crossing point, also, because of the weaving design. An exact warp yarn coordination would only occur during linen weave, i.e. 1/1 weave. When coordination is lacking it is more difficult on the one hand to find the broken warp yarn, which can likewise be located in the lower shed, the upper shed or the middle shed, and, on the other hand, it is more difficult to join together the broken warp yarn ends because of the poor accessibility. In addition to this, during stoppage of the weaving machine, a longer stopping leads to considerable stretching of the warp yarns located in the upper shed and lower shed, particularly relative to those warp yarns located in the middle shed. Because of this, fabric defects which could lead to waste occur after the error is corrected and the weaving machine is started again.
A weaving machine with an electronic control device for the control of a shedding device in accordance with a weaving program is known from EP-OS No. 0 116 292, wherein a reverse switching gear unit is located for pick finding. However, the weaving machine contains no means for warp yarn coordination.
It is the object of the invention to find a method for operating a weaving machine and a weaving machine for implementing the method by means of which the aforementioned disadvantages can be avoided.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method of controlling a weaving machine which includes a shedding device with yarn guiding eyelets, an electronic control device for the shedding device, a warp let-off device and a fabric take-off device, the electronic control device having a program memory and a process-control computer, the program memory providing a weaving program with weaving program steps and an auxiliary program, comprises stopping the weaving machine in a shed by means of a stop signal, switching by means of the auxiliary program to inverse weaving the shedding device and the weaving program step of the shed in which the weaving machine has stopped, returning by means of the auxiliary program the weaving machine to the next preceding shedding crossing point, stopping by means of the auxiliary program the weaving machine in this next preceding shedding crossing point so that the yarn-guiding eyelets are placed in a middle position, switching by means of the auxiliary program the weaving machine from inverse weaving to normal weaving according to the weaving program, and restarting the weaving machine with a start signal from the shedding crossing point utilizing the next following weaving program step.
Furthermore, the stop signal can be triggered, for example, by means of a hand switch for turning off the weaving machine or an error signal of a warp yarn guide. When the stop signal is generated, the auxiliary program switches the weaving program step of the shed in which the weaving machine stops, as well as the shedding device, to inverse weave, i.e. the opposite or negative weave, all yarn guiding eyelets must compulsorily arrive in the middle position during the return of the weaving machine into the last shedding crossing point for occupying the inverse position, no matter how complicated the weaving program may be. Accordingly, a complete warp yarn coordination is achieved in the middle position so that the warp yarns cannot be stretched differently and are optimally accessible, wherein, in particular, an incorrect warp yarn can also be found quickly, since all warp yarns lie in a plane. Accordingly, no defects of the woven fabric occur even during a longer interruption of the weaving process. Moreover, the optimum accessibility makes it possible to rapidly join together the ends of a broken warp yarn.
It is advisable that the weaving machine be stopped in the open shed after a program read-in point.
It is particularly advisable to proceed so that the special stop signal, for example, the error signal of the warp stop motion, immediately prevents the introduction of another filling yarn until the weaving machine is started.
It may possibly be advisable to set back the fabric take-off and, under certain circumstances, the warp let-off, by a restoring magnitude in order to prevent possible errors in the fabric web of fine fabrics. The correction factor of the restoring magnitude is freely selectable and depends, as a rule, on the characteristics of the fabric to be produced. Therefore, the correction factor is only adjusted once during the production of a certain fabric and is changed only when the type of fabric is changed.
The special stop signal can be an error signal of a warp yarn guide. However, it can also be released in an advisable manner by means of a hand switch if the weaving machine is to be stopped for longer periods, for example, overnight or over the weekend.
Also disclosed is a weaving machine which according to the present invention includes a shedding device, an electronic control device for controlling the shedding device, a warp let-off device, a fabric take-off device, a transmitter for generating the stop signal, means for stopping and moving back the weaving machine to a shedding crossing point, the electronic control device including a process-control computer and a memory for a weaving program with weaving program steps and an auxiliary program responding to the stop signal, the auxiliary program being capable of switching to inverse weaving the shedding device and the weaving program step of the shed in which the weaving machine has stopped, returning the weaving machine to the next preceding shedding crossing point, stopping the weaving machine in this next preceding shedding crossing point so that the yarn-guiding eyelets of the shedding device are placed in a middle position, switching the weaving machine from inverse weaving to normal weaving according to the weaving program, and restarting the weaving machine with a start signal from the shedding crossing point utilizing the next following weaving program step.
Embodiment examples of the subject matter of the invention are described in more detail in the following with the aid of the drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a weaving machine in section and in a front view of the warp let-off device;
FIG. 2 shows the weaving machine of FIG. 1 in section II--II of FIG. 1;
FIG. 3 shows the reverse switching gear unit in side view;
FIG. 4 shows the reverse switching gear unit in section IV--IV of FIG. 3; and
FIG. 5 shows a shed diagram in various phases of error removal during a breaking of warp yarn in reverse switching of the weaving program.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 4 show an embodiment example of a weaving machine comprising a warp let-off device 2, a fabric take-off device 4, a shedding device 6, a main drive 8 with a drive motor, a reverse switching gear unit 10, which is connected with the warp let-off device 2 and the fabric take-off device 4, and an electronic control device 12 for a weaving program. A weaving reed 14 and a filling yarn inserting member 16 are connected to the main drive 8 in a manner known, for example, from CH-PS No. 633 331 and not shown in more detail.
The warp let-off device 2 contains a warp beam 18 whose shaft 20 is driven by means of a worm gear unit 22. The warp yarns 24 reach from the warp beam 18 via a back rest 26 to the shafts 28 with the yarn guiding eyelets 29 of the shedding device 6 which serve to form and change the warp shed 30. The filling yarn inserting member 16 periodically engages in the warp shed 30. The inserted filling yarn is beaten up at the selvage 32 by means of the weaving reed 14. The woven fabric 34 is tensioned and taken off via the tension beam 36 and is rolled up on the fabric beam 38. The fabric take-off device 4 containing the tension beam 36 and the fabric beam 38 is driven by means of a regulating gear unit 40.
For the drive of the warp let-off device 2, the fabric take-off device 4 and the shedding device 6, a secondary drive shaft 46 is connected to the main drive 8 via bevel wheels 42, 44. This secondary drive shaft 46 carries a toothed wheel 48 which drives a drive wheel 52 for the warp let-off device 2 and the fabric take-off device 4, as well as a drive wheel 54 for the shedding device 6, via a toothed belt 50.
The shedding device 6 contains a dobby 56, whose drive shaft 58 is connected with the drive wheel 54, possibly with the intermediary of a switching coupling 60. The dobby 56, which is constructed and controlled, for example, according to EP-OS No. 0 056 098 and EP-OS No. 0 068 139, has shaft rockers 62 which are connected in each instance with a shaft 28 via a lever gear 64. Another type of shedding device with single strand control, e.g. according to DE-OS No. 33 01 931, can also be used.
The drive wheel 52 for driving the warp let-off device 2 and the fabric take-off device 4 is connected with a drive shaft 66 via the reverse switching gear unit 10, which is constructed as overlapping gear unit, the drive shaft 66 drives the worm gear unit 22 of the warp let-off device 2 on the one hand and the regulating gear unit 40 of the fabric take-off device 4 on the other hand. The drive wheel 52 is arranged at a bearing sleeve 68, see FIG. 4, which is supported on the drive shaft 66 so as to be freely rotatable. The bearing sleeve 68 projects into a housing 70 and carries a toothed wheel 72 with which a planet wheel 74 meshes. The latter is arranged at a shaft 76 so as to be fixed with respect to rotation relative to it; the shaft 76 is rotatably supported in a planet carrier 78 which is in turn rotatably supported on the drive shaft 66. At the shaft 76, on the other side of the planet carrier 78, another planet wheel 80 is connected with the shaft 76 so as to be fixed with respect to rotation relative to it. The second planet wheel 80 meshes with a toothed wheel 82 which is arranged at the drive shaft 66 so as to be fixed with respect to rotation relative to it. The planet carrier 78 is constructed as a worm wheel and contains at its circumference a worm toothing 84 which cooperates with a worm wheel 86 whose drive shaft 88 is connected with an auxiliary motor 90. The worm gear unit, which is formed from the worm toothing 84 and the worm wheel 86 is preferably constructed so as to be self-locking. Moreover, as shown in FIG. 3, the reverse switching gear unit 10 is equipped with a brake device 92 for preventing an after-running. The brake device 92 comprises a friction disk 94 which is arranged on the drive shaft 88 so as to be fixed with respect to rotation relative to it and a friction disk 96, which is arranged in the housing 70 so as to be fixed with respect to rotation relative to it, cooperates with the friction disk 94. A peg 98 arranged at the friction disk 96 engages in a groove 100 in the housing 70 which lies parallel to the drive shaft 88 and prevents a turning of the friction disk 96. A pretensioning spring 102 pretensions the stationary friction disk 96 against the friction disk 94 which is connected with the drive shaft 88.
The drive shaft 66 is interrupted at the portion going toward the the warp let-off device 2 by means of a switching coupling 104. This switching coupling is constructed, for example, as a claw coupling which is switchable by means of a switching lever 106 and an actuating device 108 so that the drive of the warp let-off device 2 can be shut off when necessary.
The weaving machine is equipped with electronic control device 12 which is connected, on the one hand, with the dobby 56 of the shedding device 6 and, on the other hand, with the drive motor 9 and with the auxiliary motor 90 of the reverse switching gear unit. Thread regulators, such as the filling stop motion 110 and the warp stop motion 112, are connected at the control device 12. The electronic control device has the usual construction of a control with programmable memory. It contains a central unit B1 with a freely programmable weaving program memory WS, e.g. a RAM memory, and an auxiliary program memory HS and a process control computer R which processes all signals and information for the control of the weaving machine. In addition, the control device contains various control blocks and a series of press buttons for triggering various functions:
B1--central unit
B2--warp yarn error control block
B3--weaving machine drive control block
B4--fabric take-off control block with correction factor adjustment
WS--weaving program memory
HS--auxiliary program memory
ST--normal start
SP--normal stop
SS--special stop
SZ--preparation of pick finding cycle
KG--normal creeping speed forward
KA--restoring magnitude release key
The restoring magnitude G is input beforehand and so as to be specific for the fabric by means of the correction switch 114 and is released by means of the release key KA. The correction factor K can be freely selected, for example, according to normal or longer stoppage of the weaving machine; warp thread breakages; pick finding etc., and is decisive for restoring the fabric take-off per program step to be set back. The restoring magnitude G is:
G=K×L,
wherein
L designates fabric length between two fillings
K designates the correction factor, wherein K=0.1 to 4.
In the control device 12 the warp yarn error control block B2 is connected with the warp stop motions 112 via a line 116 and with the central unit B1 via a line 118. The weaving machine drive control block B3 is connected to the drive motor 9 via a line 124 and to the central unit B1 via a line 126. Finally, the fabric take-off control block B4, which contains the correction switch 114 for adjusting the restoring magnitude G, is connected with the central unit B1 by means of the line 128 and with the auxiliary motor 90 of the reverse switching gear unit 10 via the line 130. The central unit B1 is connected to the dobby 56 via the line 132.
The electronic control device makes it possible to switch back the weaving program when the weaving machine is running forward so that the dobby 56, which is being driven in the forward direction, executes a reverse program flow. At the same time, the control device controls the weaving machine drive motor 9 and the auxiliary motor 90 of the reverse switching gear unit 10 so that the warp let-off device 2 and particularly the fabric take-off device 4 can be switched back, as explained in more detail in the following, for error correction during the breaking of a filling yarn and/or warp yarn. However, the control device can also let the entire weaving machine run in reverse.
FIG. 5 shows a shed diagram for a weaving machine. The individual sheds 134 formed from warp yarns 24 carry the respective weaving program steps S4, S5, S6, S7, S8 in each instance. Filling yarns 136 are inserted in the individual sheds 134. The clock pulse for the continued switching of the weaving program is taken off at a clock point 138 in each instance. The clock pulse can serve for the continued switching of the weaving program of the next respective shed or, as in the present example, the shed after the next shed.
The removal of a warp yarn breakage is effected as follows:
When the warp stop motion 112 establishes a warp yarn breakage 140 in the shed 134, for example, with the weaving program step S5, then the weaving machine is stopped in the next open shed with the weaving program step S6, specifically after the program read-in point 141. At the next shedding crossing point 142' the next weaving program step S7 would be activated because of the last clock point 138'. However, because of the error signal of the warp stop motion 112, the continued switching of the weaving program in the weaving program memory WS of the central unit B1 is interrupted and switched to an auxiliary program of the auxiliary program memory HS for the middle position of the shafts 28. In order to adjust the shedding device at the shedding crossing point 142 in such a way that all yarn guiding eyelets 29 of the shafts 28 occupy the middle position 144 (FIG. 2), the shedding device is moved back further or to the last shedding crossing point 142, respectively, on the basis of the auxiliary program corresponding to the curve 146. The respective weaving program step S6, and accordingly also the shedding device, is switched in the inverse weaving program step S6'. Because of this switching to the inverse weave all shafts and, with them, all yarn guiding eyelets, must occupy the negative, i.e. opposite position. This reverse movement is effected during the reverse movement into the shedding crossing point in which all shafts and, accordingly, all yarn guiding eyelets compulsorily occupy the middle position. In order to carry out this reverse movement the drive motor 9 is switched in its rotating direction. At the same time, the control device can move back the fabric take-off and possibly the warp let-off by a corresopnding restoring magnitude G by means of the central unit B1 and the fabric take-off control block B4, wherein this magnitude is correctable by a correction factor K, possibly at the correction switch 114. The warp yarn breakage is now removed and the weaving machine is again turned on at the start key ST; in so doing, the auxiliary program switches the control device to normal program again so that the shedding device again occupies the consequent weaving program position at the shedding crossing point 142. The weaving process is now continued again in the consequent position as can be seen from the lower shed diagram of FIG. 5.
As soon as a warp yarn breakage signal occurs at the warp stop motion 112 a further insertion of filling yarns 136 in the sheds 134 is prevented. Possibly, it can be advisable to remove an already inserted filling yarn 136.
The special stop signal caused by the error signal described above can also be released by means of the special stop key SS, wherein the same processes are released as with the error signal. The single difference consists in that the error removal is omitted. While the normal stop key SP is always released when an immediate stop is desired, the special stop key is actuated when a middle position of the yarn guiding eyelets is desired. The latter can be the case when the weaving machine is reset and particularly during a longer stoppage of the weaving machine in order to prevent different stretching of the warp yarns and, accordingly, woven fabric defects.
Other embodiment examples are possible. Instead of the reverse movement of the entire weaving machine, the dobby of the shedding device can also be uncoupled from the main drive and set back by itself by means of an auxiliary drive. | A method of controlling a weaving machine which includes a shedding device with yarn guiding eyelets, an electronic control device for the shedding device, a warp let-off device and a fabric take-off device, the electronic control device having a program memory providing a weaving program with weaving program steps and an auxiliary program, comprises stopping the weaving machine in a shed by means of a stop signal, switching by means of the auxiliary program to inverse weaving the shedding device and the weaving program step of the shed in which the weaving machine has stopped, returning by means of the auxiliary program the weaving machine to the next preceding shedding crossing point, stopping by means of the auxiliary program the weaving machine in this next preceding shedding crossing point so that the yarn-guiding eyelets are placed in a middle position, switching by means of the auxiliary program the weaving machine from inverse weaving to normal weaving according to the weaving program, and restarting the weaving machine with a start signal from the shedding crossing point utilizing the next following weaving program step. | 3 |
FIELD OF THE INVENTION
The invention concerns a process and an apparatus for drilling holes.
DESCRIPTION OF THE BACKGROUND ART
With respect to the present state of the prior art on the subject, the object of the invention is to achieve the following aims:
to be able to work in narrowly confined locations, in particular in an urban environment where the overall dimensions of the apparatus must be as small as possible, causing the least possible inconvenience,
to obtain reliable operation of the apparatus, without the risk of breakage of the apparatus, substantially whatever the conditions encountered on the terrain,
that the apparatus should be as functional and simple as possible as regards construction and use,
to permit limited manufacturing and operational costs,
to allow optimum control and guiding of the drilling, in a simple and functional manner,
to limit as far as possible the risks of disturbance of the subsoil during drilling of the hole by the apparatus.
Until now it has been proposed, to drill an essentially horizontal hole in the ground, to use a drilling rod assembly comprising a succession of drilling rod elements arranged end to end along an axis and capable of being pushed forwards, in the ground, by a drilling drive device.
Thus, a drilling machine has already been used to sink, from the surface of the soil into the sub-soil, on an inclined path, a rod assembly constituted of a large number of drilling stems or rods, screwed end to end to one another, and each being several meters in length. The direction of penetration (that is to say, of the drilling head which is at the forward end of the rod assembly) can be relatively well adjusted, so that drilling takes place first flat and obliquely downwards, until the prescribed depth is reached, then drilling is continued in an essentially horizontal direction, still by means of the guiding of the drilling head.
For drilling, the rod assembly is pushed forwards by the drilling drive device fixed to the rod assembly at the front. This rod assembly is often driven in rotation, and/or, under the action of the water which escapes from the drilling head under high pressure. The materials encountered during drilling are then expelled, most often through an internal hollow passage provided through the rod assembly.
This process is used especially for laying pipe systems over long sections, for example of 100 meters or more.
Such a drilling apparatus, which among other things must have a mounting directed obliquely downwards to guide the rod assembly, is large and weighs at least two tonnes, since the weight of the drilling machine serves in part as a stop for the force serving for the forward compression of the rod assembly.
It is considered that known drilling apparatuses, a typical example of which has just been described, do not reasonably satisfy at least the essential aims assigned here.
SUMMARY OF THE INVENTION
In order to remedy this defect and to tend towards the aims set, the invention first proposes, in order therefore to produce an essentially horizontal drilled hole, in the ground, by means of a drilling rod assembly comprising a succession of drilling rod elements to be arranged end to end along an axis and capable of being pushed forwards, in the ground, by a drilling drive device,
to produce the said starting region as an open shaft in the ground on a substantially vertical axis with a substantially constant horizontal section over the depth of the shaft, while being preferably insufficient for a man to be able to work towards the bottom of it with the said drilling assembly,
in order to dig the hole, to displace the rod assembly, in the hole, by elements, in the direction of the hole, from an opening located in a front wall of the shaft,
and to select the elements of the rod assembly so that they have an axial length less than the distance separating the said opening in the front wall of the shaft from the opposite rear wall.
This offers the possibility of producing the rod assembly from very short drilling rods (approx. 10 to 30 cm.) which will advantageously be screwed to one another.
The individual drilling rods will then be flexible only in their central region, that is to say, not in their end region for screwing to the two adjacent rods. There will preferably be no play in the screwing, since this would result in the elimination of the possibility of adjusting the orientation of the rod assembly as a whole. As a rod assembly constituted of tubes is much more rigid in the actual screwing region, without play, than in the central region of the individual rods, the rod assembly, in the screwing regions, may be regarded as substantially unable to undergo lateral displacement.
Consequently, an assembly constituted of rods in which the screwing regions represent approximately 20 to 25% of the total length of each rod should be regarded generally as being not very resilient in a transverse direction.
Owing to the fact that, for the majority of the drilling operations to be carried out within the framework of the invention, only a very small lateral deviation of the drilling will be necessary, the rod assembly constituted of a very large number of very short individual rods is appropriate. It will in fact thus be possible, commencing from a starting shaft having a section at the bottom which will not be substantially greater than the small predetermined section at the surface of the ground, to achieve horizontal advancement with a rod assembly in which the individual rods are connected, in the direction of the drilling axis, to the rear end of the rod assembly in place. The length of the individual rods will then be distinctly shorter than the length, measured in the horizontal plane, of the cross-section of the starting shaft.
And, in order to displace the rod assembly in the drilled hole, the drive device will advantageously be pressed against the wall of the shaft opposite to the opening of the hole and a forward thrust will be exerted on the elements in the hole, by means of the drive device.
Moreover, the apparatus provided in the invention, in order to produce the desired drilled hole, comprises:
a framework suitable for being lowered, at least in part, into the shaft,
drilling rod elements to be arranged end to end, being individually of a specific length,
drilling drive means displaceable in the framework between two positions, forward and rear, in order to drive the drilling rod elements and to create, while advancing, an assembly of rod elements which are relatively rigid along a substantially horizontal axis,
the said length of the elements constituting the said assembly of rod elements which is created being less than a width which the said framework has along the axis of the rod assembly.
With regard to the drilling drive means, the latter will advantageously comprise:
clamping means for clamping individually the last rod element(s) constituting the said drilling rod assembly,
thrust means, for advancing the said rod assembly by compression, along its axis in the drilling direction,
and loading/extracting means movable in the said framework between a high position and a low position in order, in one direction, to bring additional rod elements to the drilling drive means so as to lengthen the rod assembly and, in the opposite direction, to extract elements from the rod assembly, therefore to shorten it.
By the use of a very stable rod assembly, in particular by means of rods of a solid material, or at least of tubes having a very considerable wall thickness, it will thus be possible to carry out drilling essentially (and if necessary, exclusively), by advancing the rod assembly by compression. This method of proceeding is particularly well suited to work carried out commencing from a starting shaft, since the drive device intended to advance the rod assembly by compression can easily bear against the opposite wall of the shaft.
The drilling drive device may additionally comprise a passage opening for the rod assembly, such that the drilling drive device, contrary to what is customary elsewhere, does not act frontally on the rear end of the rod assembly, but instead grasps the rod assembly on its outer periphery, and maintains it in position about the longitudinal axis, exclusively by a dynamic connection, both in the axial direction and in the angular position, which makes it possible to push the rod assembly forwards, rotate it, or draw it back.
Thus, in order to displace the drilling rod assembly in the hole, it is advisable to:
clamp by means of the drive device the outer periphery of a rear element of the said assembly located in the shaft,
to advance this element towards the hole, along the axis of the rod assembly, by a length corresponding substantially to the length of the element,
and, while retaining the rod assembly already in the drilled hole in order to prevent it from moving back, to grasp another rear element of the rod assembly, and so on, element by element.
Rotation of the rod assembly, in order to scrape or "mill" the ground material ahead of the drill head is of interest only in particular cases. It is necessary, however, to be able to rotate the rod assembly through an angle of less than 360°, since it is possible to act on the direction of advancement of the drilling by way of an asymmetrical bevel, present at the point of the rod assembly, and its angular position with respect to the drilling axis.
Owing to the placing of the drilling rod in position in the direction of the drilling axis (which is essentially horizontal), it is additionally possible to introduce into the starting shaft, or to remove from the latter, the new rods to be inserted or removed, from this horizontal position, from a magazine. Thus, the difficulties entailed in modification of the direction of the rods when they are being fed in, such as jamming etc., for example, are almost completely avoided.
By means of a drilling rod changer (which will preferably be referred to as a "loader/extractor"), which has a motor of its own, the rods to be added can each be screwed onto the rear end of the rod assembly. Advantageously, the rods will first be drawn, by means of the motor of the loader/extractor and of the threaded sleeve fixed thereto, from the rod magazine located above.
The drilling drive device can undergo longitudinal translation in one direction and the other in the starting shaft, parallel to the drilling axis, at least over the length of an individual rod. Preferably, the drilling drive device can thus be displaced in one direction and the other between an advanced position, which is located immediately at the start of the drilled hole in the starting shaft, and a withdrawn position, which is located in the vicinity of the rod loader/extractor device, itself arranged against the opposite wall.
Both the loader/extractor and the drilling drive device are preferably installed in a drilling tower or framework, which is constituted of a latticework of metal tubes, one part of which can be fixed and another movable in a vertical direction. The framework will preferably be covered by plates on its peripheral walls in order to prevent earth from falling into the starting shaft. This drilling tower (or at least its movable part) is lowered, for example by means of a hand winch, from the top of the shaft.
The drilling rod magazine may be constituted by a vertical or inclined chute in which the drilling rods are arranged horizontally one above the other. In the lowest position, the chute is open at the front, in order to allow the lowermost rod to be taken from the magazine. In this removal position, the drilling rod is located vertically with respect to a section of the drilling axis, and it can therefore be picked up by the rod loader/extractor, which can be displaced vertically with respect to the drilling tower.
To this end, the changer carriage on which the motor of the loader/extractor is also situated, is raised to the height of the removal position. The threaded sleeve provided on the shaft of this motor is then introduced by screwing into the drilling rod located in the position for removal from the rod magazine. It should be noted that this rod cannot be driven in rotation, because of the other rods resting on it, or even an additional mass. After lowering to the drilling axis, a rotation in the opposite direction, and a forward thrust of the above-mentioned motor with the drilling rod taken from the magazine, serve to screw the rod onto the rear end of the rod assembly located in the drilled hole. The rod magazine preferably ends in the drilling tower below the surface of the ground, but starts above the bottom surface and can then additionally project obliquely beyond the rod assembly from the drilling tower, in order to facilitate the loading, by hand, of additional rods.
The lower part of the tower is advantageously wedged inside the starting shaft by horizontally acting clamping hydraulic cylinders, for correct holding not only in the horizontal plane but also in the vertical plane.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is described in more detail hereinafter with reference to the Figures, in which:
FIGS. 1a and 1b show in side view the lower and upper parts respectively of the drilling apparatus according to the invention,
FIGS. 2a and 2b show the lower and upper parts respectively of the apparatus according to the invention from the front, when seen on the drilling axis,
FIG. 3 shows the apparatus in an enlarged top view,
FIG. 4 is a block diagram of the operation of the process using the device of the invention for a drilling operation, separated into steps 4a to 4g,
FIG. 5 is a block diagram of the operation of the device of the present invention (separated into steps 5a, 5b and 5c), detailing in particular the means for detecting the axial position and any possible slipping of the rod assembly relative to the drilling drive device, and
FIG. 6 is a block diagram of the operation of the process using the device of the invention for an operation of withdrawal of drilling rod elements, separated into the steps 6a to 6h.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2, FIGS. 1a and 2a, respectively, each show the lower part of the drilling apparatus located in the starting shaft 2, while FIGS. 1b and 2b, respectively, show its upper part which partially projects from the surface of the ground 5.
The elements of the apparatus are arranged inside a tower 11, produced from metal profile sections, the outer surfaces of which are preferably covered, in a manner not shown in the drawing, by metal plates.
The drilling tower 11 is lowered into the starting shaft 2, for example by means of a hand winch, not shown in the drawings, and to this end may be guided vertically, for example in an auxiliary frame arranged above the starting shaft, by means of guide rollers, slides, etc.
In the lower part of FIG. 1a there can be seen, extending horizontally, the drilling axis 3, and the drilled hole 1 provided in the left-hand side wall 2a (front wall).
The tower 11 has recesses open at the bottom, provided in these side walls.
The principal elements of the apparatus according to the invention are all arranged against or in the drilling tower 11:
the drilling drive device 9, which presses the rod assembly 6 forwards towards the left, in the direction of the drilling axis 3, or which, during the extraction of the drilling rod assembly 6 from the drilled hole 1, draws the assembly 6 back,
the rod loader/extractor 12, which makes it possible to adapt, element by element, the length of the rod assembly 6 located in the hole 1, by the addition or withdrawal of additional rods 7 at its rear end,
the rod magazine 19, in which are housed the rods 7 intended to be connected to the rod assembly 6,
and also the inclined chute 24, in which the rods 7 taken from the rod assembly 6 drop in order to be cleaned therein by the operating personnel, be subjected to checking for deterioration and be re-lubricated for later use.
FIGS. 1 and 2 do not include any rod assembly 6 on the drilling axis 3 in order to make it easier to understand the drawings, unlike FIG. 3. It can then be seen that the rod assembly 6 is constituted by rods 7 (or elements) arranged one behind the other, screwed to one another at their ends. Each element 7 has an axial length L1 (FIGS. 1a and 3) less than the distance d separating the front wall 2a and the rear wall 2b of the shaft where the drilling machine has been installed, and than the length L2 (measured parallel to the axis of the rods 7) of the framework 11 (or at least of its part which descends into the shaft), between its vertical lateral front and rear columns, having the references 11a, 11b in FIG. 1a.
In FIG. 1a, one of these rods, 7d, is screwed to the threaded sleeve 34 of the motor 13 belonging to the loader/extractor device 12.
Each threaded rod 7 has on its outer periphery an annular groove 18 acting as detecting means.
As can be seen in FIG. 1a, the loader/extractor 12 is displaced essentially vertically. The drilling rod 7d is then displaced in an essentially vertical transport gap 10. The drilling drive device 9 can slide, on the drilling axis 3, along guides 29 by means of hydraulic pistons 30.
In order to press the rod assembly 6, and therefore to advance the drilling, the drilling assembly drive device 9 grasps the rod 7 located furthest to the rear (that is to say, still in the region of the drilling tower 11) and the whole of the drilling drive device 9 is displaced towards the left, by way of the position shown in FIG. 1a. The drilling drive device 9 is thus displaced alternately between the front wall 2a and the vicinity of the opposite rear wall 2b.
The device 9, in addition to this axial movement in the direction of the drilling axis 3, can also rotate the rod assembly 6, both during the linear movement and separately. To this end, a rotating jaw 33, capable of clamping the rod assembly, can rotate or pivot with respect to its housing 35, coaxially with the drilling axis 3. This method of proceeding serves to adjust the orientation, in co-operation with a bevel of known type arranged asymmetrically against the point of the rod assembly.
The drilling drive device includes another jaw 32, termed a "separating" or "unlocking" jaw, arranged ahead of the rotating jaw 33, and which can maintain the rod assembly fixed in rotation with respect to the casing 35 of the drilling drive device.
An additional clamping jaw 21 is also arranged integrally with the drilling tower 11, in the immediate vicinity of the drilled hole 1 with respect to the rod assembly 6. This clamping jaw 21, as can be seen more easily in FIG. 2a, is also constituted by two jaws, directed transversely against the rod assembly. These jaws are driven by a hydraulic jack 21' which is held, by one of its ends, in a fixed position relative to the drilling tower 11.
At the lower end of the tower, still below the drilling drive device 9, clamping cylinders 22a, 22b, extending in the direction of the drilling axis 3, are arranged in a stationary manner against the drilling tower 11. The cylinders 22a and 22b have a compression plate 25 at the free end of their piston rod. Since the drilling tower 11, in this region, has no outer covering, the outlet of the piston rods of these clamping cylinders 22 (which if necessary are driven by a hydraulic device), compress their compression plates 25 against the opposite wall of the starting shaft 2, and thus the drill tower 11 against the side walls of the shaft 2. Thus, the whole of the drilling tower 11 is fixed in the starting shaft 2, which is important for the alignment, relative to the started drilled hole 1, of the drilling axis 3 defined by the drilling drive device 9 relative to the drilling tower 11.
The loader/extractor 12 is essentially constituted by the motor 13 with its threaded sleeve 34, which is preferably arranged directly on the output shaft of the motor. The sleeve 34 is provided with a screw thread capable of being screwed onto the rear screw thread of the rods 7, so as to allow them to be assembled end to end. As can be seen in FIG. 1a, the screw thread is then preferably an external screw thread, applied along a conical surface, on the drilling rod 9, in which case a form of circular threads is preferably used. The threaded sleeve 34 consequently has an internal screw thread in the opposite direction, and the motor 13 is orientated, by its axis of rotation, parallel to the axis 3. The motor 13 can then be displaced both in the direction of the drilling axis 3 and perpendicularly to this direction (vertically along the framework 11).
To this end, the motor 13 is fixed to a motor frame 16. The frame 16 can be displaced, by means of rollers 36 having an annular groove on their outer periphery, in the direction of the drilling axis 3, along two bars preferably spaced vertically from each other, acting as guides 17 for the frame of the motor. The guides 17 are fixed on a carriage 14 which, preferably by means of rollers 39, can be displaced in the vertical direction along the carriage guides 15 in the form of bars arranged, in the direction of the drilling axis 3, at a certain distance in the drilling tower 11, in the vicinity of the side 2b.
The motor 13, by means of the loader/extractor elevator carriage 14, can be displaced in the vertical direction so as to be aligned either with the drilling axis 3, in its lowest position, or, in its highest position (FIG. 2b), with a gripper device 23, arranged in the upper region of the drilling tower 11. This gripper device is actuated by means of a hydraulic jack 23', preferably double-acting. Between these two end positions (both preferably located below the level of the surface of the ground 5), there is to be found, on the trajectory of the motor 13, the position for removal from the magazine 19 where "new" drilling rods 7a, 7b, 7c are ready. The magazine is essentially constituted by a sheath 20 of the profiled type arranged in an inclined position, the inclination increasing at maximum to a vertical position. The drilling rods 7 are installed therein from above.
At its lower end, the sheath 20 has a stop for the lowermost drilling rod 7a and is open at the rear side of this rod directed towards the motor 13.
The magazine 19 then projects preferably above the level of the ground 5, and extends towards the outside or laterally relative to the drilling tower 11, so that the operating personnel can fill it more easily with the drilling rods 7.
When the motor 13 is in alignment with the drilling rod 7a lodged in the position for removal from the magazine 19, the motor 13, by means of longitudinal displacement along its axis of rotation, accompanied by rotation of the threaded sleeve 34, can be be screwed onto the drilling rod 7a. Rotation of the latter is prevented by the weight of the drilling rods arranged above, and optionally by the weight of a mass 42, also arranged in the magazine 19. The descent towards the drive device 9 of the motor 13, with the drilling rod 7a, effects the transfer of the rod to the rod assembly 6, for connection.
Above the lower end of the magazine 19, in the vertical trajectory of the drilling rods thus transported, and below the gripper device 23, the inclined chute 24 is arranged in such a manner that its upper end is still below the gripper device 23. A drilling rod 7, driven in the gripper device 23 from above by means of the loader/extractor 12, then moves away the inclined chute 24, which can be tilted towards the outside about a pivoting axis, from this trajectory. Then the inclined chute 24 returns, by reason of the force of gravity, tilted as far as the operating position shown in FIG. 2b. In this operating position, the drilling rods 7k, held at first by the gripper device 23, drop into the inclined chute 24 after being released, and roll along, emerging laterally from the drilling tower 11, where they are received by the operating personnel for checking and storing.
A description will now be given of the operation of the device according to the invention, in particular with reference to FIGS. 4 to 6.
It starts from a drilling operation already commenced, which it is wished to continue.
In this case, the carriage 14 of the device 12 is displaced upwards (step 4a) to take a new drilling rod element 7c from the magazine. The motor frame 16 is then located with the motor 13, in the rear position brought back horizontally furthest from the drilled hole, that is to say, towards the right-hand edge 2b of the starting shaft 2 in FIG. 1a.
The carriage 14 is then displaced upwards along the guides 15 until the threaded sleeve 34 comes into alignment with the screw thread of the rod 7c, located in the position for removal from the magazine 19. The threaded sleeve 34 is then displaced on its axis of rotation towards the left, that is to say, towards the front, against the drilling rod 7c, and is driven in rotation by the motor 13 (step 4b) in such a manner as to screw the threaded sleeve 34 to the drilling rod. This screwing operation is limited to a certain duration, of a few seconds, by a timing mechanism coupled to the loader motor 13.
In order to permit the engagement of the screw thread of the threaded sleeve 34 and of the drilling rod 7c, there must be a pressure in the axial direction. To this end, the threaded sleeve 34 is displaced horizontally in the axial direction by means of the motor 13, owing to the fact that the motor frame 16 is displaced substantially horizontally relative to the carriage 14 along the guides of the motor frame 17a, 17b. The hydraulic piston 37 carries out this operation.
Since the extension and the retraction of this hydraulic piston 37 cannot be controlled with the precision corresponding to the axial advance during the screwing of a screw thread at a perfectly defined rotation speed, a spring 38 is interposed between the hydraulic piston 37 and the motor frame 16 which moves under the action of the latter, and there is preferably a spring 38a, 38b for each direction of movement. The necessary length compensation in the direction of the drilling axis 3 is thus ensured.
Moreover, in order to compensate for the faults in alignment between the axis of rotation of the threaded sleeve 34 and the drilling rod 7c located in the magazine, the threaded sleeve 34 is preferably arranged in a stationary manner on the output shaft of the motor 13. But the motor 13 is not arranged in a stationary manner against the motor frame 16. It is movable by means of rubber supports, such that its axis of rotation is able to execute, relative to the motor frame 16, both a slight transverse shift and an angular variation.
The compensation functions which have just been described are necessary not only for the removal of a drilling rod from the magazine, but also, and above all, for the placing in position and removal of a drilling rod with respect to the rod assembly 6.
Then the motor frame is brought back again, relative to the carriage 14, in the direction of the drilling axis 3, so that the drilling rod 7c, which now bears on the threaded sleeve 34, is taken from the magazine 19. The drilling rod (which in FIG. 1a is shown, in this transport position, as a rod 7d) is then moved downwards as far as the drilling axis 3.
By displacement of the motor frame 16 forwards with respect to the carriage 14 (that is to say, towards the left in FIG. 1a in step 4c), the forward end 27 of this rod is brought into contact with the rear end of the last drilling rod of the assembly 6 already located in the drilled hole, as can be seen in FIG. 3. Owing to the simultaneous rotation of the motor 13, this new drilling rod is screwed at the rear onto the rod assembly, thus prolonging the latter.
The screwing operation is carried out until a torque detector, coupled to the motor 13, indicates a sufficient degree of torque. During the screwing operation, the last rod of the assembly 6 is clamped, fixed in rotation by means of the rotating jaw 33 (step 4c) which is then in a position pushed a relatively long way towards the left, preferably at the rear end of the preceding rear element (7b in step 4c). After the end of the rotation of the motor 13, the rotating jaw 33 is loosened (step 4d) and the drilling drive device 9 (see FIG. 1a and FIG. 3) is brought back towards the right, along its two guides 29, until the rotating jaw 33 is located in the region of the last new rod 7 which has been connected, and it can be clamped by the rotating jaw 33, in order to detach from the drilling rod 7 which has just been connected to the threaded sleeve 34, by reverse rotation of the motor 13 (step 4e).
During this loosening of the jaw 33 and during the return of the drilling drive device 9, the rod assembly 6 is maintained in the position in which it was located until now, both axially and in rotation, relative to the drilled hole 1, by the fact that the jaw 21, fixed in the vicinity of the drilled hole against the drilling tower 11, clamps the rod assembly 6 (steps 4a to 4e). During the unscrewing of the threaded sleeve 34, the motor frame 16 is displaced towards the rear, relative to the carriage 14, once again horizontally by means of the hydraulic piston 37.
After loosening of the jaw 21, forward displacement of the whole of the device 9 makes it possible to displace the rod assembly 6 forwards by the length of the new drilling rod 7, owing to the fact that the whole of the drilling drive device 9 is pushed forwards, along the guides 29, by means of the hydraulic pistons 30, preferably arranged on the two lateral sides of the drilling tower 11 (force of approximately 2 tonnes). In order to adjust the direction, the rod assembly, before or during its advance, is optionally rotated slightly about the drilling axis 3 by means of the rotating jaw 33 (step 4f). Before, during or after this displacement of the device 9, the whole of the rod loader/extractor 12 is again displaced upwards, in order to seek out the following drilling rod 7 in the magazine 19 (step 4g). By repeating this operation, the rod assembly 6 is brought to the required length, and thus the drilled hole 1 advances in a controlled manner to its final point.
Since the rod assembly 6 is maintained by the drilling drive device 9 only by means of a dynamic connection, both for axial displacement and for rotational displacement, it may occur that, in an undesirable manner, the rod assembly 6 slips relative to the jaws 33 or 21.
In order to detect, and then make it possible to correct the position, at least one sensor 28, but preferably three sensors (designated as first, third and fourth detection means) 28a, 28b, 28c, are arranged against the drilling drive device 9, preferably against its housing 35. These sensors 28, which are preferably designed as inductive sensors, monitor the relative axial position with respect to the drilling rod 7 located in the region of the drilling drive device 9, owing to the fact that one of the sensors 28a reacts when the annular groove (designated as second detection means) 18 of this threaded rod 7 is exactly in front of it. If the rod assembly 6 slips in the direction of the drilling axis 3 relative to the drilling drive device 9, the annular groove 18 leaves the region of this sensor 28a, and the latter emits an error signal.
These different possibilities are clearly shown in FIG. 5, where three steps 5a to 5c are shown. "FRONT" and "BACK" show the respective front and back ends or elements.
In step 5a, it can be seen that the drilling rod assembly is too far forward in the drilled hole, since the groove 18 of the element 7b has passed the detection means 28a and has been registered by the detection means 28b.
In step 5b, it can be seen that the drilling rod assembly is in the correct position, since the detection means 28a is located opposite the groove 18 of the element 7b.
Finally, in step 5c, it can be seen that the drilling rod assembly is too far back relative to the drilling drive device, since the groove 18 of the element 7b is set back relative to the detection means 28a, and has been registered by the detection means 28c.
Each time, in steps 5a and 5b, in order to bring the drilling rod assembly into the correct position illustrated in step 5b, it is sufficient to pull back or advance the drilling drive device 9 along the drilling axis in order to advance or pull back the drilling rod assembly in the hole so as to bring the detection means 28a opposite the registering means 18 (the groove) of the element 7b.
As the other two sensors 28b, 28c are arranged in the vicinity of one another on the two sides in the direction of the drilling axis 3, the annular groove 18 should have passed one of the two sensors 28b, 28c, which has produced a corresponding signal. As a result, the direction of displacement of the rod assembly 6 relative to the drilling drive device 9 is known and, preferably after the rod assembly 6 has been fixed in the drilled hole 1 by means of the clamping jaw 21 fixed in a stationary manner against the drilling tower, the drilling drive device 9 is displaced again in the direction of the drilling axis 3, so that the sensor 28a is opposite the annular groove 18, that is to say, reassumes the prescribed position.
The procedure is as follows for removing the rod assembly 6 from the drilled hole 1, by retraction as described in steps 6a to 6h in FIG. 6:
First of all, there is provided in the drilling drive device 9 a scraper, not shown, constituted most often by one or more rubber lips or by a rubber bush, for roughly cleaning the rod assembly 6 withdrawn from the drilled hole 1.
At the start of the return operation, the clamping jaw 33 of the drilling drive device 9 holds the rearmost drilling rod of the rod assembly 6 (the element 7c in step 6a), in which case the drilling drive device 9 is in the forward position relative to the drilled hole 1, at the left-hand edge of the starting shaft 2 in FIG. 1a.
From this position, the drilling drive device 9 is brought towards the right (step 6b), by the length of a drilling rod 7, then the rod assembly 6 is fixed in the drilled hole 1 by the fact that the clamping jaw 21 arranged against the drilling tower 11 fixes that rod of the rod assembly 6 which is now the last but one, or another rod arranged further forwards (step 6c).
Then the last rod but one of the rod assembly 6 is clamped by the separating/unlocking jaw 32 (step 6c). The threaded sleeve 34 is then brought into a position of alignment with the drilling axis 3 and is screwed onto the rear end of the rod assembly 6 (step 6c), owing to the fact that the threaded sleeve 34 is rotated forwards, that is to say, as a general rule in a clockwise direction, while being displaced against the rear end of the assembly, until the sleeve and the last drilling rod 6 are screwed together sufficiently tightly. This is verified by monitoring of the torque.
The rotating jaw 33 is then subjected to rotation about the drilling axis 3 (step 6c), through approximately a half turn towards the left (direction of opening of the screw thread) so that the last rod and the last rod but one of the rod assembly 6 are partially unscrewed.
The rotating jaw 33 then disengages this last rod and is displaced forwards against the drilled hole 1, to grasp that rod of the assembly 6 which is now the last, and again withdraw it from the drilled hole until it can be removed from the rod assembly 6, as stated above. Simultaneously, or a little after, the unscrewing operation is continued and completed by the threaded sleeve 34 and the motor 13, with the threaded rod which is located there (which was initially the last), by rotation of the screw thread in the opposite direction (rotation to the left), and simultaneously, during the displacement of the rod changer towards the rear, by moving away from the rod assembly (step 6d). Before this, or at the same time, the drilling rod located on the threaded sleeve 34 is carried into the gripping region of the gripper device 23 located in the upper region of the drilling tower 11, by raising of the carriage 14 and optionally simultaneous displacement towards the left of the motor frame 16 relative to the carriage 14 (step 6e). To this end, the magazine 19 must be withdrawn from the vertical trajectory of the drilling rod by being raised or lowered. At all events, before reaching the gripper device 23, the drilling rod thus transported bears on the pivoting chute 24 in order to move it away from its trajectory.
After closure of the gripper device 23 (step 6f) by means of its piston 23', the drilling rod 7k, as can be seen in FIG. 2b, is held by the gripper device 23. The threaded sleeve 34 can then be loosened by rotation in the reverse direction of the motor 13 (step 6g), and by simultaneous rearward displacement of the motor frame 16 relative to the carriage 14.
Under the action of the opening of the gripper device 23, the drilling rod 7k drops into the inclined chute 24, which, under the effect of the force of gravity, has remained at the rear in FIG. 2b, and it rolls along this chute, moving laterally away from the drilling tower 11, for subsequent handling by the operating personnel (step 6h).
Simultaneously, or afterwards, the loader/extractor 12 is displaced downwards in order to take up the following rod of the rod assembly 6 (step 6g). | A drilled hole (1) is produced by means of a drilling rod assembly comprig a succession of rod elements (7d) to be arranged end to end. For this purpose, a vertical shaft (2) is produced in the ground, of constant horizontal section and preferably insufficient for a man to be able to work towards the bottom of it, the rod assembly is displaced therein from an opening located in a front wall of the shaft, and the elements (7) of the rod assembly are selected so that they have an axial length less than the distance separating the said opening in the front wall of the shaft from the opposite rear wall. | 4 |
FIELD
The invention relates to vehicles, and, more particularly to electric motorcycle frames.
BACKGROUND
Recent advances in electric vehicle technology have resulted vehicles that have comparable performance characteristics compared to internal combustion engine vehicles. Unfortunately, one key component, the battery, remains stubbornly expensive, resulting in costly electric cars. One cannot possibly justify the price of a new electric car compared to a similarly equipment gasoline or diesel model. If, instead, one develops the lightest possible vehicle, the electric equation just might make sense.
The lightest practical vehicle is either a motocross bike, a street legal equivalent, the enduro, or it's fully street focused version, the supermoto. Such bikes often weigh a little over 100 kg. By minimizing weight, the battery requirements are minimized, and, consequently, the price as well.
Several companies have seen the light and jumped into the fray. Unfortunately, their efforts have come up short. Many save the expense of designing a new chassis from scratch, and, instead, shoehorn an electric motor and battery pack in a frame that was originally designed for and internal combustion engine. The results have been mediocre, underpowered bikes with limited range and questionable handling.
The published US patent application 2011/0036657 A1 by Bland et al. (subsequently referred to as Bland) assigned to Brammo Inc. discloses a straight electric motorcycle chassis that comprises two sides that enclose the headstock and allow attachment of batteries from above and below. Bland places the motor at the axis of the drive sprocket, with no transmission, subsequently requiring a big, heavy electric motor to generate enough torque. The motor is also fully stressed, resulting in high maintenance costs related to motor repair or replacement. In addition, the batteries are insufficient for a reasonable top speed and range.
Zero Motorcycles, from Scotts Valley, Calif., manufactures an electric motorcycle frame using a combination of tubular and hydroformed aluminum pieces that are welded together. The myriad disadvantages of welded aluminum frames are discussed in the description, below. Like the teachings of Bland, the Zero batteries are insufficient for a reasonable top speed and range.
KTM of Austria and Quantya of Switzerland both employ welded bent steel tube perimeter frames, which can be heavy.
All of the electric motorcycle manufacturers discussed above use air cooled electric motors. Compared to liquid cooled electric motors, air cooled electric motors have lower peak power outputs and vastly lower continuous power outputs.
Given growing consumer demand for high performance, low cost electric vehicles, there is a need for a new electric motorcycle developed around a new type of chassis.
SUMMARY
The current invention relates to a vehicle frame, or chassis, and its manufacture. In one embodiment the frame comprises two cast aluminum structures that can be bolted together. The frame structures can each be cast in one piece and finish machined with one fixturing. The frame casting can include an integral motor housing that may be fully stressed and act as a torsion tube.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a motorcycle.
FIG. 2 shows motorcycle parts that attach to a motorcycle frame.
FIG. 3 shows motorcycle parts that attach to a motorcycle frame.
FIG. 4 shows a rear part of a motorcycle frame.
FIG. 5 shows a rear part of a motorcycle frame.
FIG. 6 shows a rear part of a motorcycle frame.
FIG. 7 shows a rear part of a motorcycle frame.
FIG. 8 shows a front part of a motorcycle frame.
FIG. 9 shows a front part of a motorcycle frame.
DESCRIPTION
FIG. 1 shows a motorcycle 100 . The motorcycle 100 shown is an off road or motocross bike. Motorcycles 100 comprise motocross bikes, road bikes, three wheeled bikes, and four wheeled bikes. Any three or four wheeled vehicle where the rider straddles the seat 114 of the vehicle is considered a motorcycle. Scooters are also considered motorcycles. The motorcycle 100 shown in FIG. 1 comprises an electric motorcycle, and, therefore has an electric motor and a battery box 112 .
FIG. 2 shows motorcycle parts that attach to a motorcycle frame 144 . Shown are a shroud 102 , also known as a fairing, a seat 114 , a rear subframe 116 , a rear shock 140 , a swing arm 138 , a rear suspension linkage 130 , a skid plate 142 , a battery box 112 , a motor cover 122 , a sprocket 136 , and a fork 134 . Also shown are the frame structure 200 and the second frame structure 300 .
FIG. 3 shows motorcycle parts that attach to a motorcycle frame 144 . Shown are a radiator 104 , a water pump 128 , a footpeg 126 , a rear master cylinder 124 , and a gear cover 120 . Also shown are the frame structure 200 and the second frame structure 300 .
A frame 144 for a motorcycle can be made as a single piece or several pieces that are attached together. The example frame 144 shown in FIGS. 2-3 is a two piece frame 144 comprising the frame structure 200 , also known as a rear bulkhead, and the second frame structure 300 , also known as a front bulkhead. The two piece frame 144 design allows the frame structure 200 and the second frame structure 300 to each be cast as a single piece, finish machined in one fixture, and attached together.
Using only one fixture per structure reduces time required for machining and increases accuracy of the machined surfaces. Milling machines large enough for a single structure can be cost prohibitive. Utilizing two structures, rather than a single structure, reduces the size of milling machine required to complete the operation, reducing capital costs. In addition, separating the structure into two pieces can allow machine access to additional areas of the casting, allowing more features to be integrated and reducing the complexity of fixturing and machining. Casting a single frame unit may also be quite complicated and more costly that two smaller frame castings.
A typical 3-axis milling machine setup involves clamping the workpiece in a vise where only one face is exposed for cutting at a time. A 4-axis mill setup clamps the workpiece in a rotary fixture. This allows the machine to work on virtually all faces of the workpiece that are perpendicular to the axis of rotation. Thus, by using a 4-axis milling machine, such as a horizontal milling machine with a rotary axis for the workpiece fixture, one can finish machine all of the features, or interface areas, within the tolerance specification for the frame structure 200 and the second frame structure 300 listed below and seen in FIGS. 4-9 with one fixturing per piece, each saving considerable time and expense.
In one embodiment, the frame 144 may be manufactured by casting both the frame structure 200 and the second frame structure 300 each as a single casting from 206 aluminum alloy. The frame structure 200 and the second frame structure 300 castings are then separately mounted in respective fixtures and features are finish machined in at least one working plane. 206 aluminum has some corrosion issues, so conversion coating, a process including an acid dip and passivation, followed by priming and painting would resolve those issues. Other suitable casting aluminum alloys include 201, 204, 356, and 357. In another embodiment, a one piece frame may be manufactured by casting the frame 144 as a single casting with most or all of the features and mounting points included in FIGS. 2-8 and then finish machined. In yet another embodiment, the frame structure 200 may be cast and finish machined as described above, while the second frame structure 300 may be fabricated in another manner, such as milled from billet aluminum or created by welding two or more parts together. Welding allows one to build a trellis frame structure out of steel, titanium, or aluminum or to build a twin spar aluminum frame structure commonly used for motorcycles. Alternatively, the second frame structure 300 may be built out of a composite material such as carbon fiber.
The embodiment of the frame 144 shown in FIG. 3 with the frame structure 200 and the second frame structure 300 comprises a weldless design. Welding frame components can take a considerable amount to time to accurately fixture and weld together. Welding adds expense due to inconsistencies in weld quality that require a safety margin or more robust and heavy structure to compensate for these inconsistencies. Welding can also result in stress build up and distortion in a structure requiring secondary heat treatment and straightening.
FIG. 4 shows a rear part of a motorcycle frame 144 . The frame structure 200 includes frame mounts 202 , a gear cover mount 206 , rear subframe mounts 208 , linkage mounts 210 , rear master cylinder mounts 212 , battery bolt holes 214 , skid plate mounts 216 , footpeg mounts 218 , a rear brake lever mount 220 , shroud mounts 222 , a bottom coolant port 238 , an oil sump 232 , a right side 240 , a motor housing 244 , an output shaft housing 246 , a vent hole 248 , and a shock mount bolt hole 254 .
FIG. 5 shows a rear part of a motorcycle frame 144 . The frame structure 200 includes shock mounts 204 , a motor cover mount 224 , a pass through hole 226 , swing arm mounts 228 , a top coolant port 230 , a left side 242 , a motor housing 244 , an output shaft housing 246 , a vent hole 248 , and a structural rib 250 .
The left and right sides 242 , 240 shown in FIGS. 4 , 5 are a type of side structure that connects the motor housing 244 , which may act as a torsion tube, to mounting points for other components or to other frame features. The sides 242 , 240 are shown as part of a single casting, but may also be a welded trellis structure or a composite structure. It is also possible to use only one side structure in the middle of the frame to connect the motor housing 244 to other features and mounting points.
FIG. 6 shows a rear part of a motorcycle frame 144 . The frame structure 200 includes an oil sump 232 , a drain plug port 234 , a bottom coolant port 238 , a motor housing 244 , an output shaft housing 246 , structural ribs 250 , and battery box mounts 252 .
FIG. 7 shows a rear part of a motorcycle frame 144 . The frame structure 200 includes a pass through hole 226 , a motor housing 244 , and an output shaft housing 246 .
The left side 242 and right side 240 of the frame structure 200 flank the motor housing 244 and output shaft housing 246 . The housings 244 , 246 may extend beyond the external wall of the sides 240 , 242 , or the housings 244 , 246 may be contained by the sides 240 , 242 . Alternately, one or more sides may be connected to the middle of the housings 244 , 246 . The housings 244 , 246 may be fully stressed and may act as torsion tubes to add rigidity to the frame structure 200 . Cylinders are the best structure to use for a torsion tube due to its polar moment of inertia, but other shapes can be used if appropriate. The motor housing 244 be designed to receive a motor, preferably a liquid cooled electric motor. The housing 244 may have a top coolant port 230 and a bottom coolant port 238 to allow the circulation of a coolant between the motor housing 244 and the motor.
When the motor housing 244 is used as an outer water jacket for containing coolant between itself and the motor, the motor can be contained by an inner water jacket. In this case, the motor and the inner water jacket are not required to be stressed members, while the motor housing 244 may be fully stressed.
A motor cover 122 may be attached to a motor cover mount 224 on the frame structure 200 in order to seal the motor from the elements. Likewise, a gear cover 120 may be attached to a gear cover mount 206 in order to seal the motor and/or gear reduction assembly from the elements. A shroud 102 or fairing may be attached to shroud mounts 216 , 304 . A seat 114 may be attached to seat plate mounts 324 via a seat clip and to the rear subframe 116 . The rear subframe 116 may be attached to rear subframe mounts 208 . A rear shock 140 may be attached to shock mounts 204 . A swing arm 138 may be attached to swing arm mounts 228 . Rear suspension linkages 130 may be attached to linkage mounts 210 .
A skid plate 142 may be attached to skid plate mounts 216 in order to protect the a battery box 112 . A battery box 112 may be attached to battery box mounts 252 and secured with bolts passing through the battery bolt holes 214 . Any feature that generally aids in the attachment of the battery box 112 to the frame 144 may be generally referred to as a battery box mount. The battery box 112 may be a semi stressed member when attached to the frame structure 200 , thereby adding rigidity to the frame 144 when attached while being removable without compromising the structural integrity of the frame 144 or having the rest of the motorcycle 100 lay in pieces when the battery box 112 is removed, as would be the case if the battery box 112 where fully stressed. A sprocket 136 may drive a chain to drive the rear wheel and may also be attached to an output shaft that is housed in the output shaft housing 246 .
One or more pass through holes 226 , or openings, may be used to allow passage of hoses and wires. Adding a pass through hole 226 on the motor housing 244 , as seen in FIG. 7 , allows the wires that power the motor to be routed internally in the frame 144 , a more attractive and safer solution than routing power wires externally. An o-ring or equivalent seal between the motor housing 244 and the motor can prevent coolant from entering the chamber where the power wires connect to the motor. A rubber gasket or equivalent is preferably set in the pass through hole 226 to form a seal between the motor housing 244 and the wires and to provide strain relief.
One or more vent holes 248 , 308 allow air to flow through the radiator 104 and to exit the frame 144 . One or more structural ribs 250 may be added to the frame structure 200 to increase rigidity.
An oil sump 232 may be placed in the output shaft housing 246 to provide lubrication for a gear reduction. The oil sump 232 can be drained via a drain plug port 234 . An oil level sight and oil fill port may be integrated into the gear cover 120 . A water pump 128 may be attached to a water pump mount 236 , the water pump 128 circulating a coolant to the motor and optionally to the motor control unit and the battery.
FIG. 8 shows a front part of a motorcycle frame 144 . The second frame structure 300 includes frame mounts 302 , shroud mounts 304 , a headstock structure 306 , vent holes 308 , a right side 310 , a structural rib 314 , battery box mounts 316 , skid plate mounts 318 , steering stop mounts 320 , radiator mounts 322 , seat plate mounts 324 , and a mounting plane 326 . The headstock structure 306 is designed for receiving a fork 134 . The headstock structure 306 may be a tube as shown in FIG. 8 or any other structure that holds upper and lower bearings that receive a fork 134 . A box construction type headstock structure 306 may be used to allow greater airflow through the front of the motorcycle 100 .
FIG. 9 shows a front part of a motorcycle frame 144 . The second frame structure 300 includes frame mounts 302 , shroud mounts 304 , a headstock structure 306 , a left side 312 , a structural rib 314 , battery box mounts 316 , skid plate mounts 318 , steering stop mounts 320 , radiator mounts 322 , seat plate mounts 324 , and an access hole 328 . The headstock structure 306 may receive a fork 134 . The left and right sides 312 , 310 are attached to the headstock structure 306 . A structural rib 314 attaches to the left and right sides 312 , 310 , aids in structural rigidity, and helps keep the left and right sides 312 , 310 in place during the casting and finish machining process. The seat plate mounts 324 may receive a plate or clip that receives the seat 114 . The access hole 328 can allow access to the radiator fill cap. The battery box mounts 316 may receive a battery box 112 . The skid plate mounts 318 may receive a skid plate 142 . The steering stop mounts 320 may receive steering stops. The radiator mounts 322 may receive a radiator 104 .
In addition to having the ability to cool the motor with a coolant, the frame 144 itself can act as a heat sink. Aluminum is a very good heat conductor, and the shape of the frame structure 200 allows excess head to travel from the motor housing 244 to the left and right sides 242 , 240 of the frame structure 200 where the heat may be dissipated via air convection, conduction to attached parts, or radiation.
The left and right sides 242 , 240 of the frame structure 200 as shown in FIGS. 4-7 comprise a perimeter frame construction to allow for the connection of parts including the rear swingarm 138 , rear suspension linkage 130 , rear shock 140 , rear subframe 116 , and fork 134 . Alternate constructions include a trellis frame construction and a composite frame construction.
Reference Numerals
100 motorcycle
102 shroud
104 radiator
106 steering dampener
108 steering stop
110 skid plate
112 battery box
114 seat
116 rear subframe
118 shock
120 gear cover
122 motor cover
124 rear master cylinder
126 foot peg
128 water pump
130 rear suspension linkage
134 fork
136 sprocket
138 swing arm
140 shock
142 skid plate
144 frame
200 frame structure
202 frame mount
204 shock mount
206 gear cover mount
208 rear subframe mount
210 linkage mount
212 rear master cylinder mount
214 battery bolt hole
216 skid plate mount
218 footpeg mount
220 rear brake lever mount
222 shroud mount
224 motor cover mount
226 pass through hole
228 swing arm mount
230 top coolant port
232 oil sump
234 drain plug port
236 water pump mount
238 bottom coolant port
240 right side
242 left side
244 motor housing
246 output shaft housing
248 vent hole
250 structural rib
252 battery box mount
254 shock mount bolt hole
300 second frame structure
302 frame mount
304 shroud mount
306 headstock tube
308 vent hole
310 right side
312 left side
314 structural rib
316 battery box mount
318 skid plate mount
320 steering stop mount
322 radiator mount
324 seat plate mount
326 mounting plane
328 access hole | This invention comprises a frame for an electric motorcycle. Electric motorcycles have vastly different component requirements compared to internal combustion engine motorcycles, and, therefore, require a radical redesign of the frame in order to maximize the efficiency of the system. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to pharmaceutical compounds for use in the management of pain. More particularly, it relates to histogranin-like peptides and non-peptides.
BACKGROUND OF THE INVENTION
[0002] Histogranin (HN, Scheme 1) (SEQ ID NO. 1), a pentadecapeptide whose structure presents 80% and 73% homologies with those of fragment-(86-100) of histone H4 (SEQ ID NO. 2) and osteogenic growth peptide (OGP) (SEQ ID NO. 3), respectively, was first isolated from extracts of bovine adrenal medulla (Lemaire, Eur. J. Pharmacol., 1993, 245, 247-256), a tissue recognized to contain various pain reducing substances, including the endogenous opioid peptides Met- and Leu-enkephalins and catecholamines (Boarder et al. J. Neurochem., 1982, 39, 149-154; Liston et al. Science, 1984, 225, 734-737).
[0003] I.c.v. administration of HN (SEQ ID NO. 1) and related peptides in mice dose-and structure-dependently blocked writhing induced by i.p. administration of acetic acid and tail-flick induced by radiant heat (Lemaire et al., Soc. Neurosci. 1997, 23, 674., Ruan, Prasad and Lemaire, Pharmcol. Biochem. Behav. 2000, 66, 1-9). In addition, [Ser 1 ]HN, a chemically stable analog of HN (SEQ ID NO. 1) (Shukla and Lemaire, Pharmcol. Biochem. Behav. 1995, 50, 49-54), blocked tonic pain in the rat formalin assay (Siegen and Sagan, Neuroreport. 1997, 8 1379-81) and attenuated hyperalgesia and allodynia caused by sciatic nerve injury (Siegan and Sagen, Brain Res. 1997, 755, 331-334) and intrathecal (i.t.) administration of N-methyl-D-aspartate (NMDA; Hama and Sagen, Pharmacol. Biochem. Behav., 1999, 62, 67-74).
[0000] Scheme 1:
[0000]
Histogranin (HN) (SEQ ID NO. 1): Met-Asn-Tyr-Ala-Leu-Lys-Gly-Gln-Gly-Arg-Thr-Leu-Tyr-Gly-Phe
H4-(86-100) (Histone H4 fragment) (SEQ ID NO. 2): Val-Val-Tyr-Ala-Leu-Lys -Arg-Gln-Gly-Arg-Thr-Leu-Tyr-Gly-Phe
OGP (Osteogenic Growth Peptide) (SEQ ID NO. 3):
[0007] Ala-Leu-Lys-Arg-Gln-Gly-Arg-Thr-Leu-Tyr-Gly-Phe-Gly-Gly
Histogranin(7-15) (SEQ ID NO. 4):
[0009] In the mouse writhing tail-flick assays, the analgesic effects of i.c.v. administration of HN (SEQ ID NO. 1) and related peptides are not mediated by opioid receptors and may involve a participation of dopamine D2 sites (Ruan, Prasad and Lemaire, Pharmcol. Biochem. Behav. 2000, 66, 1-9). A hypothesis is that HN (SEQ ID NO. 1) and related peptides bind to a specific receptor present in the brain (Roger et Lemaire, J. Pharmacol. Exp. Ther., 1993, 267, 350-356) and on peripheral cells (Lemaire et al., Biochem Biophys Res Commun. 1993, 194, 1323-9) and modulate processes involved in the pathophysiology of pain.
[0010] Among various HN related peptides and fragments, the C-terminal peptide HN-(7-15) (SEQ ID NO. 1) (Scheme 1) was shown to be particularly potent in the mouse writhing test with an AD50 of 8.5 nmol/mouse as compared with 23 nmol/mouse for HN (SEQ ID NO. 1) (Ruan, Prasad and Lemaire, Pharmcol. Biochem. Behav. 2000, 66, 1-9; Canadian patent application 2,219,437).
SUMMARY OF THE INVENTION
[0011] There is provided a compound of general formula I, II or III, or a pharmaceutically acceptable salt thereof:
wherein:
A is -hydrogen, —(C 1 -C 8 )alkyl or —(C 1 -C 8 )alkyl substituted by hydroxy; B is -(C 1 -C 6 )alkylguanidino, —(C 1 -C 6 )alkyl(4-imidazolyl), —(C 1 -C 6 )alkylamino, p-aminophenylalkyl(C 1 -C 6 )—, p-guanidinophenylalkyl(C 1 -C 6 )- or 4-pyridinylalkyl (C 3 -C 6 )—; D is —(CO)—, —(CO)—(C 1 -C 6 )alkylene or —(C 1 -C 6 )alkylene; E is a single bond or —(C 1 -C 6 )alkylene; Z is —NH 2 , —NH—(C 1 -C 6 )alkylcarboxamide, —NH—(C 1 -C 6 )alkyl, —NH-benzyl, —NH-cyclo(C 5 -C 7 )alkyl, —NH-2-(1-piperidyl)ethyl, —NH-2-(1-pyrrolidyl)ethyl, —NH-2-(1-pyridyl)ethyl, —NH-2-(morpholino)ethyl, -morpholino, -piperidyl, —OH, —(C 1 -C 6 )alkoxy, —O-benzyl or —O-halobenzyl; R 1 , R 2 and R 3 are, independent of one another, -hydrogen, -arylcarbonylamino, —(C 1 -C 6 )alkoylamino, —(C 1 -C 6 )alkylamino, —(C 1 -C 6 )alkyloxy, —(C 1 -C 6 )alkylaminocarbonyl, -carboxy, —OH, -benzoyl, -p-halogenobenzoyl, -methyl, —S-(2,4-dinitrophenyl), —S-(3-nitro-2-pyridinesulfenyl), -sulfonyl, -trifluoromethyl, —(C 1 -C 6 )alkylaminocarbonylamino, -halo or -amino; R 4 and R 5 are, independent of one another, -hydrogen, —(C 1 -C 6 )alkyl, -methyloxy, -nitro, -amino, -arylcarbonylamino, —(C 1 -C 6 )alkoylamino, —(C 1 -C 6 )alkylamino, -halo or 13 OH.
[0019] There are also provided methods for synthesizing compounds of Formulae I, II and III.
[0020] There are also provided pharmaceutical compositions comprising a compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, together with a pharmaceutically acceptable carrier, diluent or excipient.
[0021] In addition, there is provided a method for managing pain comprising administering a pain managing effective amount of a compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, to a subject in need of pain management.
[0022] Furthermore, there is provided the use of a compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, for managing pain or for manufacturing a medicament for managing pain.
[0023] There is also provided commercial packages comprising a compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, or a composition comprising a compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, together with instructions for their use for managing pain.
[0024] There is also provided a method of modulating COX-2 induction comprising administering an effective amount of a COX-2 induction modulating compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, or a composition comprising a compound of Formulae I, II or III, or a pharmaceutically acceptable salt thereof, to a subject.
[0025] Compounds of Formulae I, II and III were invented according to the unifying hypothesis that compounds containing basic, hydroxyphenyl and phenyl groups (or homologues) with proper spatial arrangements display HN-like biological activities.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The radical A is preferably hydrogen, CH 3 CH(OH)— or (CH 3 ) 2 CHCH 2 —. The CH 3 CH (OH)— or (CH 3 ) 2 CHCH 2 — groups may be bonded to the molecule in such a way as to provide either the R- or S-configuration at the carbon atom to which the group is bonded. As one skilled in the art will recognize, the hydrogen radical corresponds to the amino acid glycine, the group CH 3 CH(OH)— has the same structure as the side-chain from the amino acid threonine while (CH 3 ) 2 CHCH 2 — has the same structure as the side-chain from the amino acid leucine.
[0027] The radical B is preferably H 2 N—C(NH)—NH—CH 2 CH 2 CH 2 — or H 2 N—(CH 2 ) 4 —. The H 2 N—C(NH)—NH—CH 2 CH 2 CH 2 — or H 2 N—(CH 2 ) 4 — groups may be bonded to the molecule in such a way as to provide either the R- or S-configuration at the carbon atom to which the group is bonded. As one skilled in the art will recognize, the group H 2 N—C(NH)—NH—CH 2 CH 2 CH 2 — has the same structure as the side-chain from the amino acid arginine while H 2 N—(CH 2 ) 4 — has the same structure as the side-chain from the amino acid lysine.
[0028] Generally, chiral carbon atoms in the compounds of Formula I, II or III may be in either optically active R- or S-configuration. Therefore, where amino acid moieties are present in the compounds, they may have either the L- or D-configurations. Optically pure compounds, racemic mixtures, and diastereomeric mixtures are all contemplated within the scope of the invention.
[0029] Pharmaceutically acceptable salts encompass any salts of the active compounds which are suitable for the formulation of a pharmaceutical composition and which are compatible with the animal to which the compound is being administered. Such salts include, but are not limited to, salts of acids (e.g. hydrochlorides and sulphates) and salts of bases (e.g. sodium and ammonium salts).
[0030] For the synthesis of cyclic peptides (Formula I), Kaiser's oxime-resin may be used following the procedures of Nishino et al. ( J. Chem. Soc., Perkin Trans. 1, 1996, 939-946) and Osapay et al. ( Tetrahedron Lett. 1990, 31, 6121-6124), the disclosures of which are hereby incorporated by reference.
[0031] The solid-phase synthesis of the compounds of Formula II or III (Schemes 2a and 2b) may be achieved by starting with MBHA Resin (i.e. modified Merrifield resin, which is a polystyrene based resin having bound thereto a 4-methylbenzhydrylamine hydrochloride moiety) or with Rink-Amide Resin. The method may begin with neutralization of the amine hydrochloride group in MBHA resin (1) with 10% N′,N′-diisopropylethylamine/CH 2 Cl 2 (DIEA/DCM) or with the removal of the Fmoc-protecting group from Rink-Amide resin (2) with 20% piperidine in DMF. Protected N-amino acids may then be attached to the resultant amino-resin (method A or method B) or to 4-sulfamylbutyryl AM resin (3) (method C) using benzotriazole-1-yl-oxy-tris-pyrrolidino-phosphonium hexafluorophosphate (PyBOP/DIEA). The intermediates 4, 5, 6 are ninhydrin negative by the Kaiser test (Kaiser et al. Anal. Biochem. 1970, 34, 595-598).
[0032] Incorporation of specific groups may be achieved by reacting the deprotected resin 4, 5, 6 with a variety of substituted o-fluoro-nitroarens (preferably about 10 equiv.) and DIEA (preferably about 5 equiv.) in DMF or DMSO, preferably for about 2 days (Scheme 2b). The completion of the reaction leading to substituted o-nitro-aniline resin (7) may be monitored by the ninhydrin test.
[0033] In the next step, the aryl nitro group (intermediate resin product 7) may be reduced by a solution (preferably at a concentration of about 1 M) of tin(II) chloride dihydrate (SnCl 2 .2H 2 O) in N-methylpyrrolidine-2-one (NMP) in the presence of N-methylmorpholine (NMM), preferably overnight at room temperature. The resin may be washed and then immediately acylated by using symmetric anhydride generated in situ from N′,N′-dicyclohexylcarbodiimide (DCC) and corresponding carboxylic acids (path a in scheme 2b) or treated with aldehydes in NMP, preferably for about 8 hr at room temperature, followed by heating, preferably at about 50° C. for about 8 hr (path b in scheme 2b).
[0034] Resin-bound o-(N-acyl)-phenylenediamine (8) or benzimidazole (9) may be washed with DMF, MeOH, DCM and Et 2 O and then dried in vacuo overnight at room temperature. The compounds may then be cleaved from the MBHA resin with liquid hydrogen fluoride (HF) under standard cleaving conditions (Matsueda et al. Peptide, 1981, 2, 45-50, the disclosure of which is hereby incorporated by reference). Substituted-Rink-Amide resin may be treated with CF 3 COOH (TFA/H 2 O (95:5)), preferably for 1 hour at ice-bath temperature (Lee et al. J. Org. Chem. 1997, 62, 3874-3879, the disclosure of which is hereby incorporated by reference). For the removal of the compounds from the resin, the 4-sulfamylbutyryl AM resin may first be N-methylated with ICH 2 CN/DIEA in NMP and then treated with either hydroxide at room temperature or an amine in THF or dioxane at elevated temperature (Backes et al. J. Am. Chem. Soc., 1996, 118, 3055-3056, the disclosure of which is hereby incorporated by reference).
wherein B, D, E, R 1 , R 2 , R 3 , R 4 , R 5 and Z represent the groups described above and the spherical element in Schemes 2a and 2b represents the remainder of the MBHA resin, Rink-Amide resin or 4-sulfamylbutyryl AM resin, as appropriate.
[0035] Particularly preferred compounds that may be prepared by the procedures described above are:
[0000] (A) Cyclic Tetrapeptides of Formula I (See Scheme 3):
[0000]
Cyclo(-Gly-(p-chloro)Phe-Tyr-D-Arg-) [Compound I-1] (SEQ ID NO. 5)
Cyclo(-Gly-(p-chloro)Phe-Tyr-(p-amino)Phe-) [Compound I-2] (SEQ ID NO. 6)
Cyclo(-Gly-(p-chloro)Phe-Tyr-(p-guanidino)Phe-) [Compound I-3] (SEQ ID NO. 7)
Cyclo(-Gly-(p-amino)Phe-Tyr-D-Arg-) [Compound I-4] (SEQ ID NO. 8)
Cyclo(-Thr-(p-chloro)Phe-Tyr-D-Arg-) [Compound I-5] (SEQ ID NO. 9)
(B) Non-Peptides of Formula II (See Scheme 4):
N-5-guanidinopentanamide-(2S)-yl-2-N-(p-hydroxyphenylacetyl)phenylenediamine [Compound II-1]
N-5-guanidinopentanamide-(2S)-yl-2-N-(p-hydroxyphenylacetyl)-4-trifluorometyl-phenylenediamine [Compound II-2]
N-5-guanidinopentanamide-(2R)-yl-2-N-(p-hydroxyphenylacetyl)-4-carboxy-phenylenediamine [Compound II-3]
N-5-guanidinopentanamide-(2R)-yl-2-N-(p-hydroxyphenylacetyl)-4-(p-chlorobenzoyl)-phenylenediamine [Compound II-4]
(C) A Non-Peptide of Formula III (See Scheme 4):
N-5-guanidinopentanamide-(2R)-yl-2-(p-hydroxybenzyl)-5-carboxybenzimidazole [Compound III-1]
[0046] Pharmaceutical compositions comprising a compound of the present invention, or a pharmaceutically acceptable salt thereof, in admixture with a pharmaceutically acceptable carrier, diluent or excipient may be formulated by methods generally known in the art. The preparation and administration of pharmaceutical compositions are generally known in the art, for example as described in U.S. Pat. No. 5,169,833, the disclosure of which is hereby incorporated by reference.
[0047] Thus, the active compounds of the invention may be formulated for oral, buccal, transdermal (e.g., patch), intranasal, parenteral (e.g., intravenous, intramuscular or subcutaneous) or rectal administration or in a form suitable for administration by inhalation or insufflation.
[0048] For oral administration, the pharmaceutical compositions may take the form of, for example, tablets or capsules prepared by conventional means with pharmaceutically acceptable excipients such as binding agents (e.g., pregelatinised maize starch, polyvinylpyrrolidone or hydroxypropyl methylcellulose); filters (e.g., lactose, microcrystalline cellulose or calcium phosphate); lubricants (e.g., magnesium stearate, talc or silica); disintegrants (e.g., potato starch or sodium starch glycollate); or wetting agents (e.g., sodium lauryl sulphate). The tablets may be coated by methods well known in the art. Liquid preparations for oral administration may take the form of, for example, solutions, syrups or suspensions, or they may be presented as a dry product for constitution with water or other suitable vehicle before use. Such liquid preparations may be prepared by conventional means with pharmaceutically acceptable additives such as suspending agents (e.g., sorbitol syrup, methyl cellulose or hydrogenated edible fats); emulsifying agents (e.g., lecithin or acacia); non-aqueous vehicles (e.g., almond oil, oily esters or ethyl alcohol); and preservatives (e.g., methyl or propyl p-hydroxybenzoates or sorbic acid).
[0049] For buccal administration the composition may take the form of tablets of lozenges formulated in conventional manner.
[0050] The active compounds of the invention may be formulated for parenteral administration by injection, including using conventional catheterization techniques or infusion. Formulations for injection may be presented in unit dosage form, e.g., in ampules or in multi-dose containers, with an added preservative. The compositions may take such forms as suspensions, solutions or emulsions in oily or aqueous vehicles, and may contain formulating agents such as suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredient may be in powder form for reconstitution with a suitable vehicle, e.g., sterile pyrogen-free water, before use.
[0051] The active compounds of the invention may also be formulated in rectal compositions such as suppositories or retention enemas, e.g., containing conventional suppository bases such as cocoa butter or other glycerides.
[0052] For intranasal administration or administration by inhalation, the active compounds of the invention are conveniently delivered in the form of a solution or suspension from a pump spray container that is squeezed or pumped by the patient or as an aerosol spray presentation from a pressurized container or a nebulizer, with the use of a suitable propellant, e.g., dichlorodifluoromethane, trichlorofluoromethane, dichlorotetrafluoroethane, carbon dioxide or other suitable gas. In the case of a pressurized aerosol, the dosage unit may be determined by providing a valve to deliver a metered amount. The pressurized container or nebulizer may contain a solution or suspension of the active compound. Capsules and cartridges (made, for example, from gelatin) for use in an inhaler or insufflator may be formulated containing a powder mix of a compound of the invention and a suitable powder base such as lactose or starch.
[0053] The active compounds or pharmaceutical compositions thereof are generally administered to or used in animals, for example in humans for medical purposes or in domestic animals or farm animals for veterinary purposes. Preferably, the animal is a mammal, particularly a human. Selection of appropriate doses would depend on the particular patient and on the compound being used and is ultimately decided by a medical practitioner. Generally, doses may range, depending on the compound, from 200 times less to 500 times more than would be used for morphine, which could be administered, for example, 1 to 4 times per day.
[0054] The active compounds of the present invention are analgesic in various animal pain assays, particularly after central (i.c.v., i.t.) or peripheral (oral, i.p. and/or i.v.) administrations. They also potentiate the action of morphine, therefore, pharmaceutical compositions comprising the active compounds of the present invention in admixture with morphine are contemplated within the scope of the invention. The active compounds may be administered in conjunction with morphine to enhance the effectiveness of morphine.
[0055] The active compounds also block morphine tolerance and, particularly in isolated rat alveolar macrophages, they inhibit the induction of COX-2 and the secretion of PGE 2 in response to lipopolysaccharide (LPS).
[0056] The active compounds show potent analgesic activity (1.4 to 135 fold as potent as HN (SEQ ID NO. 1)) in the mouse writhing test. Significant analgesic activity is observed after both central (i.c.v.) and peripheral (oral, i.p.) administrations of compounds I-1 (SEQ ID NO. 5), II-1 and III-1. The various compounds also display high analgesic activity in the mouse tail-flick (i.c.v.) pain assay. None of the compounds (i.c.v.) induce motor dysfunction at analgesic doses as assessed by the mouse rotarod assay. In addition, compound II-1 potentiates the analgesic effects of morphine in the mouse writhing test and inhibits morphine tolerance in the mouse tail-flick assay. In isolated rat alveolar macrophages, the active compounds potently inhibit the induction of COX-2 and the secretion of PGE 2 in response to LPS.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] The invention will now be particularly described by non-limiting examples having reference to the appended drawings in which:
[0058] FIG. 1 is a graph showing the dose-dependent analgesic effects of morphine and Histogranin-like peptides and non-peptides (i.c.v.) in the mouse writhing assay.
[0059] FIGS. 2A and 2B are graphs showing the antinociceptive effects of oral and intraperitoneal administrations of HN-like peptides and non-peptides in the mouse writhing test.
[0060] FIG. 3 is a graph showing the dose-dependent analgesic effects of morphine and Histogranin-like peptides and non-peptides in the mouse tail-flick assay.
[0061] FIGS. 4A and 4B are graphs showing the potentiation (A) and prolongation (B) of the analgesic effect of morphine (i.c.v.) in the mouse writhing test by coadministration of a subanalgesic dose (3 nmol) of compound
[0062] FIG. 5 is a graph showing blockade of morphine tolerance by compound II-1 in mice (* P<0.05 as compared with control).
[0063] FIG. 6 is a graph showing the inhibitory effects of HN (SEQ ID NO. 1) and related peptides and non-peptides on PGE 2 release from LPS-stimulated rat alveolar macrophages.
[0064] FIG. 7 is a graph showing the inhibitory effects of HN (SEQ ID NO. 1), related peptides and non-peptides on the expression of COX-2 in LPS-stimulated rat alveolar macrophages.
EXAMPLES
[0065] The purity and identity of the synthetic products were confirmed by thin-layer chromatography, analytical HPLC on μ-Bondapak™ C-18 (Waters™) and FAB mass spectroscopy.
Example I
[0066] Cyclo(-Gly-(p-chloro)Phe-Tyr-D-Arg-) (I-1)(SEQ ID NO. 5). Boc-Gly-oxime-resin was first prepared by mixing oxime-resin (available from Novabiochem™) (1.5g, 0.57 meq/g) with Boc-Gly-OH (1.3 g, 9 eq) in the present of DCC (9.9 ml of DCC 8%, 4.5 eq), 4-dimethylaminopyridine (DMAP), (0.3 g, 3 eq), N-hydroxybenzotriazole hydrate (HOBt), (0.4 g, 3 eq) in 50 ml of DCM at room temperature for 12 hr. The resin was submitted to three washes with 50 ml of DCM, one wash with 50 ml of propanol-2 and two washes with 50 ml of DCM. The free oxime groups were capped by acetylation with acetic anhydride (0.4 ml, 5 eq) for 30 min. The peptide chain was then assembled according to the following coupling steps: (i) one wash with 25% trifluoroacetic acid (TFA)-DCM; (ii) deprotection with 25% TFA-DCM (30 min); (iii) two washes with DCM; (iv) one wash with propanol-2; (v) three washes with DCM; (vi) one wash with dimethylformamide (DMF); (vii) coupling of Boc-amino-acids (consecutively Boc-D-Arg(Tos)-OH (1.1 g, 3 eq), Boc-Tyr(2,6-di-Cl-Bzl)-OH (1.1 g, 3 eq) and Boc-Phe (pCl)-OH (0.8g, 3 eq)) in presence of PyBOP, (1.3 g, 3 eq), HOBt (0.13 g, 1 eq) and DIEA (0.95 ml, 6.5 eq) in DMF (45 min); (viii) three washes with DMF; (ix) two washes with DCM. Solvent volumes were 15 cm 3 g −1 resin. Coupling efficiency was checked at each coupling cycle by the Kaiser test. The peptide was cleaved from the resin by intrachain aminolysis in the presence of AcOH (0.097 ml, 2 eq) and DIEA (0.293 ml, 2 eq) in 30 ml DMF at room temperature for 24 hr. The product was obtained from the solution phase by filtration. Protecting groups were removed with anhydrous hydrogen fluoride (HF) at 0° C. for 30 min. The product was purifed by chromatography on Sephadex™ G-10 (1.5×30 cm column) and preparative reversed-phase HPLC on p-Bondapak C18 column (25×100 mm) with a gradient of 0%-50% acetonitrile in 0.1% TFA and a flow rate of 5 ml/min over 65 min. The procedure yielded 50 mg of I-1 (SEQ ID NO. 5) (Scheme 3; 11% based on starting resin).
[0067] Other cyclic peptides (Scheme 3) were prepared according to this technique with the following yields: cyclo(-Gly-(p-chloro)Phe-Tyr-(p-amino)Phe-) (I-2 (SEQ ID NO. 6); 45 mg, 9%), cyclo(-Gly-(p-chloro)Phe-Tyr-(p-guanidino)Phe-) (I-3 (SEQ ID NO. 7); 15 mg, 2%), cyclo(-Gly-(p-amino)Phe-Tyr-D-Arg-) (I-4 (SEQ ID NO. 8); 40 mg, 9%), cyclo(-Thr-(p-chloro)Phe-Tyr-D-Arg-) (I-5 (SEQ ID NO. 9); 40 mg, 9%).
Example II
Synthesis of N-5-guanidinopentanamide-(2S)-yl-2-N-(p-hydroxyphenylacetyl)phenylenediamine (II-1)
[0068] Attachment of Boc-L-Arg(Tos)-OH to MBHA-resin. The MBHA-resin (1 g, 0.67 mmol, Novabiochem™) was first neutralized with 10% DIEA in DCM (two 5 min washes with 50 ml each) and washed six times with six 50 ml fractions of DCM. The first amino acid was attached by mixing the resin for 1 hr at room temperature with 1.1 g (2.68 mmol) of Boc-L-Arg(Tos)-OH, 1.4 g (2.68 mmol) of PyBOP, 0.2 g (1.34 mmol) of HOBt, H 2 O and 0.9 ml (5.36 mmol) of DIEA in 50 ml of DMF/DCM (1:1). At the end of the coupling reaction, the resin was ninhydrin negative by the Kaiser test. The resulting mixed Boc-Arg(Tos)-MBHA-resin was washed three times with 50 ml of DMF, three times with 50 ml of DCM and then acetylated for 30 min with 0.6 ml (6.7 mmol) of Ac 2 O and 0.6 ml (3.35 mmol) of DIEA in 50 ml of DCM. The resin was washed 4 times with 50 ml of DCM, 2 times with 50 ml of MeOH, 2 times with 50 ml of DCM and dried.
[0069] Incorporation of 1-fluoro-2-nitrobenzen to Boc-L-Arg(Tos)-MBHA-resin. One g of the above-described resin (approximately 0.67 mmol) was washed with 50 ml of TFA/DCM (4:6) and subsequently deprotected for 15 min with 50 ml of TFA/DCM (4:6). The resin was washed 4 times with 50 ml of DCM, neutralized twice for 2 min each with 50 ml portions of DIEA/DCM (5:95) and washed six times with 50 ml of DCM. The next reaction was conducted by addition of 0.7 ml (6.7 mmol) of l-fluoro-2-nitrobenzene, 0.6 ml (3.35 mmol) of DIEA and 20 ml of DMF. The suspension was allowed to mix at room temperature for 24 hr, the reagents were changed and a novel suspension was made and mixed for another 24 hr. The completion of the reaction was verified by the Kaiser test. The resin then was washed 4 times with 50 ml of DMF, 2 times with 50 ml of MeOH, 2 times with 50 ml of DCM and acetylated for 30 min with 0.6 ml (6.7 mmol) of Ac 2 O and 0.6 ml (3.35 mmol) of DIEA in 50 ml of DCM. The o-nitroaniline-resin was washed 4 times with 50 ml of DCM, 2 times with 50 ml of MeOH, 2 times with 50 ml of DCM and dried.
[0070] N-5-guanidinopentanamide-(2S)-yl-2-N-(p-hydroxyphenylacetyl) phenylenediamine (II-1). One g (approximately 0.67 mmol) of the o-nitroaniline-resin was reduced with 1 M of SnCl 2 , 2H 2 O (4.5 g) and 1 M of NMM (2.2 ml) in 20 ml of NMP overnight at room temperature. The resin was washed 4 times with 50 ml of NMP, 2 times with 50 ml of DCM, 2 times with 50 ml of MeOH, 2 times with 50 ml of DCM and then immediately acylated with 0.18 M of carboxylic anhydride prepared in situ from 1 g (6.7 mmol) of 4-hydroxyphenylacetic acid, 17.3 ml (6.7 mmol) of 8% DCC/DCM, 0.5 g (3.35 mmol) of HOBt.H 2 O and 0.4 g (3.35 mmol) of DMAP in 20 ml DCM overnight at room temperature. The resin was washed with 50 ml portions of DMF (×4), DCM (×2), MeOH (×2), DCM (×2), Et 2 O (×2) and dried in vacuum. Compound (II-1) was cleaved from the resin by treatment with 15 ml of anhydrous liquid HF and 1 ml of anisole as scavenger for 1 hr at 0° C. HF and scavenger were evaporated in vacuo. The compound was extracted from the dried resin with 50 ml of DMF (×4), and then concentrated in vacuo. It was purified by gel filtration on Sephadex™ G-10 followed by preparative reversed-phase HPLC using a 25×200 mm column (Water, μ-Bondapak C18, 10 μm, 125 Å), operating at a flow 5 ml/min. The chromatography was achieved using a gradient of acetonitrile in 0.1% TFA, increasing from 15% to 65% over 1 hr. The purified compound was detected by UV at 280 nm. Yield: 120 mg (45%) (based on the substitution of the starting resin).
Example III
[0071] N-5-guanidinopentanamide-(2S)-yl-2-N-(p-hydroxyphenylacetyl)-4-trifluorometyl-phenylenediamine (II-2). The preparation of compound II-2 was performed as described above. 4-fluoro-3-nitrobenzotrifluoride was used instead of 1-fluoro-2-nitrobenzen in the 2 nd step. 1 g of the deprotected H-L-Arg(Tos)-MBHA-resin (approximately 0.67 mmol) was added 0.9 ml (6.7 mmol) of 4-fluoro-3-nitrobenzotrifluoride, 0.6 ml (3.35 mmol) of DIEA and 20 ml of DMF. The suspension was allowed to mix at room temperature for 24 hr, followed by a change of the reagents and another 24 hr of mixing. The completion of the reaction was verified by the Kaiser test. The other steps were accomplished using the same reaction conditions as those described for compound II-1. Yield: 96 mg (31%).
Example IV
[0072] N-5-guanidinopentanamide-(2R)-yl-2-N-(p-hydroxyphenylacetyl)-4-carboxyphenylene-diamine (II-3). Compound II-3 was obtained following a procedure similar to that used for the preparation of compound II-1. Boc-D-Arg(Tos)-OH was used instead of Boc-L-Arg(Tos)-OH in the 1 st step and 4-fluoro-3-nitrobenzoic acid was used in the 2 nd step. One g of the MBHA-resin (0.67 mmol) was coupled with 1.1 g (2.68 mmol) of Boc-D-Arg(Tos)-OH, 1.4 g (2.68 mmol) of PyBOP, 0.2 g (1.34 mmol) of HOBt.H 2 O and 0.9 ml (5.36 mmol) of DIEA in 50 ml of DMF/DCM (1:1) for 1 hr at room temperature. In the 2 nd step, 1 g of the deprotected H-L-Arg(Tos)-MBHA-resin (approximately 0.67 mmol) was added 1.2 g (6.7 mmol) of 4-fluoro-3-nitrobenzoic acid, 0.6 ml (3.35 mmol) of DIEA and 20 ml of DMF. The suspension was allowed to mix at room temperature for two 24 hour periods as described above. The other steps were accomplished in the same reaction conditions as those for compound II-1. Yield: 90 mg (30%).
Example V
[0073] N-5-guanidinopentanamide-(2R)-yl-2-N-(p-hydroxyphenylacetyl)-4-(p-chlorobenzoyl)-phenylenediamine (II-4). Compound II-4 was obtained following a procedure similar to that used for the preparation of compound II-3. Following acetylation of amino group with 4-hydroxyphenylacetic anhydride prepared in situ from DCC and corresponding carboxylic acid, 1 g (approximately 0.67 mmol) of the resin-bound o-(N-acyl) phenylenediamine was treated with 1.1 g (6.7 mmol) of 1,1′-carbonyldiimidazole and 0.4 g (3.35 mmol) of DMAP in 20 ml of tetrahydrofuran (THF) overnight at 4° C. then immediately coupled with 6.7 ml (6.7 mmol) of 4-chlorophenylmagnesium bromide (1.0 M solution in diethyl ether) in 20 ml of THF overnight at 4° C. The other steps were accomplished using the same reaction conditions as those described for compound II-3. Yield: 49 mg (14%).
Example VI
[0074] N-5-guanidinopentanamide-(2R)-yl-2-(p-hydroxybenzyl)-5-carboxybenzimidazole (III-1). Compound III-1 was obtained by a modification of the procedure for the preparation of compound II-3. Following the reduction of nitro group with SnCl 2 .2H 2 O, 1 g (approximately 0.67 mmol) of the o-aminoaniline-resin was immediately treated with 0.8 g (6.7 mmol) of p-hydroxybenzaldehyde in NMP with stirring for 8 hr at room temperature, followed by heating at 50° C. for 8 hr. The resultant resin was transferred to a 25 ml filter tube, washed with the following schedule (50 ml each): NMP (×3), DCM (×2), MeOH (×3), Et 2 O (×3). It was then dried overnight in vacuo at room temperature. Finally, the cleavage and purification steps were accomplished using the same conditions as those described for compound II-3. Yield: 94 mg (34%).
[0075] The purity and identity of the synthetic compounds were assessed by thin layer chromatography (TLC), high performance liquid chromatography (HPLC) and mass spectrometry (ES-MS or FAB-MS) (Table 1).
TABLE 1 Analytical properties of Histogranin-like peptides and non-peptides. ES-MS or Compounds TLC (Rf) a HPLC (k′) b FAB-MS (MH+) Peptides I-1 (SEQ ID NO. 5) 0.77 4.47 558 I-2 (SEQ ID NO. 6) 0.86 4.00 580 I-3 (SEQ ID NO. 7) 0.58* — 622 I-4 (SEQ ID NO. 8) 0.52 4.19 538 I-5 (SEQ ID NO. 9) 0.65 0.83 602 Non-peptides II-1 0.66 2.02 399 II-2 0.70 2.18 467 II-3 0.68 0.70 443 II-4 0.70 1.54 538 III-1 0.59 2.50 411 a BAWP (v/v), 1-butanol-acetic acid-water-pyridine (15/3/10/12). b by analytical reversed-phase HPLC using a 3.9 × 300 mm column (Water, μBondapak ™ C18), operating at a flow 1 ml/min. Separations were achieved using a water/acetonitrile/TFA # gradient, increasing from 0% to 50% (I-1, I-2), 0% to 65% (I-4, I-5), 15% to 65% (compounds II-1 and II-2) and from 15% to 80% (compounds II-3, II-4 and III-1) over 50 min and UV detection at 280 and 350 nm. *R f (v/v, CH 2 Cl 2 /MeOH, 8/2).
Example VII
Analgesia, Morphine Potentiation and Blockade of Morphine Tolerance
[0000] Materials and Methods:
[0076] Animals. Mice (male 20-25 g, Swiss Webster) were obtained from Charles River (Canadian Breeding Farm, St. Constant, Quebec). They were housed five per cage in a room with controlled temperature (22±2° C.), humidity and artificial light (06.30-19 h). The animals had free access to food and water and were used after a minimum of 4 days of acclimation to housing conditions. Experiments were carried out between 10:00 a.m. and 4:00 p.m. in an air-regulated and soundproof laboratory (23±1° C., 40% humidity), in which mice were habituated at least 30 min before each experiment. The experiments were authorized by the animal care committee of the University of Ottawa in accordance with the guidelines of the Canadian Council on Animal Care.
[0077] Drugs and peptides. Morphine, raclopride, naloxone, SCH-23390 were products of ENDO laboratory Inc (Garden City, N.Y.). HN (SEQ ID NO. 1), [Ser 1 ]HN, HN-(7-15) (SEQ ID NO. 4) and H4-(86-100) (SEQ ID NO. 2) were synthesized by the solid-phase procedure (Lemaire et al. Int. J. Peptide Protein Res. 1986, 27, 300-305). Cyclic tetrapeptides and non-peptides were synthesized as described above.
[0078] Administration of compounds. The i.c.v. administrations of the peptides and non-peptides in mice were performed as described by Shukla et al. (Shukla et al., Brain Res. 1992, 591,176). Peptides are dissolved in double-distilled sterile water (vehicle) and 10 μl of the peptide solution or vehicle are delivered gradually within approximately 3 sec, mice exhibiting normal behaviour within 1 min after injection. The administration site is confirmed by injecting Indian ink in preliminary experiments.
[0079] Mouse writhing test. Antinociceptive activity of HN (SEQ ID NO. 1) and related compounds were evaluated using the acetic acid-induced writhing test according to a modification (Shukla et al., Brain Res. 1992, 591,176) of the method of Hayashi and Takemori (Eur. J. Pharmacol. 1971, 16, 63). Male swiss webster [(SW)f BR] mice are injected intraperitoneally (i.p.) with 1.0% acetic acid (10 ml/kg) 5 min after i.c.v. injection of 0 (saline), 0.1, 0.5, 1, 10, 25, 50, 75 and 100 nmol of HN (SEQ ID NO. 1) or related peptides or non-peptides. The number of writhes displayed by each mouse is counted for a period of 10 min after the injection of the acetic acid solution. An abdominal stretch is characterized by the contraction of the abdominal muscles, the arching of the back ventrally such as the abdomen touches the bedding surface and the extension of one or both hind limbs. Mice are used once and then killed immediately. Groups of 10 mice are used for each dose. The analgesic activity of the peptides is assessed by the percent analgesia displayed by a test group of 10 mice. The percentage of analgesia is calculated for each dose by the formula: [(mean number of writhes in control group−mean number of writhes for the test group)/(mean number of writhes in control group)×100]. The doses producing 50% analgesia (AD50) with 95% confidence limits (95% CL) and potency ratios with 95% CL are measured by the method of Lichfield and.Wilcoxon (J. Pharmacol. Exp. Ther. 1949, 96, 99-104) using procedure 47 of the computer program of Tallarida and Murray (in “Manual of pharmacological calculations with computer programs”. 2nd ed., Springer, New York, 1987).
[0080] In order to determine the length of action of the compounds, the acetic acid solution is administered at different times after the administration of the drug, as indicated. The experiments for the assessment of the peripheral antinociceptive activity of the compounds are performed by administration of 10 or 20 μmol/kg i.p or i.v. or 0.5 or 1 mg /mouse oral of the tested compounds 30 and 60 min prior to the injection of the acetic acid solution. Data are analyzed by the Wilcoxon's paired non-parametric test. The criterion for statistical significance was P<0.05.
[0081] Mouse tail flick assay. Antinociception was also determined using the radiant heat tail-flick technique (D'Amour and Smith, J. Pharmacol. Exp. Ther. 1941, 72: 74). Briefly, the latency to withdraw the tail from a focused light stimulus was determined using a photocell. The light intensity was set to give a control reading of about 3 sec. Baseline latencies were determined before experimental treatment as the mean of two trials and a maximal latency of 12 s was used to minimize tissue damage. Post-treatment latencies were determined 5 min after i.c.v. injection. The antinociceptive effect was expressed as the percentage of the maximum possible effect, as calculated by the formula: % MPE=[(post-injection latency-baseline latency)/(cutoff latency-baseline latency)]×100. The use of % MPEs takes into account differences in baseline latencies so that these differences do not bias the quantification of antinociception. Group % MPE means were compared using one-way ANOVAs and P≦0.05 was considered significant.
[0082] The induction of tolerance to morphine was obtained as described by Verma and Kulkarni (Eur. J. Neuropsychopharmacol. 1995, 5, 81-87). Briefly, groups of 10 mice were injected i.p. for 8 consecutive days twice a day at 9.00 and 17.00 hr with saline, morphine (10 mg/kg), II-1 (4 mg/kg) or a combination of II-1 (4 mg/kg) 30 min prior to morphine (10 mg/kg). Tail-flick latency to thermal pain was recorded 30 min after the i.p. administration(s) in the morning session of days 1, 3, 6 and 8 as indicated in the figure.
[0083] Mouse rotarod assay. The rotarod treadmill (model 7600, UGO Basile, Italy) for mice was used to assess the motor side-effects of antinociceptive agents. The method used is derived from the procedure described by Dunham and Miya (J. Am. Pharmac. Assoc. 1957, 46: 208). The apparatus is constituted of a rod with a diameter of 2.5 cm suspended horizontally 50 cm above a plane working area. The rod is turning at a speed of 8 revolutions per min. Circular perpex separators are placed at regular intervals along the rod so that five mice can be tested at the same time. Before administering any compound, all animals are placed on the turning rod for one min in two consecutive rounds. Mice that fall from the rod during these conditioning experiments are excluded from the assay. For the assay, the test compounds were administered i.c.v. and the animals were placed on the turning rod for two min. The % of mice in groups of 10 mice which fell during this latter two min-experiment was recorded as the % of mice showing motor effects. Rotarod assays were conducted at different times (up to 60 min) after the administration of peptides. Statistical calculation were made using Student t-test.
[0000] Results:
[0084] Mouse writhing pain assay. Histogranin (HN) (SEQ ID NO. 1) and related peptides and non-peptides were tested for their abilities to block writhing in mice induced by intraperitoneal administration of acetic acid. All compounds (i.c.v.) blocked writhing in a dose-dependent manner ( FIG. 1 ), I-1 (SEQ ID NO. 5) being 135 and 3.9 fold more potent than HN and morphine, respectively (Table 2). The non-peptides displayed potencies that were comparable to that of morphine (in the nmol range). The lengths of action of the various compounds were evaluated by measuring the time (T 1/2 ) it took after injection of a specific dose of a compound to produce half-maximal effect. T 1/2 of HN (SEQ ID NO. 1) (50 nmol/mouse, i.c.v.) was 22.1 min (Table 2). T 1/2 of the cyclic tetrapeptides were longer than 60 min, I-1 (SEQ ID NO. 5) displaying the longest T 1/2 (>90 min at a dose of 10 nmol/mouse). T 1/2 of the non-peptides (10 nmol) ranged between 15 and 58 min, compound II-3 showing the longest T 1/2 (58 min).
[0085] Analgesic effects of peripheral administrations. Compounds I-1 (SEQ ID NO. 5), II-1 and III-1 were shown to display dose-dependent analgesic activity in the mouse writhing test after oral and i.p. administrations ( FIG. 2 ). Compounds I-1 (SEQ ID NO. 5), I-4, and II-1 also showed 84%, 71% and 35% analgesia, respectively, after i.v. administration (1 μmol/kg, not shown).
[0086] Mouse tail-flick assay. In the mouse tail-flick assay, HN related compounds of Formulae I, II and III displayed dose-dependent analgesia ( FIG. 3 ). All HN related compounds including compounds I-1 (SEQ ID NO. 5), II-i and III-1 were more potent than HN (SEQ ID NO. 1) (Table 3). Compound I-1. (SEQ ID NO. 5) (10 nmol/mouse, i.c.v.) had a T 1/2 of >120 min as compared with 45 min for [Ser 1 ]HN (50 nmol/mouse, i.c.v.).
TABLE 2 Relative potencies of Histogranin (HN) (SEQ ID NO. 1) and related peptides and non-peptides (i.c.v.) in the mouse writhing assay AD 50 (nmol/mouse) Potency ratio b T 1/2 [dose] c Compounds (95% CL) a (95% CL) a (min) (nmol) Morphine 0.72 34.8 22 [0.5] (0.66-0.78) (16.0-71.2)* HN 23.0 1.0 22.1 [50] (SEQ ID NO. 1) (12.5-47.0) HN-(7-15) 8.5 2.71 (SEQ ID NO. 4) (1.9-15.4) (0.81-34.7)* I-1 0.17 135 >90 [10] (SEQ ID NO. 5) (0.06-0.46) (27.2-783)* I-2 6.79 3.39 (SEQ ID NO. 6) (3.18-14.49) (0.86-14.8)* I-3 1.08 21.3 >60 [10] (SEQ ID NO. 7) (0.30-3.6) (3.47-157)* I-4 2.52 9.14 (SEQ ID NO. 8) (2.02-3.50) (3.57-23.3)* I-5 10.7 2.14 (SEQ ID NO. 9) (10.1-11.3) (1.16-4.65)* II-1 6.5 3.54 15 [10] (4.55-9.29) (1.82-6.87)* II-2 16.1 1.40 19 [10] (9.91-26.3) (0.54-3.63) II-3 3.16 7.27 58 [10] (1.79-5.62) (3.26-16.2)* II-4 2.61 8.87 36 [10] (1.53-4.48) (4.06-19.1)* III-1 4.14 5.56 36 [10] (32.3-7.38) (2.40-12.4)* a CL: confidence limit. b Potency ratio relative to Histogranin (HN) (SEQ ID NO. 1). c The time after injection of the compound at which half-maximal response was observed for the indicated dose. *P < 0.05 in comparison with HN (SEQ ID NO. 1).
[0087] TABLE 3 Relative potency of Histogranin (HN) (SEQ ID NO. 1) and related peptides and non-peptides (i.c.v.) in the mouse tail-flick assay AD 50 (nmol/mouse) Potency ratio b T 1/2 [dose] Compounds (95% CL) a (95% CL) a (min) (nmol) Morphine 1.57 72.6 (1.28-1.93) (47.6-10)* [Ser 1 ]HN 114 1 45.0 [50] (92-141) I-1 9.1 12.5 >120 [10] (SEQ ID NO. 5) (3.7-22.3) (4.1-38.1)* I-5 38.5 2.96 45.0 [20] (SEQ ID NO. 9) (32.5-45.4) (2.02-4.3)* II-1 14.2 8.0 21.3 [10] (11.5-17.4) (5.2-12.2)* II-2 98.6 1.16 18.5 [10] (70.0-138.8) (0.66-2.01) II-3 31.7 3.59 28.9 [10] (22.9-43.8) (2.10-6.16)* II-4 13.1 8.70 16.7 [10] (10.6-16.1) (5.71-13.3)* III-1 9.6 11.9 28.5 [10] (0.1-800) (0.12-1400) a CL: confidence limit. b Relative to [Ser 1 ]HN. *P < 0.05 in comparison with [Ser 1 ]HN.
Potentiation and Prolongation of Morphine Analgesia.
[0088] Coadministration (i.c.v.) of a subanalgesic dose of compound II-1 with morphine induced a left shift in the dose-response curve of morphine in the mouse writhing test ( FIG. 4A ). Similar effects were also observed with I-i (SEQ ID NO. 5) on the dose-response curve of morphine (i.v.; not shown). The analgesic effects of morphine (0.5 nmol, i.c.v.) were also slightly prolongated by the coadministration of compound II-1 ( FIG. 4B ).
[0089] Blockade of morphine tolerance. Morphine, injected twice a day (10 mg/kg, i.p.) for 8 consecutive days in mice, produced an increase in the tail-flick latency that remained significant as compared to the control group (saline) for only 3 days, tolerance being developed at days 6 and 8 ( FIG. 5 ). Compound II-1 (4 mg/kg, twice a day, i.p. in mice) produced a small increase in the tail-flick latency that was significant only on days 1 and 8. Compound II-1 administered 30 min prior to morphine (10 mg/kg) potentiated the analgesic effect of morphine and, on days 6 and 8, inhibited morphine tolerance ( FIG. 7 ; * P<0.05 as compared with control).
[0090] Lack of motor effect. All cyclic peptides (compounds I-1 (SEQ ID NO. 5), I-2 (SEQ ID NO. 6), I-3 (SEQ ID NO. 7), I-4 (SEQ ID NO. 8) and I-5 (SEQ ID NO. 9); 10 nmol; i.c.v.) and non-peptides (compounds II-1, II-2, II-3, II-4 and III-1, 10 nmol, i.c.v.) did not cause any motor effect in the mouse rotarod assay.
Example VIII
Inibition of Cyclooxygenase-2 Induction and Prostaglandin-2 Formation
[0091] Animals and Reagents. Lung pathogen-free male Wistar rats weighing 250-275 g −1 were purchased from Harlan-Sprague Dawley (Indianapolis, USA). These animals were shipped behind filter barriers and housed in isolated temperature-controlled quarters in an animal isolator unit (John's Scientific Inc., Toronto, Ont.). Roswell Park Institute medium (RPMI) 1640, Dulbecco's phosphate buffered saline (PBS) and dialysed fetal bovine serum (FBS) were purchased from Wisent Inc. (St-Bruno, Que.). Lipopolysaccharide (LPS, E. coli, serotype 0127:B8) was from Sigma Chemical Co. (St-Louis, Mo.).
[0092] Isolation of rat Alveolar Macrophages (AM). Animals received a lethal dose of pentobarbital sodium (100 mg/kg, MTC Pharmaceuticals Canada Packers, Cambridge, Ont.), the abdominal aorta was severed, and the trachea was canulated. The lungs were lavaged with six 8-ml aliquots of sterile phosphate-buffered saline (PBS, pH 7.4) with gentle massage of the lungs during the washings as described (Lemaire I. Am. Rev. Respir. Dis. 1985, 131, 144-149). Bronchoalveolar (BAL) cells were obtained by centrifugation at 200 g at 4° C. for 5 min, and resuspended in RPMI supplemented with 0.5% dialysed FBS and 0.8% N-2-hydroxyethylpiperazine-N′-2-ethanesulfonic acid (HEPES), which will henceforth be referred to as complete culture medium (CM). Cells were counted in a hemacytometer chamber and viability (99-100%) was determined by trypan blue exclusion. Differential analysis of cytocentrifuge smears of lavage cells (Shandon, 2.5×10 4 cells) stained with Wright-Giemsa indicated that the BAL cell population is essentially composed of macrophages (99% AM) in normal rats.
[0093] Culture and Stimulation of AM. AM (2×10 5 ) were plated into 96-well plates in 200 μl of CM alone or with LPS (1 μg/ml) in the presence and absence of HN (SEQ ID NO. 1) and related compounds at various concentrations as indicated. Cells were incubated for 20 h at 37° C. in 5% CO 2 . Following incubation, the culture supernatants were collected and frozen at −20° C., and their prostaglandin E 2 (PGE 2 ) content was measured within 2 days. Prostaglandin E 2 Determination. Prostaglandin E 2 (PGE 2 ) was determined from cell-free supernatants using a competitive enzymeimmunoassay system (Biotrack™, Amersham Pharmacia Biotech). Following dissociation of PGE 2 from soluble receptors and interfering binding proteins present in culture media, the assay is based on competition between unlabelled PGE 2 and a fixed quantity of peroxidase-labelled PGE 2 for a limited number of binding sites on a PGE 2 specific antibody. It was performed according to the manufacturer's instruction using two different dilutions of culture media. At least 4 different experiments were performed for each compound and results are expressed as mean±SEM.
[0094] COX-1 and COX-2 Immunoblotting. Macrophages were cultured at 10 6 /ml in 24-wells for 20 h in complete medium in the presence or absence of LPS (1 μg/ml). Cells were collected with a rubber policeman, pooled and centrifuged (5 min, 200×g). The pellet was washed with PBS (pH 7.4) and frozen at −80° C. The cell pellet from each sample was resuspended in 100 mM Tris, pH 7.4 and sonicated for 15 sec twice with an Ultrasonics™ cell disrupter to lyse the cells. Cell lysates were assayed for protein content by the Bradford method (Bio-Rad Laboratories). Protein from each sample (5 μg-20 μg) was denatured in Laemmli buffer for 5 min and resolved by SDS-gel electrophoresis on a polyacrylamide gel (4% stacking and 10% resolving layer) using an apparatus for minigels (Hoefer Scientific Instruments). After electrophoresis, the proteins were transferred to nitrocellulose membranes with a Transfor™ electrophoresis unit (Hoefer Scientific Instruments). The membranes were blocked overnight at 4° C. in Tris-buffered saline-0.1% Tween™ 20 (TBS-T) supplemented with 3% fat-free dried milk. After rinsing away the blocking solution with TBS-T-1% milk, the membranes were incubated for 90 minutes with primary antibody against COX-2 (1:1000, Cayman) or COX-1 (1:100, Cayman) and against actin (1:250 or 1:2000 for COX-2 and COX-1 detection respectively, Sigma). The specificity of the COX isoform-specific antibodies was tested by Western blotting of purified COX-2 (50ng) and COX-1 (500 ng) electrophoresis standards per lane (Cayman). After washes with TBS-T-l% milk, the membranes were incubated with HRP-conjugated goat anti-rabbit IgG (Santa Cruz) (1:1000 for COX-2 and 1:100 for COX-1) for 1 hr at room temperature. Excess secondary antibody was washed away with TBS-T-1% milk (3×) followed by TBS (5×). The results were visualized after developing with BM chemiluminescence blotting POD substrate (Boehringer) according to the manufacturer's instructions. Scanning densitometry was performed using a Kodak™ digital science Image Station and software. COX-2 and COX-1 signal density was normalized to actin density. Results are expressed as percent of control and represent mean±SEM of at least 3 different experiments.
[0000] Results:
[0095] Decrease of PGE 2 release through inhibition of inducible COX-2 expression. Prostaglandins are known to play an important role in inflammation and transmission of pain. Macrophages stimulated with lipopolysaccharide (LPS, the archetype of bacterial antigen), produce significant amounts of prostaglandins such as PGE 2 . LPS-stimulated release of PGE 2 from isolated rat alveolar macrophages was potently (10 −12 M-10 −7 M) and significantly (up to 50%) inhibited by HN (SEQ ID NO. 1) and related compounds. FIG. 6 represents the inhibition observed with 10 −8 M of HN (SEQ ID NO. 1), H4-(86-100) (SEQ ID NO. 2) and compounds of the three Formulae.
[0096] Inhibition of LPS-induced COX-2. Cyclooxygenase (COX), the enzymatic system responsible for the formation of PGE 2 exists under two isoforms: COX-1 and COX-2. In macrophages, COX-1 is expressed constitutively while COX-2 expression is induced by appropriate stimuli including LPS. The effects of HN (SEQ ID NO. 1) and related compounds were determined on both isoenzymes. HN (SEQ ID NO. 1), H4-(86-100) (SEQ ID NO. 2) and compounds of the three Formulae did not alter the basal level of constitutively expressed COX-1 (not shown) but significantly inhibited LPS induction of COX-2 as assessed by immunoblot analyses ( FIG. 7 ).
[0097] Having thus described the invention, it is apparent to one skilled in the art that modifications can be made without departing from the spirit and scope of the claims that now follow. | The invention relates to new basic amino acid derivatives of general formulae I, II and III, and the preparation and use thereof in treatment of pain. The compounds have histogranin-like antinociceptive, morphine potentiating and COX-2 induction modulating activities.
wherein:
A is -hydrogen, —(C 1 -C 8 )alkyl or —(C 1 -C 8 )alkyl substituted by hydroxy; B is —(C 1 -C 6 )alkylguanidino, —(C 1 -C 6 )alkyl(4-imidazolyl), —(C 1 -C 6 )alkylamino, p-aminophenylalkyl(C 1 -C 6 )-, p-guanidinophenylalkyl(C 1 -C 6 )— or 4-pyridinylalkyl(C 1 -C 6 )-; D is —(CO)—, —(CO)—(C 1 -C 6 )alkylene or —(C 1 -C 6 )alkylene; E is a single bond or —(C 1 -C 6 )alkylene; Z is —NH 2 , —NH—(C 1 -C 6 )alkylcarboxamide, —NH—(C 1 -C 6 )alkyl, —NH—(N-benzyl), —NH-cyclo(C 5 -C 7 )alkyl, —NH-2-(1-piperidyl)ethyl, —NH-2-(1-pyrrolidyl)ethyl, —NH-2-(1-pyridyl)ethyl, —NH-2-(morpholino)ethyl, -morpholino, -piperidyl, —OH, —(C 1 -C 6 )alkoxy, —O-benzyl or —O-halobenzyl; R 1 , R 2 and R 3 are, independent of one another, -hydrogen, -arylcarbonylamino, —(C 1 -C 6 )alkoylamino, —(C 1 -C 6 )alkylamino, —(C 1 -C 6 )alkyloxy, —(C 1 -C 6 )alkylaminocarbonyl, -carboxy, —OH, -benzoyl, -p-halogenobenzoyl, -methyl, —S-(2,4-dinitrophenyl), —S-(3-nitro-2-pyridinesulfenyl), -sulfonyl, -trifluoromethyl, —(C 1 -C 6 )alkylaminocarbonylamino, -halo or -amino; R 4 and R 5 are, independent of one another, -hydrogen, —(C 1 -C 6 )alkyl, -methyloxy, -nitro, -amino, -arylcarbonylamino, —(C 1 -C 6 )alkoylamino, —(C 1 -C 6 )alkylamino, -halo or —OH. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a fuel injection pump for use in internal combustion engines, including a fuel distributor driven in rotation at a speed synchronous with the engine speed. The pump further includes a valve slide surrounding the fuel distribution member and displaceable axially by a hyraulic control mechanism. Control edges, surfaces and recesses internal to the valve slide cooperate with radial bores in the fuel distribution member of the pump for controlling the overall injected fuel quantity. The pump is supplied with fuel by a fuel supply pump which is driven at a speed proportional to the engine rpm. In a known fuel injection system of this type, for example as described in U.S. Pat. No. 2,828,727, the possibilities for adaptation to the present day requirements made of engine manufacturers are very limited. In addition, the hydraulic regulator is separate from the actual injection pump.
OBJECT AND SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a fuel injection pump which permits a multiple adaptation of its regulating characteristics to the requirements of any particular engine. This and other objects are attained according to the invention by providing a pump which delivers a fuel quantity that increases with increasing rpm and which includes an arbitrarily actuatable throttle located in the pressure line of the supply pump which causes an rpm-dependent pressure gradient for the hydraulic regulator. The fuel injection pump according to the invention further provides a spring loaded pressure control valve for defining the pressure downstream of the throttle and for admitting an increasing control pressure when the fuel quantity increases. The fluidic pressure which causes the displacement of the annular valve slide is due to the pressure drop across the throttle. A particular advantage of the invention is that the control pressure and the regulated pressure are substantially independent of one another.
Another object of the invention is that regulating means are provided for the direct adjustment of the axial position of the annular valve. Another object of the invention is to provide means for changing the timing of the injection within the pumping cycle. Yet another object of the invention is to provide for a novel generation of the engine-starting fuel increase. Yet another object of the invention is to provide a novel manner of cooling the fuel injection pump.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the ensuing detailed description of two exemplary embodiments taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a longitudinal cross section through a fuel injection pump according to the invention;
FIG. 2 is a section of FIG. 1 relating to a second example of the pressure regulator according to the invention;
FIG. 3 is a cross section through the injection pump of the invention along the line III--III in FIG. 1; and
FIG. 4 illustrates a section from FIG. 1 in which the control piston is shown in its starting position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustrated exemplary embodiments of the invention are radial piston type distributor injection pumps having a hydraulic regulator. However, fuel injection pumps in which the fuel distributor and the pump element are separated also would fall within the spirit and scope of the invention.
The fuel injection pump and its regulator include the following main constituents which will be described in detail below:
A hydraulic pressure regulator 1, an annular valve control mechanism 2 for controlling the injected fuel quantity, an injection time adjustment 3, an engine start surplus control 4 as well as a control mechanism 5 for determining the pump temperature.
The hydraulic regulator includes a pressure control valve 7 as well as a pressure regulating valve 8. The pressure control valve generates a pressure which changes with rpm, in particular, in the exemplary embodiment shown, the pressure increases with increasing rpm. By contrast, the pressure regulating valve 8 produces a per se constant regulating pressure which, however, is changed as a function of rpm and load and which serves for actuating a control member affecting the quantity of injected fuel. The fuel injection pump also includes a fuel supply pump 9 driven at an rpm equal to the engine rpm and mounted rotatably within the housing 10 of the fuel injection pump. The supply pump is driven by the drive shaft 11 of the injection pump. The supply pump 9 aspirates fuel at low pressure from the interior volume 12 of the housing 10 and delivers it via a supply pump pressure line to the hydraulic pressure regulator 1. The flow cross section of the line 13 is controlled at least at one throttle 14 by an arbitrarily settable throttle element 15. The amount of fuel delivered by the fuel pump 9 increases uniformly with rpm and its static pressure depends on the position of the throttle element 15 ahead of the throttle location 14. In motor vehicles, the arbitrarily settable throttle element 15 may be connected with the gas pedal, for example.
The supply line 13 terminates downstream of the throttle location 14 into a control pressure line 16 which, in turn, terminates in a control pressure cylinder 17. The control pressure cylinder 17 includes a control pressure piston 18 which can be slidably displaced in opposition to the force of a control spring 19 and which opens an aperture 20 to varying degrees. If the fuel quantity supplied by the pump 9 via the control pressure line 16 increases, the control pressure piston 18 is moved against the force of the spring 19 in the sense of opening a larger aperture 20. The characteristics of the spring 19 and the shape of the aperture 20 together constitute a characteristic curve of control pressure versus rpm. Depending on the requirements, this characteristic curve can be linear, shallow or steep, or even curved. Pressure control valves of this type are known per se. The control pressure is not influenced directly by the throttle location 14 because any fuel quantity from the pump 9 must pass this throttle. The pressure regulating valve 8 belonging to the hydraulic pressure regulator 1 operates in a different manner. Inasmuch as the regulating pressure directly defines the injected fuel quantity, it must change in a load-dependent manner. For example, if the vehicle is climbing an incline so that the load on the engine increases and the motor rpm tends to drop, the operator attempts to increase the rpm by depressing the gas pedal further. Thus, the arbitrarily settable throttle element 38 is adjusted in a load-dependent manner. Any such adjustment must therefore have an immediate influence on the pressure generated by the pressure regulating valve.
The pressure regulating valve has a regulating piston 21 which carries an annular groove 22 that controls the terminus of a bore 23 communicating with the control pressure line 16. The regulating piston 21 is slidably disposed within a regulating cylinder 24 and moves in opposition to the force of a regulating spring 25. The regulating piston 21 divides the cylinder 24 into two regions 26 and 27. The region 27 which includes the spring 25 is connected via a line 28 with the interior 12 of the pump experiencing low pressure, whereas the region 26 communicates via a bore 29 in the piston 21 with the annular groove 22. Depending on which of the two pressures is present in the chamber 26, the regulating piston 21 is displaced in opposition to the spring 25 and changes the free cross section 23 by means of the annular groove 22. The manner of changing the flow cross section is essentially pressure relieved so that any constriction of the cross section results in a diminution of the pressure in the cylinder region 26, and an augmentation of the cross section 23 results in an increase of that pressure. It is assumed throughout that fluid may flow out of the cylindrical region 26 to a member which determines the injected fuel quantity. If a great deal of fuel flows off, the pressure in the cylinder region 26 also changes. Thus, the cross section 23 depends on the force of the spring 25 as well as on the pressure in the cylinder region 26 so that a pressure change results in a cross section change. In order to permit the regulating pressure to be changeable in load-dependent manner, one of the variables which define that pressure must be changed. According to this invention, this change takes place by altering the bias tension of the regulating spring 25. For this purpose, there is disposed a spring tensing piston 30, embodied as a stepped piston, whose annular surface experiences the control pressure of line 16 and whose large face 32 experiences the pressure prevailing upstream of the throttle location 14. A spring 33 further acts on the stepped piston 30 in the direction of the control pressure. The face 34 of the piston section 35 having the smaller diameter extends into the region 27 of the regulating cylinder 24 in which low pressure prevails. Thus, when the rotation of the throttle element 15 diminishes the size of the throttle 14, and if the rpm remains constant, the pressure in the pressure line 13 upstream of the throttle location 14 will increase. Due to this pressure increase, the spring tensing piston 30 is displaced in opposition to the spring 33, and the regulating spring 25 is loaded more heavily. The increased loading of the regulating spring 25 causes the regulating piston 21 to be pushed further into the region 26, i.e., the cross section 23 is opened to a greater extent. Thus, the pressure drop across the location 23 is diminshed and, if the rpm remains constant, the pressure in the cylindrical region 26 will increase. Such a pressure change must then result in a corresponding load-dependent reduction of the injected fuel quantity.
As soon as the amount of fuel flowing out of the control pressure line 16 through the location 23 changes, the control pressure in the line 16 also changes with respect to the speed of operation of the supply pump 9. In the present exemplary embodiment, the amount of fuel which is used for injection also flows through this cross section and changes in both load as well as rpm-dependent manner. This means that the control pressure also changes, not only rpm-dependently but also, within certain limits, load-dependently. Such an effect may be desirable, as will be explained further below. If it is not desirable, then the amount of fuel injected must be taken from the interior of the pump 12 instead of from the control pressure line 16 as is the case in known distribution injection pumps, or the fuel which is not required for injection must be pushed into the interior of the pump via the groove 61a. For that purpose, the groove 61a must be closed on the side adjacent the pressure chamber 64 and must be open on the side facing the interior 12 of the pump. The location and the width of the grooves 61 must be such that, when groove 61 is open, no fuel can flow from the pressure chamber 64 through the supply bores 47 into the interior 12 of the pump. The above-described hydraulic pressure regulator is by no means limited to the described example but may be used as a hydraulic regulator for fuel injection pumps of different construction.
A particular advantage of the pressure regulator according to the present invention is that pressure changes can be achieved rapidly and reliably and that any pressure attained will be constant if the related variables no longer change. In order to limit the stroke of the spring tensioning piston, the face 32 thereof opens an overflow bore 36 after traversing a maximum stroke corresponding to a maximum static pressure. In that position of the spring tensing piston 30, the regulating spring 25 is loaded to its maximum, i.e., the regulating piston 21 lies adjacent the face of the regulating cylinder 24. In that position, the cross section 23 experiences the least amount of throttling and thus results in the highest regulating pressure for a particular rpm. In the present exemplary embodiment this means that, when the regulating pressure is high, the tendency is to admit less fuel, whereas when the regulating pressure is low, the tendency is to increase the amount of fuel from whatever its instantaneous value happens to be. The magnitude of the regulating pressure within the cylinder region 26 is limited by an overflow bore 37 which terminates in the line 28 in which low pressure prevails and which is opened by the corresponding end face of the regulating piston 21 as soon as the latter has traversed its maximum stroke in opposition to the force of the regulating spring 25. The hyraulic pressure regulator illustrated in FIG. 1 is a so-called servo regulator, i.e., any position of the throttle element 15 results in an automatic regulation of a particular rpm, especially during load changes. Such a servo regulator requires a greater regulating time than would be required by a direct mechanical engagement. In principle however, for practical reasons and for safety reasons, the idling and the maximum rpm must be fully regulated. Any mechanical adjustment during idling might result in stalling the engine and at maximum rpm might result in running the engine at excessive speed.
FIG. 2 illustrates a hydraulic pressure regulator which is identical to that shown in FIG. 1 except for the throttling element 15. This so-called idling regulator really operates in the described manner only at idle and at maximum rpm whereas, in the intermediate rpm regions, a differently embodied throttle element 38 having cams 39 directly engages the spring tensing piston 30. Since the spring tensing piston 30 directly changes the injected fuel quantity, the fuel quantity change as a function of rpm is eliminated by this idling regulator in the intermediate rpm region. Only at idle and at maximum rpm, i.e., when the cam 39 does not engage the spring tensing piston 30 does there take place a purely hyraulic pressure regulation.
The housing 10 of the injection pump includes a bushing 41 which is closed by a plug 42. A distribution member 43 is located within the bushing 41 and is capable of axial and rotating motion. The distribution member 43 has a central bore 44 terminating at one end in the pump working chamber 45 and at the other end communicating with a distribution bore 46 leading radially outward. Radial fuel supply bores 47 are disposed between the pump chamber 45 and the distribution bore 46. Disposed in the central bore 44 between the terminus of the supply bore 47 and the distribution bore 46 is a central pressure valve 48 which is displaceable against the force of a spring 49. The pump chamber 45 is defined between two radial pistons 50. The radial pistons are driven by a cam ring 51 working via rollers 52. The rollers 52 are disposed within races 53 rotating with the distributor. The region of the distribution member 43 in which the radial pistons are disposed extends into an inner bore 40 of the enlarged end of the drive shaft 11. An appropriately profound facial groove in the enlarged end of the drive shaft 11 carries the roller races 53, whereby the distribution member 43 does not experience any of the driving forces acting on the pistons 50. A jaw-type clutch 54 couples the drive shaft 11 to the distribution member 43. This clutch permits an axial displacement of the distribution member 43 against the force of a return spring 55. The distribution bore 46 terminates in a distribution groove 56 disposed on the lateral surface of the distribution member 43 and which opens bores 57 located over the extent of the wall of the bushing 41 and which are connected with pressure lines 58 in the housing 10. The number of bores 57 or pressure lines 58 corresponds to the number of cylinders of the engine. Each of the pressure lines 58 is connected via further pressure lines, not shown, to one of the engine cylinders.
Surrounding the distribution member 43 is an annular slide 60 which has interior grooves 61 that control the termini of the fuel supply bores 47. The external surface of the annular slide 60 glides sealingly in a stepped bore 62 of the bushing 41 and is displaceable axially against a force of at least one return spring 63. A pressure chamber 64, defined by the distribution member 43, the bushing 41 and the annular slide 60, communicates through a regulator pressure line 65 with the cylindrical region 26 in the pressure regulating valve 8. Depending on the magnitude of the regulating pressure, the annular slide 60 is displaced to a higher or lower degree against the force of the return spring 63.
As may be seen in FIG. 3, the limiting edges of the longitudinal grooves 61 are not parallel, so that, depending on the axial position of the annular slide 60 with respect to the distribution member 43, the region of the grooves 61 covered by the supply bores 47 during the rotation of the distribution member 43 is of different magnitude. In the exemplary embodiment illustrated, the supply bores 47 serve at the same time as influx bores as well as efflux bores for any fuel displaced by the pump pistons 50 but not used for injection. Thus, a fuel supply via the pressure valve 48 to the engine can take place only if the supply bores 47 are blocked. Any controlled closing of these bores during the pressurized fuel delivery of the pump pistons 50 will thus define the onset of fuel delivery whereas an opening of these bores will define the termination of fuel delivery. Depending on the particular disposition of the limiting edges of the control grooves, the fuel quantity may be controlled with respect to the onset of delivery or the termination of delivery. It will be understood that the supply bores 47 must be opened by the control grooves 61 at least during a portion of the suction stroke of the pump pistons 50. The grooves 61 become larger in the direction of the pressure chamber 64 so that, during a displacement of the annular slide 60 against the force of the spring 63, the injected fuel quantity decreases. In the exemplary embodiment illustrated in FIG. 3, the cam ring 51 has four cam lobes 66 and would thus be associated with a 4-cylinder internal combustion engine. As shown, the roller 52 is just ahead of the cam lobe 66, i.e., the groove 61b is in a position just prior to its separation from the supply bore 47b. As soon as this separation is complete, the cam-induced motion of the piston can initiate fuel injection. During further rotation of the distribution member 43, the supply bore 47a overlaps the groove 61a and the injection process is terminated. In the subsequent suction stroke of the piston 50, either the supply bore 47a still overlaps the groove 61a or else the supply bore 47c already overlaps the groove 61b. The edge 61c indicates the narrowest portion of the groove 61a. For example, if this edge 61c cooperates with the bore 47a, the mutual overlap of bore and groove is especially short, i.e., the injected fuel quantity is relatively large at some particular rpm. Furthermore, the bore 47 is only opened at a later time and the termination of the fuel supply is delayed so that the delivered fuel quantity is further enlarged if the onset of delivery remains constant, for example.
When the control of the annular slide 60 is considered together with the operation of the hydraulic pressure regulator 1, it is observed that a constriction of the throttle location 14 results in an increase of the static pressure and hence an increase of the regulating pressure which, in turn, causes a displacement of the annular slide into a position which is associated with a reduced injected fuel quantity. When the load remains constant, the reduced fuel quantity results in a decrease of rpm which decreases the static pressure and hence also decreases the regulating pressure whereupon the annular slide 60 is displaced into a position corresponding to a somewhat greater injected fuel quantity. In this manner, for any adjustment of the throttle, there is automatically regulated an associated engine speed (rpm). Since the cam 66 does not have a straight line contour but rather a sinusoidal contour, the speed of the piston at any rpm is different for different points of the track of the cam lobe. Fuel is delivered by a cam lobe only during the increasing portion of the cam track. However, since the portion of the increasing part of the cam lobe which causes fuel injection is different for different amounts of fuel, the piston speed is also variable as a function of the injection time. The speed of the piston has a certain influence on the quiet operation of the engine. The earlier the onset of delivery occurs with respect to the increasing cam lobe curve, the flatter is the slope of the curve, i.e., the lower the injection velocity. It turns out that, especially for small delivered fuel quantities, the injection velocity should be as low as possible to achieve quiet operation as idling. This can only be achieved by defining the amount of fuel via control of the end of the injection process or, if the injection quantity is controlled by grooves 61 which influence both the onset and the termination of fuel delivery, both the onset and termination must be shifted in the direction of the flatter curving extent of the cam lobe 66 in the cam ring 51 without rotating the cam ring 51 with respect to the drive shaft because such rotation would shift the entire injection process in the direction of early ignition which would result in noisy operation at low rpm. The injection time adjusting mechanism 3 may be given the independent task of advancing the onset of injection for high rpm so as to extend the otherwise relatively short preparation time at high rpm. For this reason, an rpm-dependent fuel injection time adjustment is especially desirable and, in some cases, even with a load-dependent influence.
An adjustment of the onset of injection is achieved in the apparatus according to the invention by a rotation of the cam ring 51 within the housing 10. This rotation is actuated by an injection adjustment piston 68 which engages the cam ring 51 via a bolt 69. The injection adjustment piston 68 is axially slidable in a cylindrical cavity 70 and is radially sealed, defining a pressure chamber 71 and a spring chamber 72. The pressure chamber 71 communicates via a conduit 73 with the control pressure line 16 whereby the control pressure engages the injection adjustment piston 68 against the force of a spring 74. Preferably, a throttle 75 is located in the line 73 just prior to its exit into the pressure chamber 71. Inasmuch as the control pressure increases with rpm, a displacement of the piston against the force of the spring implies a displacement of the onset of injection to an earlier time. Conversely, the normal or quiescent position of the adjustment piston 68 is associated with a late onset of injection. Each time the rollers 52 pass a cam lobe 66, they exert forces tending to rotate the cam ring 51 and thus to displace the piston 68 and it is the purpose of the throttle 75 to damp the effect of these forces. The time during which such an effect takes place during the rotation is relatively short so that relatively little fuel flows from the pressure chamber 71 through the throttle 75 back into the line 73, whereas a relatively long time is available for adjusting the position of the injection adjustment piston 68. In order to perform a second load-dependent control effort, the spring chamber 72 is connected through a line 76 with the pressure chamber 64 above the annular slide 60. Preferably, both during reduced fuel supply as well as during full-load operation of the injection pump, the pressure chamber 64 receives a fuel pressure from the pressure control valve 8 which, at full load, is just large enough to permit the spring 63 to push the annular slide securely against the cam 82 and, thus, the spring chamber 72 of the injection time adjustment mechanisms 3 also receives regulating pressure via the line 76. The presence of regulating pressure in the spring chamber 72 makes it possible to use the regulating pressure to change the pressure gradient between the pressure chamber 71 and the spring chamber 72 and thus also to change the onset of injection. Furthermore, the presence of the grooves 77 in the surface of the distribution member 43, in combination with the spring-loaded spring chamber 72, causes the hydraulic communication between the pressure chamber 64 and the spring chamber 72 to be interrupted during the time of fuel injection by the pistons 50 so that the undesirable oscillations of the injection adjustment piston 68 are further shortened. In the vicinity of the stepped bore 62, the bushing 41 has bores 78 which are opened by the external surface of the annular slide 60 after having traversed a certain stroke. Fuel may flow out of the pressure chamber 64 through these bores 78 so that the control pressure changes via lines 66 and 16. This change in the control pressure causes a displacement of the injection time adjustor piston 68 in the direction of the pressure chamber 71 so that the onset of injection time also changes in the direction of a later injection beginning with a certain rpm. As already mentioned above, it may be desirable to keep the driving speed of the pump piston 50 as low as possible at low rpm. This object is attained according to the invention by providing an axial guide bolt 80 within the cam ring 51 which guides the rotational position of the annular slide 60 by cooperation with a groove 81 therein. By disposing the springs in an oblique manner, a good contact is obtained between the guide bolt 80 and the wall of the groove 81. Thus, if the cam ring 51 is rotated, the guide bolt 80 also rotates the annular slide 60. Such a rotation of the annular slide 60 does not result in any change of the association of the grooves 61 and the fuel supply bores 47 but, if the guide bolt 80 is located obliquely, then the rotational position of the annular slide 60 will be different for different axial positions. Even though the relative rotation by the cam ring 51 is the same in each axial position of the annular slide, that relative rotation changes during a relative axial displacement. For certain conditions it may be desirable to change the full-load fuel quantity, i.e., the initial position of the annular slide, depending on rpm. For this purpose, there is disposed on the housing 10 at least one cam 82 which is attached by means of shims 83 and a screw 84 and which cooperates with a cam surface 85 on the annular slide 60. Depending on the rotational position of the annular slide 60, the initial position of the slide is easily changed. The basic initial position of the slide 60 may also be changed by choosing different shims 83. Another adjustment possibility is given by a screw 66 located in the plug 42 which can change the axial position of the distribution member 43 against the force of the spring 55. The manifold possibilities of regulation and control offered by the present invention make it possible to adapt the fuel injection quantity to any operational conditions of rpm and load and not merely at maximum rpm, namely by means of the cam 82 and the cam track 85 as well as by the freely selectable association and formation of the control edges of the grooves 61 and by the manner of generating the regulation pressure.
One problem occurring in ordinary fuel injection systems is the generation of a starting excess quantity during a starting of the engine. The starting excess quantities intend to achieve a rapid run-up from zero to just beyond the idling rpm and should be shut off thereafter. There should be no influence of the starting excess control process on the other regulatory aspects or pressure control mechanisms of the fuel injection system after the event of engine starting.
FIG. 4 is an illustration of the pressure control valve 7 in a position assumed when the pump is standing still. The control pressure piston 18 is seen to be placed in its initial position by the control pressure spring 19. The control pressure cylinder 17 also includes a starting piston 88 which supports one end of the control pressure spring 19 on one face, whereas the other face supports a starting spring 89. The chambers of the control pressure cylinder 17 defined by this initial position of the control pressure piston 18 are connected via a bypass 90 which includes a throttle 91. The region of the cylinder 17 which includes the spring 19 is connected via a starting line 92 with a chamber 93 (see FIG. 1) which is limited by the distribution member 43, the bushing 41 and the plug 42. Thus, prior to starting the engine, the control pressure line 16 is directly connected with the chamber 93 via the bypass 90 and the starting line 92. As soon as even a relatively low pressure is generated in the control pressure line 16 by the supply pump 9, the distribution member 43 is displaced against the force of the spring 55 until an overflow channel 67 is opened so as to limit the stroke. The distribution member 43 causes the fuel supply bores 47 to partially overlap the surface 59 in the interior bore of the annular slide so that, at the beginning of the pressure stroke of the pump pistons 50, no fuel may return into the pressure chamber 64. In this axial position, fuel may flow into the pump working chamber during the suction stroke only via the extended region 61d of the groove 61b which serves for supplying fuel to the pump working chamber 45. Thus the entire amount of fuel which is deliverable by the pump working chamber 45 is used for injection.
When the engine reaches approximately idling rpm, the throttle 91 in the bypass 90 (FIG. 4) causes a static pressure which tends to displace the pressure control piston 18 against the force of the spring 19 and thus close the bypass 90. During the increased tension of the control pressure spring 19, it displaces the starting piston 88 against the force of the starting spring 89 and thus opens a relief bore 94. The relief bore 94 terminates in the line 28 which communicates with the interior chamber 12 of the injection pump which is at low pressure. Thus, as soon as the starting piston 88 opens the relief bore 94, there is a communication between the chamber 93 and the low pressure line 98 via the starting line 92 so that the distribution member 43 is pushed back to its stop 86 and the process of delivering a starting excess fuel quantity is thereby terminated.
In order to achieve a smooth and uniform functioning of the fuel injection pump, it is desirable to have that pump attain its operating temperature as rapidly as possible yet to prevent over-heating even for extended periods of operation. For this purpose, the pump according to the invention includes a temperature control mechanism which employs the fuel supplied to the pump which is partially returned to the fuel container since the pre-supply pump, which is not shown, always delivers as much fuel as would be required by the injection pump under extreme and maximum conditions. As illustrated in FIG. 1, fuel is supplied by the pre-supply pump via line 96 to the inner chamber of the injection pump. From the inner chamber fuel then flows through a bore 97 to the suction side of the supply pump 9 and hence to the individual regulating and control mechanisms as well as to the inlet of the actual fuel injection pump. Any unused fuel flows through a pressure sustaining valve 98 which defines the inner chamber of the pump back to the fuel container. The pressure sustaining valve 98 is associated with an upstream thermostatic valve 99 which either connects the sustaining valve 98 directly to the suction line 96 via a channel 100 or connects the sustaining valve 98 with the line 28 leading to the inner chamber 12. When the pump is cold, the largest portion of the excess fuel flows off directly via the channel 100 so that any fuel in the inner chamber 12 has a chance to warm up before being aspirated by the fuel pump 9. When the fuel pump temperature increases, an increasing amount of fuel flows through the line 28 from the inner chamber 12 to the sustaining valve 98 while the passage through the channel 100 is decreased to a greater degree. Beginning with a certain pump temperature, virtually the entire excess fuel flows through the inner chamber 12 and the line 28 to the sustaining valve 98 and is then returned to the fuel container. The described mechanism and process insure a rapid heating of the pump to its operational temperature while preventing over-heating during extended operation.
The above-described characteristics are not limited to the illustrated and described combination, but are also intended to be viewed as independent inventions which may be used individually or in combination with already known characteristics.
Furthermore, the foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A fuel injection pump is driven by the engine via a drive shaft that also rotates a cam ring. The cam ring reciprocates radial pistons which deliver fuel under high pressure to fuel lines located around an axially sliding distribution member. The amount of fuel delivered is determined in part by the timing of the opening of a pressure relief channel which is opened by a sliding annular ring surrounding the distribution member. The position of this ring and hence the fuel quantity delivered is adjusted by the equilibrium between spring forces and fluid pressure from a regulating valve. A separate pressure control valve adjusts the pressure gradient across an arbitrarily settable throttle which also affects the regulating pressure. Separate mechanisms adjust an engine starting excess quantity and a fuel bypass which is thermostatically controlled to maintain the pump operating temperature within prescribed limits. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to an electronic musical instrument, and more particularly to a keyboard type electronic musical instrument including a voltage controlled tone signal generator.
With a prior art electronic musical instrument, the tone signals derived upon key operation from tone generators are filtered by a tone coloring filter (lowpass filter) having a preselected frequency characteristic to impart a desired tone color to the tone signal. Namely, the cutoff frequency of the tone coloring filter for determining its passband is predetermined to a specified value. Particularly in the pedal tone pitch range, therefore, the balance in respect of tone color and tone volume between a higher pedal tone and a lower pedal tone is lost due to the loudness characteristics of the human ear to generate unnatural musical sounds. This is because, in case of comparison of a lower tone with a higher tone in the pedal tone pitch range, the human ear has a lower sensitivity to the lower tone.
Also with a recently developed synthesizer type electronic musical instrument having a voltage controlled oscillator and a voltage controlled lowpass filter and designed to control the cutoff frequency of the lowpass filter in accordance with the control voltage waveforms whose voltage levels vary as a function of time, arrangement is not so made that the control voltage waveform applied, in case of a higher pedal tone, to the lowpass filter is different from that in case of a lower pedal tone. As a result, there is produced an undesired difference in respect of tone color and tone volume between the lower pedal tone and the higher pedal tone, as in the case of the abovementioned prior art electronic musical instrument.
SUMMARY OF THE INVENTION
The object of the invention is to provide a voltage controlled type electronic musical instrument which is capable of generating, particularly in case of the pedal tones, musical sounds well-balanced in respect of tone color and tone volume throughout the pitch range.
The electronic musical instrument according to the invention comprises a keyboard section for producing a pitch determining voltage signal indicating the note of an operated key, a voltage controlled oscillator for producing a tone signal having a pitch frequency determined by the pitch determining voltage signal, and a tone coloring filter for imparting a desired tone color to the tone signal.
According to the invention, the tone coloring filter is of a voltage controlled type, and is operated in response to the pitch determining voltage signal from the keyboard section, so that the cutoff frequency for a lower note tone becomes higher than that for a higher note tone. As a result, the harmonic content of the lower note tone is increased as compared with that of the higher note tone, thereby to reduce the undesired difference in respect of tone color and tone volume between the higher note tone and the lower note tone. Where, particularly concerning pedal tones having a tone pitch range of two octaves, the cutoff frequency for the lowest note tone (C1) and the cutoff frequency for the highest note tone (C3) are shifted, respectively, by about half the octave in mutually opposite directions with respect to the cutoff frequency for the middle note tone (C2) of the two-octave range, a good result was obtained.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of an electronic musical instrument according to an embodiment of this invention;
FIG. 2 is a circuit arrangement of the keyboard section of FIG. 1;
FIG. 3 shows waveform A of a control voltage signal supplied to the voltage controlled oscillator and voltage controlled filter of FIG. 1, and waveform B of control voltage signal supplied to the voltage controlled amplifier of FIG. 1;
FIG. 4 shows an example of the inverting circuit of FIG. 1;
FIG. 5 shows the voltage relationship between output signals (pitch determining voltage signal) from the keyboard section and the inverting circuit of FIG. 1 with respect to note names; and
FIG. 6 shows a cutoff frequency characteristic of VCF with respect to the note names.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows one embodiment of this invention. In the drawing a reference numeral 11 shows a voltage controlled oscillator (hereinafter referred to as VCO). VCO 11 generates, in response to a pitch determining voltage signal obtained by key operation at a pedal keyboard section 12, a tone signal having a pitch (frequency) for the note of an operated key. The tone signal from VCO 11 is coupled to a voltage controlled filter (hereinafter referred to as VCF), where a tone color is imparted to the tone signal, and then to a voltage controlled amplifier 14 (hereinafter referred to as VCA). The outut of VCA 14 is fed through an output amplifier 15 to a loudspeaker 16. Control voltage generators 17 to 19 are provided to control the pitch, tone color and tone volume of the tone signal and coupled to VCO 11, VCF 13 and VCA 14, respectively. Control voltage generators 17 to 19 generate, in response to a trigger signal obtained by the key actuation at the keyboard section 12 which continues from key depression to key release, control voltage signals which are coupled to VCO 11, VCF 13 and VCA 14 respectively. VCO 11 is adapted to transiently vary according to the waveform of the control voltage signal from the control voltage generator 17, the frequency of the tone signal corresponding to the operated key; VCF 13 has this cutoff frequency transiently varied according to the waveform of the control voltage signal from the control voltage generator 18; and VCA 14 has its amplification gain controlled according to the waveform of the control voltage signal from the control voltage generator 19 to impart a desired envelope to the filtered tone signal from the VCF 13.
FIG. 3 shows the graphical representation of control voltage waveforms obtained from the control voltage generators 17 to 19. In FIG. 3, waveform A shows the positive going control voltage applied to VCO 11 and waveform VCF 13 and B shows the positive going control voltage applied to VCA 14. When the key is depressed the voltage waveform A rises, during an attach time or rise time, from an initial level to an attack level and then decays, during a first decay time, from the attack level to a normal level. The normal level is continued until the key is released. After release of the key, the voltage waveform further decays, during a second decay time, from the normal level to the initial level.
When the voltage waveform A is fed to VCO 11, a tone signal is so controlled that its frequency abruptly varies during the key depression time from the initial level frequency which is somewhat lower than the normal level frequency to the attack level frequency which is somewhat higher than the normal level frequency. Thereafter, the tone signal frequency approaches, during the first decay time, to the normal level frequency which is the correct frequency for the pitch determining voltage from the keyboard section 12. After lapse of the first decay time, the tone signal frequency becomes equal to the normal level frequency. After release of the key, the tone signal frequency decays, during the second decay time, from the normal level frequency to the initial level frequency. That is, the tone signal frequency obtained from VCO 11 is modified according to the voltage waveform which varies as a function of time.
When the voltage waveform A is supplied to VCF 13, the cutoff frequency of the voltage controlled filter is controlled in accordance with the waveform and, consequently, the tone color of the tone signal is transiently modified. In this case, the cutoff frequency of VCF 13 becomes higher as the control voltage waveform goes more positive.
A voltage waveform B rises, upon depression of the key, from a cutoff level to a peak level. After lapse of the attack time, the voltage waveform is returned, during the first decay time, to a sustain level, and the sustain level is continued until the key is released. After release of the key, the voltage waveform decays, during the second decay time, from the sustain level to the cutoff level. When the voltage waveform B is supplied to VCA 14, such an envelope as is shown in the waveform B is imparted to the tone signal. When no voltage waveform B is applied to VCA 14, VCA 14 is in the cutoff state. It will be understood that VCA 14 is operated as a tone keyer.
With the electronic musical instrument of this invention, the above mentioned VCO 11, VCF 13 and VCA 14 and control voltage generators 17 to 19 may be of the known configurations. The control voltage generators 17 to 19 may be so designed as to cause various parameters of the waveform to be controlled by parameter controlling voltages. To this end, parameter controlling voltage generators 20 are additionally provided. In this case, the generators 20 may be provided with a power source and parameter controlling potentiometers connected across the power source. The sliders of the potentiometers should preferably be placed on the control panel of an electronic musical instrument so as to enable a player freely to control various parameters of the waveform of the control voltages. The magnitude of each parameter controlling voltage is adjusted by the potentiometer slider. Such an example was invented by Hiyoshi et al and disclosed in U.S. Pat. application Ser. No. 457,646 filed on Apr. 3, 1974, and now U.S. Pat. No. 3,897,709. U.S. Patent application under Ser. No. 472,827 filed on May 23, 1975, and now U.S. Pat. No. 3,902,392 by Nagahama also discloses similar construction for such portion. U.S. application Ser. Nos. 457,646 and 472,827 are both assigned to the same assignee as the present application.
FIG. 2 shows the arrangement of the keyboard section 12 from which a pitch determining voltage signal is supplied to VCO 11. The voltage of a power source E (e.g. 2 volts) is divided by a voltage dividing circuit arrangement including resistors R1, R2 and R3 where R2 = (2 1/12 + 2 1/12 - 2)R1 and R3 = (2 1/12 - 1)R1, and the normally open fixed contacts of key switches S1, S2, S3, . . . . are connected to the respective voltage dividing points. The movable contacts of the respective key switches are connected to the normally closed fixed contacts of the adjacent key switches. When a plurality of keys are depressed at a time, a voltage of the voltage dividing point connected to the key switch actuated by the key corresponding to the highest note of actuated keys and having a value decisive of the note is fed to VCO 11 in the key switch arrangement shown. There are further provided key switches SO1, SO2, SO3 . . . . which are ganged with the key switches S1, S2, S3 . . . . respectively. When the key is operated, a trigger signal which is a negative going voltage of change from a power source voltage E1 volts to zero volts is supplied to the control voltage generators 17 to 19. The control voltage generators 17 to 19 start the formation of control voltages upon receipt of the trigger signal.
As the frequencies of tones show an exponential function with respect to the note names, the voltage value of the pitch determining voltage signal given forth by the keyboard section 12 should also vary, as illustrated by the curve A of FIG. 5, exponentially with respect to the note names.
According to this invention, the pitch determining voltage signal delivered from the keyboard section 12 is supplied to VCF 13 through an inverting circuit 21 which can produce output voltages the magnitude variation of which with respect to the note names is opposite to that of the pitch determining voltage signals from the keyboard section 12, as shown by the curve B of FIG. 5. That is, the output voltage of the inverting circuit 21 when a lower note key is depressed becomes greater than that when a higher note key is depressed.
Accordingly, it will be noted that the cutoff frequency of VCF 13 varies as shown in FIG. 6 in accordance with the output of the inverting circuit 21. That is, the cutoff frequency of VCF 13 when a lower note tone is played becomes higher than that when a higher note tone is played, thus more increasing the harmonic content of the lower note tone than that of the higher note tone.
As apparent from the control wave A of FIG. 3, VCF 13 of FIG. 1 is so designed that the cutoff frequency becomes higher as the voltage value of the control voltage signal increases. For this reason, in the embodiment of FIG. 1, a pitch determining voltage signal is applied to VCF 13 through the inverting circuit 21. However, VCF 13 may be so arranged that the cutoff frequency becomes lower as a value of control voltage decreases. In this case, a pitch determining voltage signal may be applied to VCF 13 without inverting.
FIG. 4 is a circuit diagram using an operational amplifier 22 suitable for the inverting circuit 21. The operational amplifier 22 is preferably a μA741 HC monolithic operational amplifier manufactured by Fairchild Camera and Instrument Systems. The pitch determining voltage signal of the keyboard section 12 is applied to the inverting input terminal of the operational amplifier 22.
Therefore, the pitch determining voltage signal is inverted by the operational amplifier 22. However, the output of operational amplifier 22 is subjected to a level shift of +1.5V, thus providing the output characteristic as shown by the curve B of FIG. 5. By the output of the inverting circuit 21, VCF 13 has the cutoff frequencies for the lowest and highest notes C1 and C2 increased and decreased, respectively, by about half octave with respect to the cutoff frequency for the middle note C2. | This invention provides an electronic musical instrument comprising a keyboard circuit for producing a pitch determining voltage signal representing the note of an operated key, a voltage controlled oscillator for producing a tone signal having a tone pitch determined by the pitch determining voltage signal, and a voltage controlled lowpass filter for imparting a desired tone color to the tone signal. The voltage controlled lowpass filter is responsive to the pitch determining voltage signal from the keyboard circuit to control the cutoff frequency of the voltage controlled lowpass filter in such a manner that the harmonic content of a higher tone signal is decreased from that of a lower tone signal. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of Taiwan application serial no. 94147759, filed Dec. 30, 2005. All disclosure of the Taiwan application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a circuit board with an embedded chip, and more particularly, to a thermally enhanced coreless thin substrate with an embedded chip and method for manufacturing the same.
[0004] 2. Description of Related Art
[0005] Conventionally, the circuit board, the chip package and the combination of modularized chip package components are separately manufactured and applied. In general, the electronic device so fabricated, for example, a multi-chip package module has a thicker structure and a longer route for electrical transmission. FIG. 1 is a schematic cross-sectional view of a conventional multi-chip package module. The conventional multi-chip package module 100 in FIG. 1 mainly comprises a circuit substrate 110 , a plurality of chips 120 and a heat sink 130 . The chips 120 can be flip chips with a plurality of bumps 121 or chip package components. The substrate 110 has a plurality of inner connecting pads 113 disposed on a top surface 111 and a plurality of outer connecting pads 114 disposed on a bottom surface 112 . The chips 120 are disposed on the top surface 111 of the substrate 110 and are electrically connected to the inner connecting pads 113 through the bumps 121 . The heat sink 130 is attached on the chips 120 . In general, a plurality of solder balls 140 are bonded to the outer connecting pads 114 . Because the substrate 110 is a printed circuit board fabricated in a laminate or build-up technique, the packaging and modular combination of these chips 120 are applied independently. Therefore, the multi-chip package module 100 is thicker than usual and the average electrical transmission paths are longer, and signal transmission is more vulnerably interfered through cross-talk effect.
SUMMARY OF THE INVENTION
[0006] Accordingly, at least one objective of the present invention is to provide a thermally enhanced coreless thin substrate with an embedded chip. A patterned carrier metal layer inside a substrate includes at least one heat sink portion and at least one chip is disposed on the heat sink portion. A dielectric layer inside the substrate covers the chip. A wiring layer inside the substrate is formed on the dielectric layer. The wiring layer electrically connects the chip to the patterned carrier metal layer. The present invention joins a substrate, a chip and a heat sink of a conventional multi-chip package module together to form an integral thin board type electronic device. As a result, the thickness of the device is pared down and yet the structure is able to provide the embedded chip with an enhanced capacity to dissipate heat and tighter seal. Hence, its assembling ability, interconnection reliability and electrical performance are improved and its subsequent packaging density and resistance to cross-talk effect are enhanced.
[0007] Another objective of the present invention is to provide a method for manufacturing a thermally enhanced coreless thin substrate with an embedded chip. The patterning of the patterned carrier metal layer in the substrate is performed after the formation of the wiring layer inside the substrate so that the patterned carrier metal layer functions as a carrier for the chip, a heat sink for the chip and an electrical connection with the chip.
[0008] According to the present invention, a thermally enhanced coreless thin substrate with an embedded chip mainly comprises a patterned carrier metal layer, at least one chip, a dielectric layer and a wiring layer. The patterned carrier metal layer at least comprises a heat sink portion. The chip is disposed on the heat sink portion. Furthermore, the chip has a plurality of electrodes. The dielectric layer is formed on the patterned carrier metal layer and covers the chip. In addition, the dielectric layer has a plurality of through holes. These through holes are linked to the patterned carrier metal layer, and the dielectric layer exposes the electrodes on the chip. The wiring layer is formed on the dielectric layer. The wiring layer includes a plurality of first trace lines and a plurality of second trace lines. The first trace lines are electrically connected to the patterned carrier metal layer via the through holes and the second trace lines are electrically connected to the electrodes.
[0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0011] FIG. 1 is a schematic cross-sectional view of a conventional multi-chip package module.
[0012] FIG. 2 is a schematic cross-sectional view of a thermally enhanced coreless thin substrate with embedded chips according to one embodiment of the present invention.
[0013] FIGS. 3A through 3M are schematic cross-sectional views showing the process of fabricating a thermally enhanced coreless thin substrate with embedded chips according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
[0015] FIG. 2 is a schematic cross-sectional view of a thermally enhanced coreless thin substrate with embedded chips according to one embodiment of the present invention. The thermally enhanced coreless thin substrate 200 with an embedded chip mainly comprises a patterned carrier metal layer 210 , at least one first chip 220 , a first dielectric layer 230 and a first wiring layer 240 . The patterned carrier metal layer 210 at least comprises a heat sink portion 211 . The patterned carrier metal layer 210 can be fabricated by patterning a copper foil or other conductive films. In the present embodiment, the patterned carrier metal layer 210 further comprises a plurality of connecting pads 212 for electrically connecting to external devices. Preferably, the patterned carrier metal layer 210 is a wiring layer having a wiring structure capable of minimizing the number of wiring layers inside the substrate.
[0016] The first chip 220 is disposed on the heat sink portion 211 by adhesion or eutectic bonding. Furthermore, the first chip 220 has a plurality of electrodes 221 and the electrodes 221 can be bonding pads or bumps. The first chip 220 further includes an integrated circuit component (not drawn).
[0017] The first dielectric layer 230 is formed on the patterned carrier metal layer 210 and covers the first chip 220 . The first dielectric layer 230 is fabricated using an electrically insulating material such as polyimide (PI) or polyethylene terephthalate (PET). The first dielectric layer 230 has a plurality of through holes 231 and the through holes 231 are linked to the patterned carrier metal layer 210 . Furthermore, the first dielectric layer 230 also exposes the electrodes 221 . The first wiring layer 240 is formed on the first dielectric layer 230 . The first wiring layer 240 comprises a plurality of first trace lines 241 and a plurality of second trace lines 242 . The first trace lines 241 are electrically connected to the connecting pads 212 of the patterned carrier metal layer 210 via the through holes 231 . The second trace lines 242 are electrically connected to the electrodes 221 . The first trace lines 241 may electrically connect to the corresponding second trace lines 242 either directly or through other wiring layers.
[0018] In the process of fabricating the thermally enhanced coreless thin substrate 200 with an embedded chip, the heat sink portion 211 of the patterned carrier metal layer 210 is used for supporting the first chip 220 . By forming the first dielectric layer 230 over the patterned carrier metal layer 210 and covering the first chip 220 , the first chip 220 is embedded within the patterned carrier metal layer 210 and the first dielectric layer 230 to enhance its heat dissipating capacity and reduce its package thickness. Therefore, the patterned carrier metal layer 210 can save a conventional chip carrier, a heat sink and at least one wiring layer inside the carrier substrate because it is a single component with all the foregoing functions. Furthermore, at least one chip is embedded in the interior of the thermally enhanced coreless thin substrate 200 .
[0019] In the present embodiment, the thermally enhanced coreless thin substrate 200 with an embedded chip further comprises a first solder mask layer 291 formed underneath the patterned carrier metal layer 210 . The first solder mask layer 291 exposes the connecting pads 212 on the patterned carrier metal layer 210 . Furthermore, the first solder mask layer 291 has an opening 292 that exposes the heat sink portion 211 so that the heat sink portion 211 has an exposed surface for providing the thermally enhanced coreless thin substrate 200 with good heat dissipation. Preferably, the exposed surfaces of the connecting pads 212 have a plated layer 213 , for example, a nickel-gold plated layer to prevent the oxidation of the connecting pads 212 . Moreover, the plated layer 213 may also be formed on the exposed surface of the heat sink portion 211 . In the present embodiment, an additional second dielectric layer 251 may also be formed on the first wiring layer 240 . A second wiring layer 261 is formed on the second dielectric layer 251 and the second wiring layer 261 is electrically connected to the first wiring layer 240 . Because the second dielectric layer 251 is used for isolating the first wiring layer 240 from the second wiring layer 261 , the thickness of the second dielectric layer 251 can be smaller than the first dielectric layer 230 . Moreover, the number of wiring layers and dielectric layers can be gradually increased until the desired wiring structure is obtained. In the present embodiment, the thermally enhanced coreless thin substrate 200 with an embedded chip may be used to replace a conventional multi-chip module. A third dielectric layer 252 is formed on the second wiring layer 261 and a third wiring layer 262 is formed on the third dielectric layer 252 . The second wiring layer 261 and the third wiring layer 262 are used to electrically connect with the first trace lines 241 and the second trace lines 242 of the first wiring layer 240 . Furthermore, a fourth dielectric layer 253 covers the third wiring layer 262 . At least one second chip 270 can be disposed on the second wiring layer 261 . A plurality of electrodes 271 of the second chip 270 is electrically connected to the second wiring layer 261 . Preferably, the substrate 200 further comprises a patterned covering metal layer 280 formed on the second chip 270 and the fourth dielectric layer 253 . The patterned covering metal layer 280 at least comprises a heat sink portion 281 attached to the second chip 270 . In addition, a second solder mask layer 293 is formed on the uppermost layer of the substrate 200 to cover the circuit section of the patterned covering metal layer 280 . The second solder mask layer 293 has an opening 294 that exposes the heat sink portion 281 of the patterned covering metal layer 280 . If the patterned covering metal layer 280 has a plurality of connecting pads 282 , the second solder mask layer 293 also exposes the connecting pads 282 . Preferably, a plated layer 213 is formed on the exposed surfaces of the heat sink portion 281 and the connecting pads 282 to prevent oxidation. Thus, the thermally enhanced coreless thin substrate 200 with embedded chips not only has superior assembling ability and interconnection reliability, but also has a higher wiring density and thinner package dimension. Moreover, the substrate 200 has a better electrical performance. Not only are the interconnections between the chips 220 and 270 within the substrate 200 enhanced, cross-talk effect between transmission wires is also minimized as well.
[0020] The method of manufacturing the thermally enhanced coreless thin substrate 200 is shown with reference to a series of cross-sectional diagrams from FIGS. 3A through 3M . First, as shown in FIG. 3A , a carrier metal layer 210 ′ is provided. The carrier metal layer 210 ′ can be a copper foil. At least one of the first chip 220 is attached to the carrier metal layer 210 ′ through adhesion or eutectic bonding method. Moreover, the electrodes 221 of the first chip 220 face upward and are exposed. Then, as shown in FIG. 3B , the first dielectric layer 230 is formed on the carrier metal layer 210 ′ by a digital inkjet printing or a stencil printing method, and the first dielectric layer 230 covers the first chip 220 but exposes the electrodes 221 . Preferably, the digital inkjet printing method is used because the first dielectric layer 230 can be shaped into various kinds of patterns and its thickness in different areas can be carefully controlled. For example, the first dielectric layer 230 is thinner over the first chip 220 and thicker over the carrier metal layer 210 ′. The through holes 231 may be formed in-situ with the formation of the first dielectric layer 230 or afterwards through performing an exposure and development process. The through holes 231 are linked to the carrier metal layer 210 ′. Thereafter, as shown in FIG. 3C , the first wiring layer 240 is formed on the first dielectric layer 230 by etching the copper foil or performing photoresist interior plating. The first trace lines 241 of the first wiring layer 240 are electrically connected to the carrier metal layer 210 ′ via the through holes 231 . The second trace lines 242 of the first wiring layer 240 are electrically connected to the electrodes 221 . Next, as shown in FIG. 3D , the second dielectric layer 251 is formed on the first wiring layer 240 . In the present embodiment, the second dielectric layer 251 has suitable through-hole structures for exposing the first trace lines 241 and the second trace lines 242 of the first wiring layer 240 . Then, as shown in FIG. 3E , the second wiring layer 261 is formed on the second dielectric layer 251 . The second wiring layer 261 is electrically connected to the first wiring layer 240 . After that, as shown in FIG. 3F , the third dielectric layer 252 is formed on the second wiring layer 261 . The third dielectric layer 252 has suitable through-hole structures for exposing parts of the second wiring layer 261 . Subsequently, as shown in FIG. 3G , a thermal compression fixture 310 is used to dispose the second chip 270 on the third dielectric layer 252 . As shown in FIG. 3H , the electrodes 271 of the second chip 270 are electrically connected to the second wiring layer 261 . Afterwards, as shown in FIG. 3I , the third wiring layer 262 is formed on the third dielectric layer 252 . Next, as shown in FIG. 3J , the fourth dielectric layer 253 is formed on the third wiring layer 262 . Similarly, the digital inkjet printing technique can be used so that the outer surface of the fourth dielectric layer 253 is almost flushed with the second chip 270 and prevented from covering the second chip 270 . Then, as shown in FIG. 3K , a covering metal layer 280 ′ is formed on the second chip 270 and the fourth dielectric layer 253 . Next, as shown in FIG. 3L , an exposure and development process is used to form a mask 321 on the carrier metal layer 210 ′ and a mask 322 on the covering metal layer 280 ′ for etching the carrier metal layer 210 ′ and the covering metal layer 280 ′. For example, a dry film or a photoresist layer may serve as the masks 321 and 322 . Afterwards, as shown in FIG. 3M , the carrier metal layer 210 ′ is patterned to form the patterned carrier metal layer 210 that comprises the heat sink portion 211 and the connecting pads 212 . Meanwhile, the covering metal layer 280 ′ is patterned to form the patterned covering metal layer 280 that comprises the heat sink portion 281 and the connecting pads 282 . Finally, as shown in FIG. 2 , the first solder mask layer 291 is formed on the patterned carrier metal layer 210 and the second solder mask layer 293 is formed on the patterned covering metal layer 280 to produce the thermally enhanced coreless thin substrate 200 with embedded chips. Therefore, the carrier metal layer 210 ′ functions as a chip carrier, a heat sink and an electrical connection for the chip in the manufacturing process.
[0021] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | A thermally enhanced coreless thin substrate with embedded chips, which mainly includes a patterned carrier metal layer, at least one chip, at least one dielectric layer and at least one wiring layer, is disclosed. The chip is attached to a heat sink portion of the patterned carrier metal layer. The dielectric layer is formed over the patterned carrier metal layer and covers the chip. The wiring layer is formed on the dielectric layer for electrically connecting the patterned carrier metal layer and the chip. In the process of manufacturing the thermally enhanced coreless thin substrate with embedded chips, the heat sink portion is formed by patterning the patterned carrier metal layer after finishing the formation of the wiring layer. Thus, a thin board type electronic device that combines a heat sink, a carrier substrate and embedded chips together to form an integral unit is fabricated. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to the field of handheld computing devices. Specifically, the present invention discloses a method and apparatus for synchronizing information between a desktop computing system and a handheld computing device.
BACKGROUND OF THE INVENTION
[0002] Handheld computing devices or “palmtops” typically weigh less than a pound and fit in a pocket. These palmtops generally provide some combination of personal information management, database functions, word processing and spreadsheets. Users of palmtops may also own personal computers (PCs) running applications that manage data similar to the data carried in the palmtops. In such cases, the user normally would want the data on their palmtop to be easily synchronized with the data on their PC.
[0003] A number of programs today transfer data between palmtops and PCs, but they are currently limited in functionality. Some programs transfer all the information from the palmtop to the PC without regard for the prior content on the PC. These programs assume that changes to that particular data are only made on the palmtop, and that the changes made on the palmtop take precedence over any changes made on the PC. As a result, any independent updates made directly on the PC will be lost.
[0004] Other methods use ‘flags’ to facilitate synchronization. These methods create update ‘flags’ in each record that has changed, both on the palmtop and the PC. Corresponding files on the palmtop and the PC are then compared, and if one or more flags are set in a file, the file is recognized as having changed. If both the palmtop and PC files have changed, the flags are used to determine which records need to be updated in the other file. The databases of most existing programs, however, do not contain such flags since the databases of most existing programs were not designed to be synchronized. Thus, a different method must be used to synchronize data from programs that are already on the market.
[0005] Some programs attempt to synchronize the data on the PC with the palmtop by comparing the information in each application and prompting the user for answers to determine which data to overwrite. For example, U.S. Pat. No. 5,392,390 describes a method for reconciling information between two calendar database files by interrogating the user about which file to update when a difficult case arises. Although these types of programs provide an advantage over programs that assume only one database has changed since they do not indiscriminately overwrite data, they are cumbersome and time consuming. Using these methods, users may have to spend an inordinate amount of time answering questions whenever they attempt to synchronize information between their palmtops and their PCs.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide a solution to the problem of synchronizing records on two different computer systems. It is a further object of the present invention to present a method that reconciles two changeable databases without any user interactions. Specifically, the present invention discloses a method and apparatus for automatically reconciling records in corresponding files on palmtop and a personal computer (PC) by comparing the records in the palmtop and PC files with the records in a backup file in a backup directory from the previous synchronization.
[0007] When a user is ready to synchronize information on the two computer systems, the palmtop is connected to the PC. The present invention then compares each record of a file on the palmtop with the records in the backup file in the backup directory to determine whether each record on the palmtop file is new, updated or if it has been deleted from the palmtop file. Next, a comparison is performed between the contents of the corresponding file on the PC and the backup file in the backup directory to determine whether each record on the PC is new, updated or if it has been deleted from the PC file. The results of both compares are stored, e.g., in a new file called a reconcile file, or a temporary data structure. After all the records in both files have been checked, the results of the compare, whether stored in a reconcile file or temporary data structure, are copied over the selected files on the palmtop, the PC and the backup file in the backup directory, thus guaranteeing that all three files are identical after the synchronization. The reconcile file is then deleted.
[0008] Other objects, features and advantages of the present invention will be apparent from the accompanying drawings, and from the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The objects, features, and advantages of the present invention will be apparent from the following detailed description of the preferred embodiment of the invention with references to the following drawings.
[0010] [0010]FIG. 1 illustrates a palmtop connected to a PC containing a backup file from the previous palmtop-PC synchronization.
[0011] [0011]FIG. 2 illustrates the comparison of a current palmtop calendar file and a current PC calendar file with the backup calendar file in the backup directory on the PC, and the writing of the results to a reconcile file.
[0012] [0012]FIG. 3 illustrates the copying of the updated information in the reconciled calendar file to the backup calendar file in the backup directory, the PC and the palmtop.
[0013] [0013]FIG. 4 illustrates the final result of the present invention, with the deletion of the reconcile file, leaving the backup calendar file in the backup directory, the PC calendar file and the palmtop calendar file synchronized.
DETAILED DESCRIPTION
[0014] The present invention discloses a method and apparatus for automatically reconciling records in a file on a palmtop with records in a corresponding file on a personal computer. In the following description, for purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the present invention. Furthermore, the present invention is described using one possible embodiment. For example, the present invention is described with reference to calendar files. However, any type of data files can be synchronized using the teachings of the present invention. Thus, the teachings of the present invention can be used to synchronize to-do lists, address lists, phone lists, and any other record oriented database file.
[0015] Referring to FIG. 1, when a user is ready to synchronize information on the two computer systems, palmtop computer 100 is connected to personal computer (PC) 200 with a communication link 10 . The communication link may consist of a serial data line or any other type of data communication line between the palmtop computer 100 and PC 200 . Palmtop computer 100 and PC 200 each contain versions of corresponding files, 101 and 201 . It is possible and likely that corresponding files 101 and 201 have been altered with new, modified, and deleted records since the last synchronization.
[0016] The synchronization process is conceptually illustrated in FIG. 2. The synchronization process is controlled by computer instructions that can be stored on magnetic media on the PC 200 . The present invention uses a backup directory 203 stored on the PC. Backup directory 203 contains a backup file that stores the file state from a previous synchronization of the PC 200 and the palmtop 100 . The backup file is used to reconcile the records in a file on the palmtop computer 100 with the corresponding file in the PC.
[0017] To create an initial backup directory 203 , the palmtop and PC files are merged. For example, if the PC 200 starts with a calendar file and the palmtop 100 does not have a calendar file, then PC calendar file 201 will be copied into a backup calendar file 202 in the backup directory 203 . Backup calendar file 202 in backup directory 203 will be used to create the same records on palmtop 100 , thus synchronizing palmtop calendar file 101 and PC calendar file 201 with backup calendar file 202 in backup directory 203 . If both PC 200 and palmtop 100 start out with calendar files, then the two calendar files will be merged, and exact duplicate records will be filtered out. The resulting merged file will then be used for the palmtop calendar file 101 , PC calendar file 201 , and the backup calendar file 202 .
[0018] [0018]FIG. 2 illustrates the record synchronization process where a PC calendar file 201 and a palmtop calendar file 101 each contain a plurality of records that have been modified. The PC also contains backup calendar file 202 stored in backup directory 203 , comprising a calendar file from the previous synchronization between palmtop computer 100 and PC 200 . The plurality of records in the PC calendar file 201 and the corresponding palmtop calendar file 101 are then each compared to the records in the corresponding backup calendar file 202 in backup directory 203 to determine new, updated or deleted records. In one embodiment, the results of the compare operations are then used to create a single reconcile file 204 that contains all the new records, modified records, and unmodified records. The deleted records are removed. The contents of the reconcile file 204 are then copied to PC file 201 , palmtop file 101 , and backup calendar file 202 in backup directory 203 (FIG. 3). All three calendar files are thus synchronized. Finally reconcile file 204 is then deleted as illustrated in FIG. 4.
[0019] In another embodiment, the intermediate results of the compare operations may be stored in a temporary data structure that contains all the new records, modified records, and unmodified records. The deleted records are removed. The contents of the data structure are then copied to PC file 201 , palmtop file 101 , and backup calendar file 202 in backup directory 203 (FIG. 3). All three calendar files are thus synchronized. The temporary data structure is no longer used.
[0020] To fully describe what occurs during the comparison process, Table 1 lists all the possible cases and what occurs during the record synchronization process, according to one embodiment.
TABLE 1 CONDITION RESULT METHOD Record was added to a Record is copied into Record was not found in file. reconcile file. backup file or other file. Record was added Record is copied into Record was not found in into both files and reconcile file. backup file but matched exactly with exactly the same contents. a record in the other file. Record was deleted Neither record is Record was found in one file from one file but still copied into the and the backup file but not the exists in the other. reconcile file. other file. Record was deleted Copy changed record The record that was deleted is from one file but the into the reconcile gone in both files so it cannot same record in other file. be copied. The changed record file has been changed. acts like a new record since it does not exist in the backup file. Record was deleted Neither record is The record that was deleted is from both files. copied into reconcile gone from both files so it file. should not be copied. Record was modified Copy changed record Changed record is not found in one file. into the reconcile in backup file making it appear file. as a new record. The original record in the other file matches a record in the backup but not in the original file making it a deleted record. Same record was Record is copied into Both records are new but since changed in both files the reconcile file. they match exactly only one exactly the same way. record is created in the reconcile file for them. Same record was Both records are Both records appear as new changed in both files, copied into the records since neither match but not in the exact same way. reconcile file. any records in the backup file.
[0021] The first column of Table 1 lists the possible conditions of the records in the files to be reconciled. The second column of Table 1 describes how each type of record condition is handled during the reconciliation process. The third column explains how each condition is recognized by the present invention.
[0022] For example, in one embodiment, if a record is added into the calendar file on the palmtop 100 and a different record is added into the corresponding calendar file on the PC 200 , then the synchronization system of the present invention will copy both records into the reconcile file. The reconcile file will later be copied back into the backup calendar file in the backup directory, the palmtop calendar file and the PC calendar file, synchronizing the records in the three calendar files. Similarly, if the same record is changed in one way in the palmtop calendar file and changed a different way in the PC calendar file, then both changed records will be copied into the reconcile file. Given that neither altered record will match any records in the backup file, both records will then appear as new records in the backup calendar file in the backup directory, the palmtop calendar file and the PC calendar file.
[0023] In the preferred embodiment of the present invention, key contents of a record are identified. Key contents consist of an index field or a group of fields that can be used for record compares. Matching key contents indicate that this is the same record. The preferred embodiment uses these key contents to reduce the time to find matching records and perform the compare.
[0024] The embodiment of the present invention as described above assumes that the palmtop files and the PC files have records with identical field order and field names. However, this is not necessary to practice the synchronization method of the present invention. In cases where file formats are non-identical, prior art methods exist to perform translations or conversions of file formats, thus allowing the present invention to function after the non-identical file formats are in a format where records can be compared. This flexibility in file formats is an important feature of the present invention because it allows information to be synchronized between palmtop and PC applications that use different file systems and file formats.
[0025] Although the present invention has been described in terms of specific exemplary embodiments, it will be appreciated that various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims. | Many users of handheld computing devices or “palmtops” also own personal computers (PCs) running applications that manage data similar to the data carried in the palmtops. In such cases, users are likely to want the data on the palmtop to be synchronized with the data on the PC. The present invention discloses a method and apparatus for reconciling database files on a palmtop with corresponding database files on a PC. | 6 |
This application is a continuation-in-part of application Ser. No. 07/565,047, filed Sep. 9, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for synchronizing the growth of clostridia useful in the production of solventogenic cells, enzymes, antibiotics, useful toxic proteins, or refractile endospores. Vegetative cells of bacteria of the genus Clostridium may be massively converted to synchronized solventogenic cells of essentially the same critical length, or the conversion allowed to proceed in a manner such that the production of refractile endospores is selectively induced. More particularly, the bacteria are synchronized in cell number and mass by selective subculturing in a medium containing a slowly metabolizable carbon source to avoid random cell growth. The synchronized cells are elongated to at least three times the length of vegetative cells, at which point they become solventogenic. Synchrony of cell mass and number is stabilized by addition of at least about 0.01M of a divalent cation to the medium. If solventogenesis is to be preserved, growth must be inhibited by chemical or physical means. Where preparation of enzymes, antibiotics or toxic protein producing cells is desired, cell growth may be arrested at selected growth stages beyond the solventogenic stage by inhibition of cell division or DNA replication.
2. Description of the Prior Art
Some anaerobic, thermophilic, endospore-forming bacteria of the genus Clostridium are capable of only limited metabolic production of enzymes, antibiotics, toxic proteins, or for producing solvents by acetone-butanol-ethanol (ABE) fermentation. The special capabilities of this genus are largely attributable to their expanded genetic versatility, where significant production of endospores occurs only under a particular physiological condition. Endospores are characterized by their ability to withstand extreme conditions which would destroy the cells in their vegetative state. The morphological changes exhibited by clostridial cells are related to changes in cellular enzyme activity. Depending upon the culture conditions, these bacteria can enter either an acidogenic phase or a solventogenic phase in the process of growth. Regulation of the overall sporulation process is thus a necessary prerequisite to the commercial production of cellular metabolites.
Some species of bacteria of the genus Clostridium are directly capable of converting low cost biomass wastes, such as xylan, or other pentose polymers, into solvents without prior depolymerization of the substrate. By virtue of the fact that certain clostridia are anaerobic and thermophilic, industrial fermentation processes using this genus may be carried out at relatively high temperatures. As a consequence, recovery of their fermentation products requires less energy because it can be accomplished by vacuum distillation directly from the fermentation vessel. Vacuum recovery also reduces the problems associated with solvent toxicity to the fermenting cells. The clostridia have high metabolic rates thus reducing the required residence time in the bioreactor and the ratio of end products to cells is high, maximizing the total bioreactive output. In addition, the use of a thermophilic system along with a simplified culture medium and defined and massive numbers of inoculated cells, assures that the system is inherently less subject to contamination. Sterilization of the raw materials therefore may be eliminated.
Lignocellulosic biomass material, the cheapest and most abundant feedstock for bacterial fermentation processes, has three major fractions: crystalline cellulose, hemicellulose, and lignin, each of which must be separately processed. Cellulose can be hydrolyzed to glucose with acid or enzyme catalysts. However, acid catalyst continue to degrade the resulting glucose. Furthermore, enzyme processes are not yet well developed and consequently are not cost efficient. Hemicellulose is largely composed of xylan, which is easily hydrolyzed to xylose but difficult to ferment to ethanol with existing fermentation technologies. Lignin is not a sugar polymer and, therefore, cannot be fermented to produce ethanol but can be thermochemically converted for use as a liquid fuel additive.
Use of anaerobic Clostridium acetobutylicum for industrial solvent production began at least as early as the 1920's employing a cane molasses feedstock. However, the best solvent yield obtainable was about 1.8% and even this yield was unreliable and unstable due to the susceptibility of C. acetobutylicum to phage (bacterial virus) infection. The method of the present invention enables control of the rates and yields of product formation and use of cheaper lignocellulose feedstocks. In especially preferred forms, the present invention utilizes thermophilic organisms of the genus Clostridium which, because of their ability to grow at elevated temperatures, make the process more energy efficient. In addition, thermophilic clostridia are not susceptible to phage infections.
One form of synchronous elongation of Clostridium thermosaccharolyticum is described in a chapter by Edward J. Hsu, one of the inventors hereof, in Spore Research, published by Academic Press (London, 1976, pp. 223-242), but that description makes no reference to synchronous growth of the cells in the presence of a divalent cation capable of stabilizing the cells during at least final multiplication thereof.
Ethanol-producing mutants of Clostridium thermosaccharolyticum are described in U.S. Pat. No. 4,652,526 issued to Edward J. Hsu, one of the inventors hereof. This patent also makes no mention of synchronous growth of cells in a growth medium under conditions where a divalent cation is added to stabilize the cells.
Hartmanis, et al. in Applied Microbiology and Biotechnology, Vol. 23 (1986) at pp. 369-371 describe repetitious subculturing of Clostridium acetobutylicum in a growth medium containing quantities of divalent cations. A small amount of calcium was included in the starter culture to prevent degeneration of the cells after only three transfers. The addition of CaCO 3 permitted as much as ten transfers without degeneration. The calcium addition thus eliminated the need for multiple heat shock treatments for the preparation of a starting culture. However, synchronization of growth in the number of cells and their effective mass was not carried out to produce a substantially homogeneous cell population. The authors described a process wherein each subculture was allowed to progress for at least about a 24 hour interval to produce heat resistant spores. It was reported that the minor amount of calcium in the growth medium appeared to render the spores more heat-resistant.
U.S. Pat. No. 4,778,760 to Ishida, et al. indicates that a slight amount of calcium (4 ppm) is useful to stabilize a thermostable α-amylase-producing thermophilic anaerobic bacteria of the Clostridium class. However, the calcium is not utilized as a component of the growth medium for the bacterial cells.
SUMMARY OF THE INVENTION
The present invention allows bacteria of the genus Clostridium to be prepared which are useful for selective production of solvents, such as ethanol and butanol at significantly higher levels than heretofore obtainable. In addition, enzymes or antibiotics may be selectively produced. Of equal importance is the fact that whereas previously solvent recoveries have not exceeded about 1 to 2%, this process permits as much as about 11% of the solvent to be recovered. Butanol and ethanol may be recovered in a ratio of 2:1 at solvent recovery levels of 11%. The ethanol recovery ratio is increased to 1:1 at solvent recovery levels of 6.5%. Advantageously low cost feed stocks may be used as the growth medium for specially prepared cells. Optionally, the process of cell preparation may be allowed to proceed to full spore formation, all of which is accomplished more efficiently than with past practices.
The preferred method hereof broadly includes synchronized growth in the number and mass of substantially anaerobic clostridial cells to a critical length. The cells are grown in batch cultures on a low cost carbon source growth medium. The resultant cells of the synchronized culture are at exactly the same stage in the division cycle and the individual cells and their respective processes are said to be "in phase". Depending on the desired end product, the cells may be harvested and stored or the procedure continued with stabilization of the cells by addition of a divalent cation source, followed by inhibition of cell growth. The resultant bacteria are capable of continued metabolism for extended periods of time. Metabolic end products which may be isolated from such cells include solvents, carbohydrate degrading enzymes, proteases, lipases, nucleases, antibiotics, parasporo-like protein crystals, and other toxic proteins as, for example, those which are useful as organic insecticides.
The preferred growth medium is a species-specific basal medium containing about 0.1 to 15.0% on a weight to volume basis of a slowly metabolized carbon source. The growth rate of the bacteria in such medium should be 10-90% less than the maximum growth rate K m for the bacteria in their optimum growth medium. Most preferably, the carbon source may be a pentose polymer such as xylan which may be economically obtained from wheat straw, rice straw, rice hulls, cornstalks, corncobs, fruit peels, hemicellulose and cellulosic residues from paper mill waste or other suitable organic agricultural, industrial, or urban waste.
The cells are synchronized by one or more preferred methods of repeated dilution, centrifugation, or membrane filtration, each followed by repeated subculture. The cells are grown at a temperature of from about -20° C. to about +10° C. of the species-specific optimum growth temperature. The growth period is limited to about 1.0 to 1.5 generations, or 1.0 to 1.5 times the "doubling" time, that is, the time required for a culture to multiply two to three times the initial concentration. At least about three to four discrete growth periods interspersed respectively with two to three dilutions, centrifugations or membrane filtrations to remove cell metabolic wastes are required to synchronize the cells. In preferred embodiments the synchronized cells are all of essentially the same critical length within a range of from at least about 3× and preferably about 4× to about 20× the length of normal vegetative cells. However, the cells may be elongated up to 100× their vegetative length.
The elongated, synchronized cells are subcultured to allow the cells to further multiply from about 1.0 to 12.0 generations, that is, the time required for the culture to multiply 2 to 4,096 times their prior concentration. The cells are subcultured in a growth medium containing a divalent cation such as calcium, magnesium, manganese, iron, or zinc to stabilize the activity of the cells and to prevent their death, lysis or aggregation. Good results are obtained by addition of at least about 0.01M of the divalent cation to the growth medium. A quantity of the divalent cation may be utilized which exceeds the solubility thereof in the growth medium, with the excess of the divalent compound dissolving as the divalent cation is incorporated in the cells undergoing multiplication. Better results are obtained if the divalent cation concentration is maintained at a level of from at least about 0.01M to about 0.2M with the preferred concentration of the divalent cation being at least about 0.1M. Three kinds of media may be used: one in which xylan is the sole carbon source, and the xylan is supplemented with a divalent cation; one in which xylan is supplemented with an additional carbon source that is the divalent salt of an organic acid; and one in which the divalent salt of an organic acid is the sole carbon source. An organic calcium compound such as calcium gluconate, lactate, acetate, butyrate, or formate is preferred. Synchronized cells stabilized with calcium gluconate can be sustained, even in the presence of growth inhibitors, for six months calcium gluconate is the most preferred divalent cation source because it provides not only as the required divalent calcium ion, but also serves as an excellent carbon source which is metabolized in a manner similar to that of glucose but at a much slower rate.
Cultures that are synchronized by sequential transfer (at least two subcultures) in a medium that contains a slowly metabolizable carbon source results in a type of modified cell division not previously reported for any type of bacteria, including the Clostridium species. In accordance with the present invention the cells, for example, elongate 16× to 20×, and form a single septum to divide the cell in an unusual modified manner such that the filament is equally divided into two cells that remain elongated. When septation is observed on the newly formed cells that are 8× to 10× in length, it is either to divide the cell equally once again, or terminally to form a spore septum. Therefore, a cell elongates, for example, to 16×, divides equally to form two cells that are elongated 8× and subsequently divided to form four cells that remain elongated 4× (the critical length).
Suitable sources of a slowly metabolizable carbon source include amygdalin, arabinose, cellobiose, galactose, glycogen, melibiose, α-methylglucoside, β-methylglucoside, raffinose, salicin, starch, trehalose, xylan, Ca-acetate, Ca-butyrate, Ca-citrate, Ca-formate, Ca-gluconate, and Ca-lactate.
Previous attempts to produce a relatively homogeneous population of free, refractile spores of C. thermosaccharolyticum have been unsuccessful. The method of the present invention includes culture-conditions that permit the complete differentiation of vegetative cells to such an extent that virtually 100% free refractile spores may be produced.
Where the desired end product is cells to be sold as a commodity, they may be harvested and washed by repeated centrifugation and resuspension or by filtration and stored at 4° C. On the other hand, if the desired end product is spores, the temperature of the stabilized culture is preferably raised or lowered beyond the culture growth range, e.g., -20° C. to about +10° C. of the optimum temperature for growth. Cell division will cease at that temperature, but cell differentiation, spore formation and metabolism will continue. If the desired end product is one that can be produced by elongated, sporulating cells, e.g. solvents, growth of the resulting synchronized, stabilized cells is preferably inhibited by temperature modification, or use of antimicrobial chemical agents such as antibiotics and dyes. Spore formation as well as cell division cease upon such addition but metabolic processes such as solvent production continue.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of alternative pathways for production of spores only, spores plus solventogenic cells, or only solventogenic cells;
FIG. 2 is a graphic representation of the correlation of synchronous growth, production of solvents, and the utilization of paraffin oil, by a culture incubated in xylan basal medium enriched with calcium gluconate. (Curves A, B and C, respectively).
FIG. 3 is a graphic representation of calcium incorporation by an individual cell in the synchronous culture incubated in xylan basal medium enriched with calcium gluconate;
FIG. 4 is a graphic representation of calcium incorporation by an individual cell in the synchronous culture incubated in xylan basal medium enriched with calcium carbonate; and
FIG. 5 is a graphic representation of calcium incorporation by an individual cell in the synchronous culture incubated in a calcium gluconate medium.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is apparent from the schematic representation of FIG. 1, cells which have been subjected to regulated, synchronized growth that induces elongation may be used selectively to carry out separate metabolic processes identified as pathways I, II and III respectively. When the cells are used in a process represented by pathway I, the elongated cells are solventogenic and solvents may be produced for an extended period of time when cell division is arrested. If cell division is inhibited by physical means such as temperature shift and incubation is allowed to proceed, spore formation commences and spores ultimately become the predominant product. If growth is inhibited by antimicrobial agents, even under extended incubation times, solvents remain as the predominant product. When the cells are used in a process represented by pathway II, the result is primarily spore production. When the cells are used in a process as indicated by pathway III, principally solvents are produced.
In accordance with a preferred procedure, a basal growth medium #1 is prepared by supplementing a liquid peptone-yeast extract or other medium of conventional composition with a slowly metabolized carbon source. The preferred medium limits growth of the bacteria to at least about 10% less than the maximum growth rate K m in an optimum species-specific growth medium. A preferred growth medium in this respect is a pentose material such as xylan. Sufficient xylan should be added to provide about 0.5% of the pentosan on a weight to volume basis.
Xylan, a pentosan compound commonly present in plant cell walls and woody tissue may be obtained by grinding up wheat straw, or any of a number of agricultural, industrial and urban organic waste products. The xylan can be added to the basal medium untreated and in powdered form. Alternatively, the xylan can be hydrolyzed with hot dilute hydrochloric or other acids to yield xylose, a crystalline aldose sugar commonly called wood sugar, having the general formula C 5 H 10 O 5 . Xylose can also be obtained by coculturing a cellulolytic organism such as C. thermocellum along with the C. thermosaccharolyticum of the present method on the cellulose basal medium.
A stock culture is prepared by introducing cells of an exponentially growing culture of the genus Clostridium into a suitable broth medium, such as pea broth. Particularly preferred forms of clostridial bacteria are of the species thermosaccharolyicum American Type Culture Collection Strains (ATCC) #7956, National Canner's Association (NCA), #3814. However species which may be used include perfringens ATCC #13124, thermocellum ATCC #27405, thermohydrosulfuricum ATCC #35045, acetobutylicum ATCC #824, thermosulfurigenes ATCC #33743, thermoaceticum Deutsche Sammlung von Mikroorganismen (DSM) #521, thermoautotrophicum DSM #1974, beijerinckii ATCC #25752, and butyricum ATCC #19398.
Synchronization of cell growth may be accomplished by either conventional serial dilution, filtration or centrifugation techniques. Following incubation at the optimum growth temperature and time for a particular clostridial species to reach a cell density of at least about 1×10 6 , about one volume of the stock culture is inoculated for each 10 volumes of the xylan basal medium for incubation as a batch culture, identified as basal medium #1 in FIG. 1.
The basal medium #1 containing the Clostridium batch culture is incubated for a time and a temperature which is specific for the preferred species of Clostridium to multiply two to three times the initial concentration or about 1.0 to 1.5 generations.
A basal growth medium #2 is then prepared which is identical in composition to basal medium #1. About one volume of the Clostridium batch culture in medium #1 is transferred to basal medium #2 for each 10 volumes of the basal medium #2, again for incubation as a batch culture. This culture is similarly maintained at an optimum growth temperature for the species until the culture in medium #2 multiplies two to three times or about 1.0 to 1.5 generations or until the cells reach a concentration of at least about 2-3×10 5 .
A growth medium for use in supporting cell metabolism carried out along one of the metabolic pathways I, or II is prepared by supplementing the xylan basal medium previously described with an organic or inorganic divalent cation source. A growth medium for metabolic pathway III contains a peptone-yeast extract basal medium supplemented with the divalent salt of an organic acid as the sole carbon source. The cation serves to stabilize the cells against death, lysis or aggregation. Preferred divalent cations are magnesium, manganese, iron, zinc, and calcium. Particularly preferred cation sources include organic calcium compounds.
If it is desired to produce both solventogenic cells and spores, metabolic pathway I is used and a preferred stabilization supplement in this respect is calcium gluconate. A growth medium #3 is prepared by supplementing xylan basal medium with at least about 4.3% calcium gluconate on a weight to volume basis (0.1M).
An inoculant of about one volume of the batch culture in basal medium #2 is transferred to growth medium #3 for each 100 volumes of the growth medium. The 1:100 diluted inoculant is incubated as a batch culture for at least about 1 to 12 generations, or 1 to 12 times the "doubling" time or until the cells reach a concentration of about 2×10 10 or 2 to 4,096 times the initial concentration, at which time the cells demonstrate a high degree of synchrony in both cell mass and cell number. About 90% or more of these cells are elongated a minimum of four times and exhibit a modified cell division such that they remain elongated at a critical length of at least three times and preferably four times their vegetative length. Synchronous, solventogenic cells are harvested at the end of this time, with negligible numbers of spores.
Alternatively, the synchronous, solventogenic cells may be subjected to treatment conditions which would inhibit their growth so that the products of their continued metabolic processes may be harvested. DNA replication and cell division may be inhibited by physical means such as increasing or decreasing the temperature of the cells and growth medium from about +10° C. above or -20° C. below the species-specific optimum growth temperature respectively. In other embodiments, growth may be inhibited by application of a sublethal dose of an antimicrobial agent. Particularly preferred antimicrobial agents are chloramphenicol, mitomycin, nalidixic acid, and acridine orange.
If the goal is solvent production using metabolic pathway I, division of the elongated solventogenic cells is inhibited and solvent production continues during further incubation with negligible concomitant spore production and utilization of paraffin oil as an additional carbon source. As shown in FIG. 2, inhibition of the specially prepared, synchronized cells causes them to enter a stage of incresing solventogenesis. After a given period of time, which varies depending on the species of bacterium selected, solvent production diminished to a low percentage, indicating continuation of later stages of sporulation.
If incubation is allowed to continue, antibiotics such as polymyxin, bacitracin, carbohydrases such as amylase, proteases, lipases, nucleases, parasporo-like protein crystals, and ultimately, refractile, mature, free spores are produced.
If the desired end product is spores and their related products, then a preferred metabolic pathway is represented by process II of FIG. 1, wherein a preferred divalent cation supplement is calcium carbonate. A growth medium #4 is prepared by supplementing xylan basal medium with about 1.1% calcium carbonate on a weight to volume basis (0.1M).
An inoculant of about one volume of the batch culture in basal medium #2 is transferred to growth medium #4 for each 100 volumes of the growth medium. The 1:100 diluted inoculant #4 is incubated as a batch culture until the cells again exhibit synchrony in cell mass and number and elongate to at least four times their vegetative length. They exhibit modified cell division such that the daughter cells remain elongated at the critical length. Binary fission of the synchronous cells is inhibited by physical means, such as increasing or decreasing temperature. Continued incubation of this inhibited, synchronized culture results in production of antibiotics, enzymes, parasporo-like crystals, and finally refractile, mature free spores with a low percentage of solvents.
If the desired end product is only solventogenic cells, a preferred metabolic pathway is III of FIG. 1 wherein a medium #5 is prepared for use as a growth medium by supplementing a liquid peptone-yeast extract medium of conventional composition with an organic calcium compound as the sole slowly metabolized carbon source. A preferred organic calcium compound is calcium gluconate present at a level of at least about 4.3% on a weight to volume basis (0.1M).
An inoculant of about one volume of the batch culture in basal medium #2 is transferred to growth medium #5 for each 100 volumes of the growth medium. The 1:100 diluted inoculant #5 is incubated as a batch culture until the cells exhibit synchrony in cell mass and number and elongation to the critical length of about four times their vegetative length with modified cell division. Synchronous, solventogenic cells are harvested at the end of this time, with a low percentage of spores. Where the goal is solvent production using metabolic pathway III, DNA replication and cell division may be inhibited by physical means such as temperature shift, or by use of antimicrobial agents, and the culture is further incubated until solvents are produced, and then continued until solvent production is significantly decreased.
The metabolic products of pathways I, II and III, may be recovered in accordance with various conventional procedures. For example, if the product is a solvent produced at high temperatures, that is to say, temperatures at or above 50° C., recovery may be by vacuum fermentation as described by D. L. Pavia, et al., Introduction to Organic Laboratory Techniques, A Contemporary Approach, at 548-552, (W. B. Saunders, 1976), and Cysewski and Wilke, "Rapid Ethanol Fermentation Using Vacuum and Cell Recycle", Vol. XIX Biotechnology and Engineering, 1125-1143, 1977. If the product is a solvent produced at temperatures below 50° C., the product may be recovered by standard distillation processes. Enzymes, such as carbohydrases are extracellular products which are recovered by removing cellular debris by filtration or centrifugution. If further purification of enzymes from crude extract is desired, recovery may be as described by D. I. C. Wang, et al., Fermentation and Enzyme Technology, at 238-310, (John Wiley & Sons, 1979). Parasporolike protein crystals and useful toxic proteins are contained within the spores and may be harvested by repeated centrifugation or filtration. The cells are centrifuged or filtered, resuspended, again centrifuged or filtered, resuspended, and again centrifuged or filtered. Pure, dry spores are then recovered. If the product is antibiotics, recovery is by conventional extraction with a solvent such as propanol or butyl acetate as described by Crueger and Crueger in Biotechnology: A Textbook of Industrial Microbiology, at 99-103, (Sinauer, Science Tech, 1982).
Growth medium #5 may be substituted in the above described procedures for xylan basal medium #1 and #2. In other respects the procedures remain the same including the final 1:100 dilution into growth medium #5. The dilute inoculant is incubated as a batch culture until the cells exhibit elongation, synchrony and modified cell division as previously described. Synchronous, solventogenic cells are harvested at the end of this time, with negligible numbers of spores.
As another alternative procedure, growth of the synchronous, solventogenic cells may be inhibited to channel the energy of the cells into metabolism rather than cell division and to permit harvesting of the products of their continued metabolic processes. The temperature of the cells and growth medium may be increased to about 10° C. above or decreased to about 20° C. below the species-specific optimum growth temperature respectively, or a sublethal dose of an antimicrobial agent may be administered. The growth-inhibited culture is further incubated and solvents are produced with negligible concomitant spore production. After a given period of time which varies depending on the bacterial species, the percentage of solvents produced varies as, for example from 6% to as high as about 12% and the butanol:ethanol ratio varies as, for example 1:1 to 2:1.
In other embodiments, the step of subculturing in a second basal medium is repeated and the initial dilution into fresh medium is repeated prior to transfer into a third growth medium. The initial dilution into fresh basal medium may be from about 1:2 to 1:100, which may be repeated, and the final dilution may be from about 1:2 to 1:500. Repeated centrifugation or membrane filtration and resuspension may be substituted for serial dilution as a method for synchronization of the cultures. The serial dilution, or separation of cells by filtration or centrifugation, assures that the density level of the bacterial cells present in each succeeding batch subculture is no greater than about one half of the density of the bacterial cells in the immediately preceding culture.
In all embodiments tested, in order to maintain solventogenesis for extended periods, the elongated, synchronous cells appeared to require a carbon source that is slowly metabolized; normal cell division must be stopped by a temperature shift or the addition of chemical growth inhibitors; and the cells must incorporate calcium. FIGS. 3-5 compare calcium incorporation of individual synchronized Clostridium thermosaccharolyticum cells to the calcium incorporation of the typical asynchronous, short, vegetative cells. As illustrated by Curves A1-A4 in each of the Figures, it can be seen that incorporation of calcium stabilized the solventogenic cells and protected them from the high concentrations of solvents that were subsequently produced. Conversely, the Curve B cells of each Figure that were not synchronized prior to the addition of excess calcium, remained as typical, short, vegetative cells, that did not incorporate high concentrations of calcium and were predominantly acidogenic. However, even in these acidogenic cells, when cell division was stopped at 45 hours by shifting to 35° C., the cells elongated, produced solvents, and there was an increase in calcium incorporation.
EXAMPLE I
This example sets forth the preferred procedures for synchronizing the growth of cell number and mass and altering cell division in cultures of wild type Clostridium thermosaccharolyticum, (ATCC) #7956.
Pea Broth
Six dried Alaskan seed peas in 10 ml of 2% peptone solution, autoclaved for 15 minutes, immediately overlayed with 2 ml of sterile vaspar.
Stock Cultures
Inoculation of pea broth with an exponentially growing culture of C. thermosaccharolyticum, followed by incubation for 8 hours at 56° C. The stock culture was then stored at 4° C. Stock cultures were transferred at 3-6 month intervals. Stock cultures were activated by incubation for 12 hours at 56° C.
Batch Cultures
One ml of activated culture was transferred to 10 ml of fresh basal medium for use as a batch culture.
Basal Medium
0.2% peptone
0.5% yeast extract
0.01% CaCl 2 .2H 2 O
0.1% (NH 2 ) 4 SO 4
0.01% MgSO 4
0.01% MnSO 4 .H 2 O
0.0005% ZnSO 4 .7H 2 O
0.0005% CuSO 4 .5H 2 O
0.0001% (NH 4 ) 6 Mo 7 O 24 .4H 2 O
0.00005% FeSO 4 .7H 2 O
0.000002% p-aminobenzoic acid
0.0001% thiamine hydrochloride
0.0000001% biotin
in one liter of water. The thiamine hydrochloride and biotin were filtered, sterilized, and added to the medium after autoclaving. 0.5% (w/v) xylan was added as a carbon source. Media pH was adjusted to 7.0 with 1M NaOH and then sterilized. The medium was preincubated to 56° C. and used within one day.
Procedure
All procedures were performed under anaerobic conditions using the Hungate procedure. A stock culture was activated, transferred to preincubated basal medium containing 0.5% xylan as a carbon source, and incubated at 56° C. for 6 hours, at which time the cell density was approximately 3×10 8 cells/ml. A 1 ml aliquot of the culture was aseptically transferred to 10 ml of fresh, preincubated xylan basal medium and again allowed to grow as a batch culture at 56° C. After four hours, the culture reached a cell density of approximately 1×10 8 cells/ml. A 1 ml aliquot of the culture was aseptically transferred to 100 ml of fresh preincubated xylan basal medium which had been supplemented with at least about 4.3% (0.1M) calcium gluconate. The culture was maintained in a serial dilution bottle and overlayed with 40 ml of sterile paraffin oil to ensure maintenance of anaerobic conditions. The culture was incubated in a rotary water bath shaker at 56° C. and 150 rpm. After 45 hours, the culture reached a cell density of approximately 2×10 9 cells/ml.
These solventogenic cells were harvested by centrifugation at 22,000× g for 30 minutes, resuspended in sterile distilled water, centrifuged at 22,000× g for 30 minutes, resuspended in sterile distilled water, centrifuged at 22,000× g for 30 minutes, at which point the cells were ready for immobilization and storage at 4° C.
The cells were differentially counted under a microscope using a Petroff Hausser counting chamber to determine the total number of cells, length of individual cells, number of sporangia, and number of refractile spores. An Olympus phase contrast microscope with a magnification of 400× was used. The morphology was confirmed at 1,000×.
The culture supernatant fluid was analyzed by gas-liquid chromatography (GLC) using a Hewlett-Packard GLC, Model 5700, equipped with a flame ionization detector and strip-chart recorder. Primary metabolites were separated on a stainless steel column (0.31 cm by 1.82 m) packed with 100/120 Chromosorb W AW coated with 10% SP-1000/1% H 3 PO 4 (Supelco, Inc.). The column was conditioned for 48 hours at 200° C. For analysis the injection port temperature was 200° C. and the detector temperature was 250° C. Prepurified nitrogen was used as the carrier gas with a flow rate of 40 ml/min. Hydrogen and compressed air flow rates were 30 and 300 ml/min, respectively. The electrometer range was set at 10 -11 A/mv with an attenuation of 16 and a range of 10. The oven temperature was held at 80° C. for 2 minutes after injection of the 10 microliter sample, then programmed to 170° C. at a range of 8° C./min, followed by a 2 minute hold period. Metabolite percentages were calculated from the area of standard reference peaks and converted to millimolar concentrations.
Samples obtained for counting and GLC analysis were subsequently centrifuged at 2200× g for 30 minutes to separate the cells from the culture medium. The cells were resuspended in sterile distilled water and the procedure repeated three times, following which the pellet was resuspended in 5 ml of sterile distilled water and sonicated to 90% disruption, as confirmed by phase-contrast microscopy. A model 400 Dionex ion chromatograph equipped with a Hewlett-Packard 9000 computer and autosampler was used for ion chromatographic analysis. Cations were separated on a CS-1 column. The eluent for sodium, ammonium, and potassium was 8 mM HCl plus 1 mM 2,3-diaminopropionic acid at 2.0 ml/min. The eluent for magnesium, manganese, and calcium was 48 mM HCl plus 8 mM 2,3-diaminopropionic acid at a flow rate of 0.8 ml min -1 . Anions were separated on an AS4A column using an eluent of 1.92 mM sodium carbonate plus 2.4 mM sodium bicarbonate at 2.0 ml/min.
Results
Cultures synchronized by repeated transfer in xylan medium within 6 hours and subsequently grown for 45 hours in the presence of xylan enriched with excess calcium gluconate demonstrated a high degree of synchrony both in cell mass and cell number. Differential count of the cells revealed 69.3% synchrony in cell mass and 76.7% synchrony in cell number. More than 90% of these synchronous, solventogenic cells elongated a minimum of four times and exhibited a modified cell division such that they remained elongated at a critical length of at least four times vegetative length. The number of refractile spores was negligible.
EXAMPLE II
The procedure of Example I was repeated except that the first incubation of a 1:10 dilution of the stock culture was followed by a second incubation of a 1:10 dilution of the culture in fresh, preincubated xylan basal medium. This dilution was again allowed to grow as a batch culture at 56° C. After 4 hours, the culture reached a cell density of approximately 1×10 8 , and the remainder of the procedure of Example I was completed. More than 90% of these synchronous cells elongated a minimum of four times and exhibited a modified cell division such that they remained elongated at a critical length of at least four times vegetative length. The number of refractile spores was negligible.
EXAMPLE III
The procedure of Example I was repeated except that after 45 hours the temperature was lowered to 35° C. by dipping the culture in an ice bath and transferring it to a rotary incubator at 35° C. The culture was incubated for an additonal 135 hours (180 hours total incubation time) at 35° C. After 180 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
Correlation of synchrony in cell number and corresponding concentration of solvents is shown in FIG. 5. Curve A shows the total cell count, with the degree of synchrony shown parenthetically as a percentage. Curve B shows the absolute concentration of solvents produced, with alcohol shown parenthetically on a volume/volume basis. The total millimolar solvent concentration is equal to the sum of the concentrations of the individual solvents: acetone, butanol, ethanol, isopropanol, and methanol.
Although solvents were produced from the beginning of the fermentation, the total millimolar concentrations, shown in Curve B, were relatively low during the synchronous growth period shown in Curve A. When the temperature was shifted to 35° C. after 45 hours of incubation, the arrested, elongated cells entered a stage of increasing solventogenesis such that at 115 hours the total concentration was 3.6%, at 130 hours the concentration increased to 6.3%, and at 145 hours the concentration further increased to 9.8%. The highest concentration of solvents, 10.6%, was observed at 175 hours.
EXAMPLE IV
The procedure of Example III was repeated except that following the reduction in temperature the culture was incubated for an additional 155 hours (200 hours total incubation time) at 35° C. After 200 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
EXAMPLE V
The procedure of Example III was repeated except that following the reduction in temperature the culture was incubated for an additional 200 hours (245 hours total incubation time) at 35° C. After 245 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced significant amounts of antibiotics, such as polymyxin, bacitracin, carbohydrases such as amylase, proteases, lipases, nucleases; parasporo-like protein crystals, and refractile, mature, free spores.
EXAMPLE VI
The procedure of Example I was repeated except that after 45 hours the temperature was increased to 70° C. by transferring the culture to a rotary incubator at 70° C. The culture was incubated an additional 135 hours (180 hours total incubation time) at 70° C. After 180 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE VII
The procedure of Example VI was repeated except that after increasing the temperature to 70° C. the culture was incubated an additional 155 hours (200 hours total incubation time) at 70° C. After 200 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
EXAMPLE VIII
The procedure of Example VI was repeated except that after shifting the temperature to 70° C. the culture was incubated an additional 200 hours (245 hours total incubation time) at 70° C. After 245 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced antibiotics, carbohydrases, parasporo-like protein crystals, and refractile, mature, free spores.
EXAMPLE IX
The procedure of Example I was repeated except that after 45 hours chloramphenicol was added to give a 20 micromolar final concentration in order to prevent further cell division. The culture was incubated for an additional 27 hours (72 hours total incubation time). After 27 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1
EXAMPLE X
The procedure of Example IX was repeated except that after addition of chloramphenicol the culture was incubated an additional 42 hours (87 hours total incubation time). After 87 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
Calcium incorporation by an individual cell in the synchronous culture incubated in xylan basal medium enriched with calcium gluconate is shown in FIG. 3. The highest solvent production correlated with the highest calcium incorporation as shown in Curves A1-A4. Cell division was stopped at 45 hours by addition of chloramphenicol in Curve A1, nalidixic acid in Curve A2, mitomycin in Curve A3, and acridine orange in Curve A4. The cells treated with nalidixic acid of Curve A2 produced 7.1% solvents at 72 hours, which correlated with the highest incorporation of calcium, 3,162 nanomoles. When acridine orange was added to the synchronized cells in the same medium, shown in Curve A4, the solvent concentration reached 8.1% with calcium incorporation of 1,163 nanomoles. Curve B represents the calcium incorporation by an individual cell in an asynchronous culture incubated in the same medium.
EXAMPLE XI
The procedure of Example I was repeated except that a sporulation medium of xylan with 1.1% (0.1M) calcium carbonate was used. After 45 hours the cells exhibited a high degree of synchrony both in mass and number. Differential count of the cells revealed 48.8% synchrony in cell mass and 56.3% synchrony in cell number. More than 90% of these synchronous, solventogenic cells elongated a minimum of four times and exhibited a modified cell division such that they remained elongated at a critical length of at least four times vegetative length. The number of refractile, mature free spores was negligible.
EXAMPLE XII
The procedure of Example XI was repeated except that after 45 hours, the temperature was lowered to 35° C. by dipping the culture in an ice bath and transferring it to a rotary incubator at 35° C. The culture was incubated for an additional 200 hours (245 hours total incubation time) at 35° C. After 245 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced antibiotics, carbohydrases, parasporo-like protein crystals, and refractile, mature, free spores.
EXAMPLE XIII
The procedure of Example XII was repeated except that after 45 hours, the temperature was increased to 70° C. by transferring the culture to a rotary incubator at 70° C. The culture was incubated for an additional 200 hours (245 hours total incubation time) at 70° C. After 245 hours, the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced antibiotics, carbohydrases, parasporo-like protein crystals, and refractile, mature, free spores.
EXAMPLE XIV
The procedure of Example XI was repeated except that after 45 hours nalidixic acid was added to give a 20 micromolar final concentration in order to prevent further cell division. The culture was incubated for an additional 27 hours (72 hours total incubation time). After 27 hours, the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produce negligible solvents and may produce antibiotics, carbohydrases, parasporo-like protein crystals, and refractile, mature, free spores.
Calcium incorporation by an individual cell in the synchronous culture incubated in xylan basal medium enriched with calcium carbonate is shown in FIG. 4. Although these cells did not produce high concentrations of solvents, the highest solvent production (0.2-0.4%) correlated with the highest calcium incorporation as shown in Curves A1-A4. Cell division was stopped at 45 hours by addition of chloramphenicol in Curve A1, nalidixic acid in Curve A2, mitomycin in Curve A3, and acridine orange in Curve A4. The synchronous cells inhibited with nalidixic acid of Curve A2 incorporated 12,492 nanomoles of calcium at 72 hours and 40-50% of the cells showed signs of terminal swelling indicative of Stage IV to V of sporulation. In contrast, synchronous cells in the same medium inhibited with acridine orange of Curve A4 incorporated 754 nanomoles of calcium and produced 0.4% solvents. Curve B represents the calcium incorporation by an individual cell in the asynchronous culture incubated in the same medium.
EXAMPLE XV
The procedure of Example I was repeated except that a sporulation medium with at least 4.3% calcium gluconate as the sole carbon source was used. After 45 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner were highly elongated and solventogenic. Refractile, mature, free spores or refractile sporangia were not produced in significant amounts.
EXAMPLE XVI
The procedure of Example XV was repeated except that after 45 hours the temperature was lowered to 35° C. by dipping the culture in an ice bath and transferring it to a rotary incubator at 35° C. The culture was incubated for 135 hours (180 hours total incubation time) at 35° C. After 180 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE XVII
The procedure of Example XV was repeated except that after temperature reduction the cells are incubated an additional 155 hours (195 hours total incubation time). After 195 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
EXAMPLE XVIII
The procedure of Example XV was repeated except that after 45 hours the temperature was increased to 70° C. by transferring the culture to a rotary incubator at 70° C. The culture was incubated an additional 135 hours (180 hours total incubation time) at 35° C. After 180 hours the culture reached a density of approximately 2×10 9 cell/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE XIX
The procedure of Example XVIII was repeated except that after increasing the temperature the culture was incubated an additional 155 hours (195 hours total incubation time) at 70° C. After 195 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
EXAMPLE XX
The procedure of Example XV was repeated except that after 45 hours chloramphenicol was added to give a 20 micromolar final concentration in order to prevent further cell division. The culture was incubated for an additional 27 hours (72 hours total incubation time). After 27 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE XXI
The procedure of Example XV was repeated except that after the addition of chloramphenicol the culture was incubated an additional 42 hours (87 hours total incubation time). After 87 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
Calcium incorporation by an individual cell in the synchronous culture incubated in calcium gluconate medium is shown in FIG. 5. The correlation between the peak in solventogenesis and calcium incorporation is shown in Curves A1-A4. Cell division was stopped at 26 hours by addition of chloramphenicol in Curve A1, nalidixic acid in Curve A2, mitomycin in Curve A3, and acridine orange in Curve A4. The synchronous cells treated with nalidixic acid of Curve A2 produced 9.1% solvents at 72 hours, which correlated with the incorporation of 1,940 nanomoles of calcium. Curve B represents the calcium incorporation by an individual cell in the asynchronous culture incubated in the same medium.
EXAMPLE XXII
The procedure of Example I was repeated except that the basal medium contained at least 4.3% calcium gluconate was used as the sole carbon source. After 26 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner were highly elongated and solventogenic. Refractile, mature, free spores or refractile sporangia were not produced in significant amounts.
EXAMPLE XXIII
The procedure of Example XII was repeated except that after 26 hours the temperature was lowered to 35° C. by dipping the culture in an ice bath and transferring it to a rotary incubator at 35° C. The culture was incubated for 135 hours (180 hours total incubation time) at 35° C. After 180 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE XXIV
The procedure of Example XXII was repeated except that after temperature reduction the cells are incubated an additional 155 hours (195 hours total incubation time). After 195 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
EXAMPLE XXV
The procedure of Example XXII was repeated except that after 26 hours the temperature was increased to 70° C. by transferring the culture to a rotary incubator at 70° C. The culture was incubated an additional 135 hours (180 hours total incubation time) at 35° C. After 180 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE XXVI
The procedure of Example XXV was repeated except that after increasing the temperature the culture was incubated an additional 155 hours (195 hours total incubation time) at 70° C. After 195 hours the culture reached a density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
EXAMPLE XXVII
The procedure of Example XXII was repeated except that after 26 hours chloramphenicol was added to give a 20 micromolar final concentration in order to prevent further cell division. The culture was incubated for an additional 27 hours (72 hours total incubation time). After 27 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 10.6% solvents with a butanol:ethanol ratio of 2:1.
EXAMPLE XXVIII
The procedure of Example XXII was repeated except that after the addition of chloramphenicol the culture was incubated an additional 42 hours (87 hours total incubation time). After 87 hours the culture reached a cell density of approximately 2×10 9 cells/ml. Cells prepared in this manner produced 6.5% solvents with a butanol:ethanol ratio of 1:1.
The use of an oleaginous material as an overlay for the growth medium during cell multiplication serves the dual function of maintaining an anaerobic environment for growth of the cells and at the same time provides a secondary carbon source. A saturated hydrocarbon such as paraffin oil is the preferred oleaginous agent, primarily because of its availability at a reasonable cost. Furthermore, the use of paraffin oil as an overlay for the growth medium allows a standard vessel to be used for fermentation thus avoiding the necessity of employing expensive fermentation equipment which usually incorporates cooling apparatus, aeration and agitation means. In the present process, slow mechanical mixing of the growth medium is adequate under conditions such that the agitation does not interfere with the oxygen-excluding, coherent characteristics of the oleaginous layer. An open top concrete, metal or wood vessel is suitable in this respect, thus permitting the utilization of existing structures.
In like manner, in view of the fact that the only external energy required is that necessary to increase the temperature of the growth medium to a required level, e.g., about 56° C. in the case of C. thermosaccharolyticum, thermal energy obtained from solar power will in many instances be adequate, particularly if the growth medium is introduced into a metal walled vessel exposed to the sun. In the case where the carbon source is the spent liquor from a pulp mill, that liquor is generally available out of the plant at a temperature of at least about 90° C. and therefore need only to be allowed to cool to the desired level before being used in the fermentation processes described herein. | A method is disclosed for producing specially prepared bacteria of the genus Clostridium for producing solvents, enzymes, antibiotics, toxic proteins, or spores. Cell elongation to a critical length of at least about 3x is induced in an economical, abundantly available growth medium by serial subculturing under controlled conditions to effect synchronization of growth in the number of the cells and their effective mass and to produce a substantially homogeneous cell population. At least about 0.01M of a divalent cation such as calcium is added to the synchronized cells of critical length to stabilize the cells against death, lysis or aggregation. Where bacterial production of solvents is desired, cell division is inhibited by temperature shift or by chemical means when the cells reach a synchronized solventogenic state. Solvents produced by the specially prepared bacteria may be economically and readily recovered by conventional distillation procedures or the like. If the specially prepared bacteria are to be used for production of products other than solvents, growth of the synchronized, stabilized cells is inhibited by temperature shift and the cells are allowed to differentiate and continue metabolism and sporulation until the resultant bacteria are useful for preferential production of the desired enzymes, antibiotics or toxic proteins. Spore formation may be permitted to continue until substantially the entire cell population constitutes refractile mature free spores, which may be harvested and stored for future use. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to warp knitted fabrics. It particularly relates to an open mesh structure with a stand-off design for athletic apparel.
2. Background Art
When an athlete performs, perspiration from the athlete's body may lead to a “sticky” feeling when the perspiration lingers on the skin surface. Consequently, many athletes wear mesh jerseys (e.g., football, track, soccer, hockey, etc.) that have open holes in the jersey fabric (open mesh design) allowing perspiration to escape from the skin surface through the holes in the athletic garment. These mesh jerseys and other garments provide greater personal comfort and a more breathable environment to the high-performance perspiring athlete. Many such open mesh garments are produced, for example, using warp knitting machines.
Warp knitted open mesh structures known in the art (such as the well known “Football Mesh” Jersey) are often constructed of, for example, at least two continuous filament synthetic yarns such as nylon or polyester. Such yarns may be carried, for example, by two guide bars of a warp knitting machine. The fabric may be stitched using a variation of the Atlas technique wherein both guide bars knit in opposite directions leaving clean holes in the fabric. Such clean holes may be created in the mesh design by using ground yarns that do not knit on the same needle therein leaving subsequent repetitive courses knitted without a connection between the two adjacent needles. The resulting fabric has the known open hole mesh structure. Commonly, the resulting fabric has a flat surface with a population of open holes staggered throughout but spaced equidistantly, while the non-hole solid closed portions generally comprise approximately 50% of the remaining fabric surface.
Despite the afore-mentioned moisture reduction qualities, the base of the open mesh jersey fabric still lays directly on the skin of wearer, often resulting liquid saturation of the jersey after perhaps minimal use. When perspiration occurs, the fabric may become heavier with sweat content, stick to the wearer, or otherwise cease to comfortable athletic apparel. Therefore, there is a need for an athletic jersey design providing greater comfort and breathability to the athlete.
SUMMARY OF THE INVENTION
The present invention overcomes the previously mentioned disadvantages by providing an open hole mesh fabric structure with a stand-off design. In accordance with the present invention, the open hole mesh fabric includes raised members positioned at a different height (depth) from the fabric base which effectively separates a major portion of the fabric from the wearer. The fabric may be knitted on a warp knitting machine having at least five guide bars, wherein one guide bar may be, for example, a Jacquard guide bar. A warp knitting machine including a Jacquard guide bar is described in U.S. Pat. No. 5,628,210 to Mista et al., entitled WARP KNITTING METHOD, MACHINE, AND FABRIC MADE THEREFROM.
In accordance with the present invention, a traditional two-dimensional open hole mesh fabric is particularly knitted with raised members that stand at a different height than the fabric base on the technical back of the fabric. The raised members add a third dimension of depth or thickness to the fabric and are knitted in the solid areas between the open holes of the fabric located in the fabric base. Advantageously, the raised members are the only portions of the fabric which contact the fabric wearer during fabric use wherein the number of members are placed in a pre-determined, appropriate ratio with the number of holes located in the fabric base. These raised fabric members may also be referred to as “raised dots” or “high-density support sections”.
The three-dimensional fabric structure enables the ground structure or base of the fabric to be suspended from (i.e., stand-off) the wearer's body thereby significantly reducing the surface area and volume of fabric material contacting the skin surface. The separation of the fabric base from the wearer's skin provides a superior level of comfort and breathability to the apparel user. The comfort and convenience of the apparel fabric may be further enhanced by selecting fabric materials with hydrophilic or hydrophobic properties. These advantageous materials include, but are not limited to continuous filament synthetic polyester and nylon yarn material. Also, chemical finishes and treatments may be added to the fabric to enhance apparel functionality.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary stitch diagram illustrating a stitch pattern of a ground yarn of a fabric according to the present invention.
FIG. 2 is an exemplary stitch diagram illustrating a stitch pattern of an elastomeric yarn of a fabric according to the present invention.
FIG. 3 is an exemplary diagram illustrating a stitch pattern of a first and second threaded yarns of a fabric according to the present invention.
FIG. 4 is a stitch diagram illustrating a stitch pattern of a Jacquard yarn of a fabric according to the present invention.
FIG. 5 is a diagram of an exemplary guide bar configuration for construction of a fabric according to the present invention.
DETAILED DESCRIPTION
A preferred embodiment of a fabric according to the present invention may be constructed using a warp knitting machine having at least five guide bars. The exemplary knitting machine may include a plurality of pattern bars wherein at least two different groups of pattern bars are selected from the plurality of available frontmost pattern bars. Also, in a preferred embodiment, the fabric may have a repeat length of 28 stitches and a repeat width of 16 needles, although any suitable repeat length or width may be used.
FIGS. 1 and 2 illustrate exemplary stitch patterns for a “ground” yarn and an “elastomeric” yarn for use in constructing a fabric according to the present invention. In constructing a fabric according to the present invention, a preferred knitting machine includes guide bars #4 and #5 that knit the ground yarn and the elastomeric yarn to form a base fabric construction. Preferably, guide bar #4 is a fully threaded ground bar that stitches the ground yarn in an exemplary stitch pattern as shown in FIG. 1, using a preferred chain stitch, although any suitable stitch may be used. Guide bar #5 (the backmost bar in the illustrated example) advantageously lays a LYCRA spandex yarn or other elastomeric yarn into the fabric, as shown in FIG. 2 .
FIG. 3 provides a stitch diagram showing the stitching patterns for a first threaded yarn and a second threaded yarn of a fabric according to the present invention. The first and second threaded yarns may be carried by guide bars #1 and #2 of an exemplary knitting machine such as that described above. Guide bars #1 and #2 may include, for example, 24 pattern bars, wherein the group of pattern bars 1 - 12 (the frontmost group) comprise guide bar #1 and the group of pattern bars 13 - 24 (the second frontmost group) comprise guide bar #2. Also, in this exemplary embodiment, guide bars #1 and #2 are positioned such that guide bar #1 stitches on top of guide bar #2 during knitting. The stitching patterns followed by these guides bars help create the raised members of the present invention.
As shown in FIG. 3, both guide bars #1 and #2 preferably knit first and second threaded yarns, respectively. Guide bar #1 may form a float of a magnitude equaling, for example, 6 needles (5 needle spaces) while guide bar #2 may make a float of a shorter magnitude equaling, for example, 4 needles (3 needle spaces) at the same time and location in the fabric so that the two floats overlap. Floats of other magnitudes may be utilized as well. Guide bars #1 and #2 may preferably be threaded in a 1-in, 15-out arrangement.
As the fabric relaxes during and after knitting, the floats formed by guide bar #1 “collapse” (i.e., contract to a smaller width and/or increased density) from the fabric base and stand erect from the ground structure of the fabric in the form of raised members 10 , 12 . These raised members ( 10 , 12 ) may be referred to as “raised dots” or “high-density support sections. In concerted action with guide bar #1, the floats formed by guide bar #2 both support and help push the raised members ( 10 , 12 ) away from the fabric base structure thereby maximizing the height and thickness of the raised members. These raised members ( 10 , 12 ) may take the form of “croquet hoops” or “McDonald Arches”. It is noted that these terms and other alternative terms used herein are being used for purposes of clarity, and should not be construed as limitations on the present invention, and that the raised members ( 10 , 12 ) may be formed in any suitable shape using different float lengths, yarns and other variables as understood by one skilled in the art.
In accordance with an embodiment of the present invention, a Jacquard bar, which is either a single bar or, as illustrated, a compound set of 2 bars, is designated as guide bar #3 (in the next position following guide bars #1 and #2) and may knit a Jacquard yarn in an exemplary stitching pattern as shown in FIG. 4 . As illustrated in FIG. 4, the Jacquard bar (guide bar #3) preferably follows a stitching pattern that creates open holes in the fabric. In concerted action with guide bar #3, the raised members formed by guide bars #1 and #2 advantageously alternate with the open holes formed by the Jacquard yarn, wherein the raised members are positioned in the closed spaces (no open holes) of the fabric base. In a preferred embodiment, the formation of the open holes may be independently controlled such that the population of raised members to open holes in the fabric follows a useful, pre-determined ratio ensuring apparel quality and functionality.
In constructing a fabric according to the present invention, a warp knitting machine is preferably provided with a fall plate located in the next position following guide bar #3. The fall plate functions to help lift and position both the first and second threaded yarns being knitted by guide bars #1 and #2 (forming floats and raised members) and the Jacquard yarn being knitted by guide bar #3 to the technical back of the fabric. This function of the fall plate helps ensure that the raised members are predominately located on the technical back of the fabric structure while also ensuring that the technical face side of the fabric structure is smooth and clean (traditional two-dimensional form). This action also helps to ensure the aesthetic quality of the garment's outer face. Advantageously, the raised members on the technical back of the fabric contact the wearer, thereby forcing most or all of the ground structure away from the wearer and enabling convenient and comfortable use of the garment. The open holes in the invention fabric allow efficient discharge of moisture for enhanced comfort to the wearer.
Any suitable yarns may be used to form a fabric according to the present invention. It is understood in this respect that the terms “threaded yam”, “Jacquard yarn”, “ground yarn”, and “elastomeric yarn” are purely used for convenience and clarity, and are not meant to imply or create any limitation of the present invention. Preferably, the first and second threaded yarns may be 5 ply to 8 ply synthetic continuous flat filament or textured nylon yarns. These yarns may comprise a multifilament yarn of 30 to 150 denier and a filament count of 10 to 200 filaments. In a particularly preferred embodiment, a relatively heavy 8 ply 70/34 textured nylon may be used. These yarns force the floats to collapse resulting in the raised members (standing off from the fabric base) of the invention fabric.
Similarly, the Jacquard yarn may preferably be a synthetic continuous flat filament or textured nylon yarn (multifilament) of 10 to 100 denier and a filament count of 5 to 150 filaments. The ground yarn may be a synthetic continuous flat filament or textured nylon yarn (multifilament) of approximately 20 to 150 denier and a filament count of approximately 5 to 200 filaments. The elastomeric yarn is preferably a spandex yarn (synthetic continuous filament) of 40 to 400 denier, a preferred width being 140 denier.
In accordance with the present invention, the fabric described herein may be formed using a multi-bar Raschel Warp Knit Machine, preferably on the Textronic type MRSEJF 31/1/24 (24 gauge) which is sold and manufactured by Karl Mayer Textile Machine in Obershausen, Germany. As shown in FIG. 5, this exemplary warp knitting machine is a 31 bar machine that includes 24 guide bars ( 20 ) in the frontmost positions numbered 1-24, two Jacquard compound bars ( 30 ) in positions 2-26, and a fall plate ( 32 ) in the 27 th bar position. Also, the machine includes a ground stitching bar ( 34 ) in position 28 , two “inlay” bars ( 36 , 38 ) in positions 29-30 (which need not be used with the present invention), and a backmost Lycra bar ( 40 ) in position 31 for the elastomeric yarn.
In another embodiment in accordance with the present invention, the fabric described herein may be reproduced using an alternative warp knitting machine, an example being the Karl Mayer Textronic Type MRSEJF 53/1/24. This machine has the Jacquard bar positioned behind the fall plate (rather than in front of the fall plate) enabling the raised member design to be produced wherein the yam knitted by the Jacquard bar is not forced to the technical back of the fabric. Again, it is understood that these warp knitting machines are exemplary and the present invention is in no way limited to the two described knitting machines.
Also, in accordance with the present invention, the fabric construction process may include chemical applications to further enhance apparel quality and performance. The chemical applications may include, but are not limited to hydrophobic applications such as Zonyl 7040 (a product of CIBA Chemical), Zepel (a product of Dupont), Scotchgard (a product of 3M Company), chemical coating, and laminating. A fabric according to the present invention may include any useful combination of the raised member design, yarn ingredient selection, and chemical applications.
It is noted that those skilled in the art can understand that the invention fabric described herein is not limited to sports applications. Additional applications of the present invention may include, but are not limited to general medical and sports medicine uses. Therefore, any further uses of the invention fabric described herein are contemplated here and are within the scope of the invention.
It is similarly noted that those skilled in the art will understand that the invention fabric may be constructed using additional guide bars and/or pattern bars. Also, the fabric of the present invention may of course include more features such as additional yarn elements. This list of additional features is not exclusive, and it is to be understood that any such embodiments are contemplated here and are within the scope of the present invention. | A fabric with an open mesh structure includes raised members that effectively separate the wearer from the fabric base. The raised members add a third dimension of depth or thickness to a traditionally two-dimensional piece of apparel allowing the fabric base to remain separate from the wearer's body which provides greater comfort and breathability to the wearer. The raised members are placed in useful proportion with the open holes and closed spaces of the fabric enhancing the quality and functionality of the apparel. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 62092311 filed on Dec. 16, 2014.
FIELD OF THE INVENTION
[0002] The invention relates to an air travel scheduling platform that incorporates turbulence forecast and other safety data into search results and flight query filters such that air travelers can choose flight options that minimize their risk of experiencing turbulence, or exposure to other hazardous events. It also allows travelers to monitor turbulence and other hazardous forecasts for specified flights.
BACKGROUND OF THE INVENTION
[0003] Turbulence is a natural phenomenon created by atmospheric pressure—chaotic, irregular motion of air like a rodeo bronco or pogo stick. For many fliers, encountering air turbulence is the most challenging and unnerving aspect of air travel. It arrives without warning. The effects of turbulence, which can cause an aircraft to shake and move suddenly and erratically from side to side or up and down, can be distressing and even frightening, sparking fear that the airplane is out of control and about to crash or break apart. From inside an airplane, it can range from minor bumpiness that can jostle the beverage on your tray table to powerful jolts that can structurally damage the plane and injure its passengers. According to the Federal Aviation Administration, turbulence is the number one cause of in-flight injuries to airline passengers and flight attendants in nonfatal accidents; often suffering bruises and broken bones. In the United States each year, pilots report about 65,000 accounts of moderate or greater turbulence and 5,500 accounts of severe turbulence. Turbulence is responsible for roughly 75% of all aviation weather-related accidents and incidents causing tens of millions of dollars in annual injury claims, according to the National Transportation Safety Board. Global changes in climate are expected to result in bumpier flights and scientists conclude that air turbulence is increasing. The damage to airplanes might be low but the damage to people is high. Despite placating statements, turbulence can rattle even the most well-adjusted experienced fliers because of our lack of control and limited understanding of atmospheric conditions and airplane mechanics. There is a large population of anxious fliers or people with a phobia to fly and everybody responds to flying differently.
[0004] There are several things to guard against the effects of turbulence. While wearing your seat belt during the entire flight is the most important, you can also choose flights that are likely to encounter less turbulence. For example, in the summer, the sun heats the earth's surface unevenly, often producing more turbulent air. If you choose to fly early in the day in summer, you're more likely to have a smoother flight. Fliers who are especially bothered by turbulence choose a seat over the wings of the aircraft, which puts them close to the center of mass and reduces the effects of turbulence.
[0005] Some geographic regions have better weather forecasting infrastructure than others, and some aircraft are outfitted with cockpit weather information systems that have superior capabilities to others. There are many variables that have to be taken into account in forecasting and avoiding turbulence, including: (1) weather forecasts; (2) aircraft factors such as onboard sensors, turbulence decision aids, user interface, presentation of data, size and type of aircraft; (3) route factors such as typical traffic, terrain, typical flight plan, obstacles, special use airspace, ground and satellite coverage; (4) human factors such as pilot experience and airline training. Taking all these factors into account it is possible to predict with some degree of certainty what the probability is of turbulence, and how severe the turbulence might be.
[0006] There are other hazardous conditions related to travel, including exposure to communicable diseases. During the flu season, for instance, a passenger may be more readily exposed to the virus if they travel to, or connects through an airport that is located in a region that typically has many flu cases that time of year. However, there is currently no way to account for this when planning a flight that may connect through such a high risk region. When someone connects in an airport in a region with many cases of the flu, they may be exposed in the airport where local people are also stationed, as well as on the plane where locals will also be travelling. Furthermore, taking two flights may increase the statistical risk to them of contracting the flu given increased exposure to others on the flight. It may be preferred to choose a flight that is less crowded too. There may also be current epidemics, such as Ebola where people prefer to avoid certain countries, but there is currently no warning system or indicators on travel reservation systems to help people with such requests.
SUMMARY OF THE INVENTION
[0007] Oftentimes there will be a number of options to the traveler regarding the type of aircraft, day of travel, connection airports, and more. For these reasons, one aspect of this invention that would be comforting to the traveler to assist in their decision making is a platform which does some or all of the following: (1) compiles a database (aggregating/storing/pooling information neatly into search fields) distinguishing type of aircraft, history of previous routes flown/flight-paths, average altitude flown, average flight time, FAA complaints/incident reports, seat location on aircraft, historical weather patterns, and future weather forecasts for each route flown; (2) allows a user to search, sort and filter for flights which take into account turbulence risk, or other risks; (3) present flight options to the user a custom and unique output for them to make and monitor more informed flight reservation decisions; (4) monitor a flight as departure time approaches and update a user with more refined turbulence, or other risk, predictions.
[0008] Since specific seat position on certain aircrafts may be more or less favorable during turbulence, the availability of specific seats could also affect the turbulence risk for available seats on that flight. The turbulence risk comprises two components: the probability of turbulence and the intensity of the turbulence forecasted. These may be combined into a single score giving certain weights to each factor, and could also have certain threshold limits to each factor before they contribute to the combined score (for instance, low turbulence intensity may be ignored even if there is a high probability of it occurring).
[0009] In another aspect of this invention a more general risk score can also be presented to the user, and may include statistics about major fatalities by an airline, or type of aircraft. The two scores, turbulence risk and fatality risk may be combined into a single hazard score and presented to the user (also allowing the user to query only certain flights that meet a minimum threshold for the score, or sort flight results by the hazard score).
[0010] Also certain air space regions may be in close proximity to areas of political unrest and conflict such that a civil airplane would be at increased risk flying near the region due to either intentional or unintentional interception of some form of surface-to-air or air-to-air weapon. Tracking, indicating and using such information about worldwide events would be useful in allowing someone to choose a flight path, or airline connections, with a lower risk. Some airports may also be in regions that are at a higher risk of some form of terror or other attack, and therefore may be avoided by the traveller. Another factor to consider is the track record and thoroughness of security procedures at each airport. By avoiding those airports, or countries, with suboptimal procedures, a traveller is decreasing their risk for the journey.
[0011] Another factor to consider is the age of the equipment, the type of equipment and track record of the manufacturer. Any current recalls, and the history and maintenance track record of the airline. By considering all such factors, a comprehensive hazard score can be given to the overall risk associated with each flight choice and path.
DESCRIPTION OF THE FIGURES
[0012] FIG. 1 shows a web-based flight search results page with incorporated turbulence forecast information; and
[0013] FIG. 2 shows a calendar flight planner which with incorporated turbulence information.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The invention is described in detail with particular reference to a certain preferred embodiment, but within the spirit and scope of the invention, it is not limited to such an embodiment. It will be apparent to those of skill in the art that various features, variations, and modifications can be included or excluded, within the limits defined by the claims and the requirements of a particular use.
[0015] One embodiment of the invention is for an airline reservation system that is web based. It is best described by way of the accompanying figures. With reference now to FIG. 1 a web-based flight search results page 100 with incorporated turbulence forecast information is shown. The search results page 100 has three tabs which are for Round Trip 102 , One Way 104 , and Multi-City 106 searches respectively. On the search results page 100 shown, the One Way 104 tab is highlighted indicating that the user has selected to search for a single trip from the airport in the Origin field 108 to the airport in the Destination field 122 . A class dropdown selector 124 and number of travelers dropdown selector 126 specify the respective class and number of seats as additional search parameters. The user specifies the desired date of travel in the date field 110 . There are also a number of facets that can be modified by the user: stops 112 , price 113 , airline 114 , times 116 , turbulence 118 , and a dropdown selector for more facets 120 . These facets dynamically update with the search results to that the user can refine the search as is conventionally done in advanced searches that give the user control over many filters. The turbulence facet 118 is one aspect of this invention and allows a user to filter results based on the degree of turbulence forecasted. For instance, they may only want to see flights that are predicted to have a low degree of turbulence. The Sort by facet 128 shows that the search results are sorted ascending from Lowest Price. Other sort options might include to sort ascending from Lowest Turbulence forecasted, or by number of stops. The graph button 130 allows a user to switch to the graph and calendar view 200 of FIG. 2 where they can appreciate the price distribution on various days as well as the turbulence predicted on various days as described in more detail below. The flight search results 132 shows three flight matches for the search parameters. Each result has a price 144 , airline logo 146 , airline name 148 , departure time illustration 150 on the timeline 156 , flight duration 156 , and the number of stops 154 . Each result also has a turbulence forecast, which is a low forecast 138 for the first result 134 , a high forecast 140 for the second result, and a medium forecast 142 for the last result. The graphical representation of the turbulence forecast gives the user an easy way to appreciate the synthesis of many inputs in which the turbulence forecast is derived. Such inputs may have included: (1) weather forecasts for each leg; (2) aircraft factors for each leg of the proposed flight in the search result, such as onboard sensors, turbulence decision aids, user interface, presentation of data, size and type of aircraft; (3) route factors such as typical traffic, terrain, typical flight plan, obstacles, special use airspace, ground and satellite coverage for each leg; (4) human factors such as pilot experience and airline training for each leg; (5) seat availability for the leg of each flight for optimum placement in the event of turbulence. When the user is ready to select a flight, they can select it using the selector 136 which would give more details about the proposed flight route and allow them to proceed to book it either on the same website, or refer them to the airline or other booking site to complete the booking.
[0016] With reference now to FIG. 2 a calendar flight planner view 200 is shown which incorporates turbulence information. The top section 202 is identical to the flight search results page 100 of FIG. 1 . Below the top section 202 is a calendar 204 for the month labelled October 220 . The left arrow button 218 and right arrow button 214 allows the user to change month backward and forward respectively. The price distribution graph 206 shows the lowest price flight for any given day in the calendar. A turbulence forecast indicator 208 is present for all days where flights are available. It proportionally represents the number of flights with low, medium and high turbulence risk scores. The turbulence risk score comprises the probability and intensity of turbulence as described above. If there are no flights with a high turbulence risk score on a particular day then a two-color turbulence forecast indicator 210 is shown. The calendar day 212 is shown along with the lowest flight price 216 for each day.
[0017] Another aspect of this invention is guiding the traveler to choose the seats on the aircraft that are most optimal during turbulence. While the invention may be embodied in a flight search engine that is separate from the seat selection platform (as this is typically hosted on the airline site), guidance to the user can still be given by way of a seat map that shows, for instance, green, yellow and red areas, where green are the preferred seats when there is turbulence, red being the worst seats to be in when there is turbulence, and yellow would be in between. Full integration into the seat selection platform would be ideal, as the airline would be able to offer this guidance on the same screen as the seat selection is made.
[0018] The data regarding forecast and current incidence of specific communicable diseases is increasingly becoming more readily available. The Center of Disease Control publishes data, as well as travel advisories, and there is also data that can be gathered in real time from electronic medical record systems, pharmacy fulfillments, and other sources. The search engine could take into account these disease patterns in issuing alerts and recommendations on travelling through regions that are less likely to result in exposure to the infectious agent. For instance, for someone travelling from New York to Los Angeles, they may have the option of direct flights, in addition to cheaper flights that connect in Chicago in the winter. Forecasts may show that there is a high incidence of flu in the Chicago area during the travel time and show such data in the flight search results, in a way similar to the turbulence risk, so that the traveler can make an informed decision about which flight they should choose. | The invention relates to an air travel scheduling platform that incorporates turbulence forecast and other safety data into search results and flight query filters such that air travelers can choose flight options that minimize their risk of experiencing turbulence, or exposure to other hazardous events. It also allows travelers to monitor turbulence and other hazardous forecasts for specified flights. | 6 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to percussion impact implements and in particular embodiments to drumsticks and methods of making the same, and particularly to drumsticks fabricated using fibers and resin.
2. The Related Art
Percussive sounds have since ancient times been obtained by striking a flexible membrane with a wooden object. Controlled and more reproducible sounds resulted when the wood object was a straight rod. Hence the development of the modern drumstick. With the passing of time, innovations occurred including a degree of taper at the front end of the stick, the stick being finished off with a tip, and the use of a wood having a modicum of flexibility. A select hickory was the wood of choice.
Prior to World War II, the hickory selected for sticks was of the highest grade and thoroughly seasoned. Shortly after the war, the availability of seasoned top quality hickory deteriorated to a point where the stick makers either closed down periodically or sought out substitute material. None could meet the standards set by seasoned hickory. Warpage, splitting and variation in physical properties was a serious problem.
Wood is essentially cellulose distributed randomly throughout the system held together with a very poor adhesive resin. Both components are highly susceptible to erosion by water, even moisture. Its resistance to failure varies from inch to inch.
Numerous attempts have been made to fabricate drumsticks having improved durability over conventional wooden drumsticks.
U.S. Pat. No. 4,047,460 to Fielder et al. discloses a drumstick fabricated from short fibers embedded in a nylon matrix. The short fibers are randomly oriented, and the drumstick contains approximately 30% by volume fibers and 70% by volume nylon matrix. The drumstick is made in two parts, which are welded together to make the drumstick. The drumstick also contains a hollow bore extending through a substantial portion of the handle length.
U.S. Pat. No. 4,114,503 to Petillo discloses a drumstick containing a core having arms extending outward and an outer shell which fills the space between the core and the arms and extends to the outer surface of the drumstick. The core is constructed of a material having a high tensile and shear strength, such as aluminum. The outer shell is constructed of segments which may be wood such as hickory.
U.S. Pat. No. 3,147,660 to Brilhart discloses a drumstick fabricated from unidirectional fibers and resin and molded through the application of heat and pressure. The drumstick may contain a hollow cavity drilled into the handle portion, into which an acoustical foam material is placed.
Two piece construction as in several of the above patents may make it difficult and/or expensive to obtain drumsticks with minimal variance from stick to stick because of the multiple steps involved to make separate components and accurately attach the components together. Additionally, a stick having multiple parts to attach together, such as a core with arms as in Petillo has a more complex structure than a single piece molded stick. Similarly, drilling a cavity into a stick adds complexity to the process and requires more manufacturing steps than a molding process alone.
It would be desirable to provide a drumstick which is more durable than conventional wooden drumsticks, yet can closely duplicate the weight, feel, and tonal qualities of wooden drumsticks. In addition, it would be desirable to provide drumsticks whose properties do not significantly vary from stick to stick, and which is relatively easy to manufacture. Embodiments of the present invention are directed towards these and other objectives.
SUMMARY OF THE DISCLOSURE
Embodiments of the present invention relate to a drumstick formed of a resin body having a plurality of fibers within the body and a filler material and optional colorant distributed throughout the body.
Further embodiments of the present invention relate to a method for fabricating a drumstick including a step wherein a plurality of fibers are drawn through an adhesive bath to wet the fibers with resin and filler composition and then assembled into a larger fiber bundle. The bundle is then wrapped around a roller. Next, a predetermined amount of the bundle is removed from the roller and mounted on a hook. The bundle is then drawn into a molding robe and cured.
Drumsticks according to embodiments of the present invention possess superior attributes over wooden drumsticks. The matrix of resin and filler, along with the fibers, provide a stick which is stronger than wood and more resistant to failure. In addition, the variance stick to stick in properties such as strength and weight is significantly less than typical conventional drumsticks made of wood.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects, advantages and features of the present invention will become apparent from the detailed description, below, when read in conjunction with the accompanying drawings (which, for illustrative purposes, are not drawn to scale), where:
FIG. 1 is a plan view of a drumstick according to a preferred embodiment of the present invention.
FIG. 2 is a cross sectional view along the line 2'--2' in FIG. 1.
FIG. 3 is a cross sectional view showing a drumstick according to another embodiment of the present invention.
FIG. 4 is a schematic showing the initial steps in manufacturing drumsticks according to certain embodiments of the present invention.
FIG. 5 is a schematic showing equipment used for placing drumsticks into molds prior to curing according to certain embodiments of the present invention.
FIGS. 6(a) and 6(b) are plan views of mechanisms for tensioning the fiber as it is drawn along the processing system, according to certain embodiments of the present invention.
FIG. 7 is a flow chart showing steps in a method for manufacturing drumsticks according to certain embodiments of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
This description contains the best mode for carrying out the present invention and is made for the purpose of illustrating the principles of the invention, and is not to be taken in a limiting sense. The scope of the invention is determined by reference to the appended claims.
Embodiments of the present invention relate to drumsticks and methods for their manufacture. FIG. 1 shows a plan view of a drumstick 10 having tip 18, butt end 20, and tapered region 22. FIG. 2 shows a cross section along the line 2'--2' of FIG. 1. In cross section, fibers 12, matrix 14, and microspheres 16 can be seen. The fibers and microspheres 16 may be uniformly distributed in the matrix material 14.
A variety of fiber, matrix, and microsphere materials may be used in the fabrication of the drumsticks according to embodiments of the present invention. Fiber materials may include various synthetic and natural fibers. For example, a preferable material is the aramid fiber Kevlar (trademark; available from E. I. DuPont de Nemours), due to its favorable mechanical and decomposition resistance properties. Other fiber materials which could be used include, but are not limited to, other aramids, polyester, polyethylene, carbon graphite, Spectre (trademark; available from Allied Fibers Corp., a subsidiary of Allied Signal), cotton, nylon, and fiberglass. Different fiber materials may be mixed together in order to obtain particular physical properties or to obtain a certain external appearance such as an exotic multicolor grain.
Various matrix materials can also be used, including, but not limited to epoxies and other resin materials. A preferable epoxy resin is Araldite (trademark; available from Ciba/Geigy Corp. ). Other polymeric compositions may also be used.
In preferred embodiments, a filler is mixed into the matrix and used primarily for weight reduction purposes. Such filler may comprise microspheres of suitable material. The microspheres take up volume in the drumstick and weigh less than a comparable volume of matrix material. The microspheres are preferably substantially uniformly distributed in the matrix. The filler materials may be chosen on the basis of weight, volume, strength, tonal quality and whether the microsphere will change size during or after processing. The filler material may also contribute to the rigidity and strength of the drumstick. In preferred embodiments, the microspheres comprise generally spherical bodies having a diameter within the range of about 1 micron to about 5000 microns and made of a suitable material such as ceramic, glass, polymeric materials or the like. While spherical bodies are preferred due to manufacturing efficiencies and consistent reproducability, in other embodiments, bodies of other morphologies may be used as an alternative to spherical bodies.
Preferable microspherical materials which possess suitable properties include volcanic spheres, such as Dicalite (trademark; available from Grefco Inc.); and thermoplastic spheres, such as Expancel (trademark; available from Nobel Industries, Sweden), Ucar (trademark; available from Union Carbide Chemicals), PM6545 (available from PQ Corp.), and Duolite (trademark; available from Pierce & Stevens Corp.). Non-spherically shaped filler materials may also be used either with or in place of the microspheres. Examples of preferred non-spherical materials include wood flour, Silcell (trademark, available from Silbrico Inc.), Dicalite Diatomite (trademark; available from Grefco Inc. ). In addition or as an alternative to the above-discussed fillers, air bubbles may be used as a filler in order to save more weight.
The drumsticks may have shaped tips disposed on the tapered end. Tips may be fabricated from various materials, including, but not limited to nylon, polycarbonate, aramid, polyurethane, wood, and metal. The tips may be bonded to the stick using an adhesive, for example, cyanoacrylate (made by Permabond International or an epoxy. Alternatively, tips may be composed of shaped ends of the sticks themselves, as opposed to be manufactured apart from the sticks and later attached to the sticks.
The sticks may be colored using a pigment or a dye. Potential dyes include organic dyes, metal complex dyes, and phosphorus dyes. One particular pigment which has been used is Orasol (trademark, available from Ciba/Geigy). The sticks may take on various wood grain appearances either with or without colorant.
Marking (model no., manufacturer, etc.) may be provided on the sticks using an epoxy ink, hotstamp foil, laser etch, or hot etch.
FIG. 3 shows a cross sectional view of a particular embodiment in which short fibers (also called staples) 24 are present in the matrix material 14 along with fibers 12 and microspheres 16. These short fibers 24 may be used to improve certain strength properties of the drumstick. The short fibers 24 may be made from a variety of fiber materials including those discussed above. A preferable choice is an aramid staple.
The following description is an example of a process according to preferred embodiments of the present invention, for fabricating drumsticks using Kevlar fiber as the fiber material. However, as discussed above, other fiber materials may be used as an alternative or in addition to Kevlar fiber. The process is typically performed in a manner so that a plurality of sticks are fabricated at the same time. For clarity much of the following explanation refers to the manufacture of one stick.
As shown in FIG. 4, rolls 28 of Kevlar fiber are mounted on creels 26 supported on a backboard. Each strand 30 of Kevlar fiber is acted on by a mechanism (such as a draw rolling system) for drawing it along a processing system as shown in the diagram of FIG. 4. The mechanism may contain one or more tensioning devices 29 for controlling the tension on a fiber as it is drawn along the processing system. The spring tensioning device 29 may be comprised of a spring mechanism 31 (FIG. 6(a)) or a mechanism comprising moveable openings 35 and/or supports 37 through which the fiber 30 is thread as shown, for example in FIG. 6(b). The mechanism 31 has an adjustable control 41 so as to regulate the amount of tension on the fiber 30 as it passes through the mechanism.
The fiber strands 30 are drawn through an adhesive bath 32 and assembled into a larger bundle 33 made up of a suitable number (such as approximately 4-16) of the original strands before the back end of the bath 32. The bath 32 contains a mixture of resin chemicals and microspheres. The strands 30 are thoroughly wetted and coated with the liquid chemicals and microspheres in the bath 32.
The bundle 33 is then drawn though a small opening 34 (for example, either attached to or disposed in the wall of the container holding the bath) to squeeze out excess resin. Next the bundle 33 travels to a rotating disc 36 where a timer or counter system controls the number of turns to be made. The rotating disc 36 supports three posts 37 around which the bundle 33 is wrapped during rotation of the disc. One complete loop around the three posts 37 results in a predefined perimeter length (for example 36 inches).
The number of loops of the bundle 33 to form a drumstick is preferably within the range of about 1-150 loops and varies with each model and size of stick. A suitable number of loops are are removed from the posts 37 of the rotating disc 36 and mounted on a hook 56. The hooked looped bundle 60 is then drawn through a molding tube 58, as shown in FIG. 5. The molding tube 58 may be constructed from suitable materials including metals such as steel and stainless steel. However, further embodiments may employ a variety of other materials for the molding tube 58, for example polymers. A suitable releasing agent may also be used within the molding tube 58. In addition, further embodiments may use a tubular mold which is shaped to provide for tapering or other design features in the mold itself.
The molding tube 58 is opened at both longitudinal ends, and may be sized to be slightly shorter than the length of the looped bundle 60 once it has been pulled through the molding tube 58. For example, with the perimeter of the looped bundle, being, for example, about 36 inches as noted above, when the looped bundle 60 is hung from the hook 56 and pulled through the molding tube 58, the length from one end of the looped bundle 60 to the other end is about 18 inches. Preferably, when the looped bundle 60 is pulled through the molding tube 58, both curved ends of the looped bundle 60 extend outside of the molding tube 58. In this regard, the length of the molding tube 58 is preferably shorter than the length of the looped bundle 60 pulled through the molding tube 58 (e.g. about 17 inches long for an 18 inch long pulled fiber bundle).
Multiple molding tubes 58 (one per stick) are fixed to a rack which is held to a structure at the top of which sits an air-oil cylinder 54. Initially the cylinder 54 pushes a bar on which a dozen or so thin mold rods 55 are mounted. Each mold rod 55 is coupled to a hook 56 onto which a looped bundle 60 is supported. The cylinder 54 is then activated and the looped bundle 60 is drawn up though the molding tube 58 to a precalculated stop point. The stop point is calculated such that the curved parts 62 of looped bundle 60 are located just outside of the ends of the molding tube 58. At this point the filled tubular mold is ready for a curing step. Such curing may be performed in a suitable oven, at about 250° C. for 15-30 minutes at atmospheric pressure in air. The curing conditions may vary depending on the exact materials used.
The cured looped bundles may be removed from the tubes by means of power driven metal (preferably steel) rods or rams, each rod or ram being slightly smaller in diameter than the inner diameter of the molding tube 58. The rods are pushed through the molding tubes 58 to thereby push out the cured looped bundles. The ends of the cured looped bundle may then be cut to proper size.
With the curved ends 62 of the looped bundle 60 cut away, the remaining stick has unidirectional fibers extending along the length of the stick and substantially parallel to each other. Depending on the type of stick desired, the ends may be rounded or radiussed, the sticks tapered, and the tips ground from the drumstick or bonded to the drumstick. One minute exposure at 25° C. in air is generally adequate for a satisfactory bond between the tip and the stick, when using Permabond (trademark; available from Permabond International) as a bonding material. The bond improves with time at room temperature. The sticks are then marked with model and logo information.
FIG. 7 shows a diagram outlining steps in a preferred method for manufacturing sticks. Step 1 involves drawing fiber through a bath containing resin. Step 2 involves winding the fiber into loops, using, for example, a roller. Step 3 involves cutting off the appropriate amount of fiber loops for making a stick. Step 4 involves placing the fiber loops into a mold. Step 5 involves the curing of the filled mold, preferably in an oven. Step 6 involves the removal of mold. Step 7 involves the cutting off of the looped ends of the fiber, and step 8 is the finishing of the stick, by, for example, sanding or grinding and either forming or attaching a tip to the stick.
Drumstick embodiments may contain varying ratios of resin to fiber to filler, depending on the desired type of stick and size. Sticks can be specifically tailored to a drummer's needs with regards to many properties, including weight, flexibility, hardness, appearance, and tonal quality to name a few. Preferred embodiments have weight percentages of 32 to 42% resin, 40 to 60% fibers, and up to 20% filler. Preferred volume percentages include 30 to 40% resin, 10 to 60% fibers, and up to 60% filler.
Embodiments of drumsticks according to the present invention provide numerous advantages over conventional wooden drumsticks. First, it is possible to produce sticks with minimal weight variance stick to stick. Preferably such variance is less than 1 gram. This means any two sticks in a model type will look, feel, and play substantially the same.
In preferred embodiments, responsiveness is similar to that of wood and tends to not vary from stick to stick as does wood. The sticks provide uniform balance and depending on the materials used and finish, feel like a wooden stick in the drummers hand. The sticks may also be fabricated to look like a variety of grained woods.
Longevity may be maximized due to the use of a composite which is stronger and more resistant to impact and to the elements (such as water & sweat) than wood. Additionally, the sticks may be manufactured at an affordable price. Finally, sticks according to preferred embodiments of the present invention produce sounds similar to those produced by wooden sticks.
The scope of the present invention is not limited to the specific embodiments discussed above. For example, mechanisms (hydraulic, pneumatic, gear operated, ball screw actuator-type linear actuator, or other mechanical device) other than an air-oil cylinder may be used to place the bundled fiber into a mold. In addition, the roller may contain less than or more than three posts for rolling the bundle. Alternatively, the fiber may be wound around a cylindrical or other shaped device. | A drumstick body and method for fabricating the same, the drumstick body having resin coated fibers and a filler material. The method includes the steps of coating at least one fiber with resin, wrapping a length of the fiber around a roller, placing the length of fiber into a mold, and curing the resin to form a solid drumstick body. | 6 |
[0001] This application is a continuation in part of application Ser. No. 11/332,801, filed Feb. 12, 2006, now pending.
[0002] This application is filed within one year of, and claims priority to Provisional Application Ser. No. 60/898,882, filed Jan. 31, 2007.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to electronic information surveillance and security systems and, more specifically, to a Method and Apparatus for enhancing the detection of Weak Emitters.
[0005] 2. Description of Related Art
[0006] The embodiments of the present invention describe a significant enhancement to systems for detecting the presence and locations of weak emitters. The embodiments describe an enhanced way of detecting weak emitters utilizing the system described by U.S. patent application Ser. No. 11/332,801, by eliminating the false alarms through an innovative Doppler differentiation approach.
[0007] Details disclosed in previously filed U.S. patent application Ser. No. 11/332,801: “Method And Apparatus For Detecting The Presence And Locations Of Radio Controlled Improvised Explosive Devices In Real Time,” are incorporated herein by reference in that the system and method of the present invention builds upon and/or modifies the basic design and operation disclosed in that application.
[0008] What is needed to eliminate the false alarms of a moving weak signals detection system (such as, for example, the “Street Sweeper” system described by patent application Ser. No. 11/332,801) is to augment that prior art system with the following: 1) The replacement of the roof antenna with two antennas, one on the front of the vehicle, and one on the rear, and 2) The addition of delay memory hardware and digital downconverters, and finally 3) The addition unique real-time algorithms, running on the DSP processors of the delayed digital downconverter outputs (these will be described future).
[0009] In conclusion, it is the inventor's position that no invention formerly developed provides this unique method to reduce the false alarms of moving weak signal detection systems through Doppler differentiation. This invention represents an important enhancement to me prior art method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a drawing of the system invention as it is typically installed inside a vehicle with the additional hardware antennas;
[0011] FIG. 2 is a flowchart depicting the signal processing method employed by the present invention;
[0012] FIGS. 3A and 3B show graphical depictions of the invention as it is traveling down a roadway and how it's physical location relative to the weak emitter, equates to the signals that it is receiving from the front and rear antennas; and
[0013] FIGS. 4A and 4B show the difference between two profiles and how those can be used to further resolve the tangential distance of the detected weak emitter from the centerline midpoint of the vehicle. This additional feature of the invention provides yet another discriminator to weed out false alarms.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] The following description is provided to enable airy person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a Method and Apparatus for Enhancing the Detection of Weak Emitters.
[0015] FIG. 1 shows a drawing of the system invention as it is typically installed inside a vehicle with the additional hardware antennas (Moving Weak Signal Detection System Vehicle 200 ) The operation of the original moving weak signal detection system design (outlined by patent application no. U/332,801) will not be covered here. Only the augmentation of the embodiments of the present invention will be described in this document.
[0016] As before the vehicle detects the presence of weak emitter energy and logs detected anomalies in its event logs. This original detection is now used as a qualifier stage of identifying anomalies. The embodiments of the invention of this patent application takes all qualified “hits” and performs a more rigorous analysis.
[0017] When a qualifying hit signal is found by the wideband system (that process is defined by patent application Ser. No., 11/332,801), that particular frequency value is passed off to an internal firmware algorithm of the Central Processor 100 that then tasks two Direct Digital Downconverters (DDC's) to pluck out those signals and digitize them. The process of using DDC's to pluck out delayed, signals is described by a different previously filed U.S. patent application Ser. No. 10/829,858, entitled “Method And Apparatus For The Intelligent And Automatic Gathering of Sudden Short Duration Communications Signals,” also written by this author.
[0018] The Front Antenna 28 and Rear Antenna 26 are both connected to the Central Processor 100 . Note that the locations of the two antennas are of extreme importance to this invention (front and rear of the vehicle).
[0019] According to embodiments of the present invention the signals from these two antennas are also connected to delay memory modules. The purpose of this delay memory modules is that after the detection in the wideband system occurs, there is enough time for the Central Processor 100 to allocate the two DDC channels and tune them to the detected frequency. One DDC is allocated to monitor the signals from the front antenna and other one from the rear antenna. Thus it is possible to “go back” in time. The DDC's then hand off fee signals to DSP chips that use a much more narrowband FFT resolution (as opposed to the wideband FFT approach of the qualification stage. This more narrowband processing of the signals provides a better signal to noise ratio at the signal that was earlier Determined to be interesting by the wideband detector (qualification stage). The resulting FFT bin data streams are then fed to an FPGA where continuous frequency comparisons are performed to determine the maximum Doppler difference between the two signals received between the front and the back antennas.
[0020] FIG. 2 is a flowchart depicting the signal processing method 302 A employed by the present invention.
[0021] As the vehicle 200 A proceeds down the street, the receiver subsystems 102 A-C of the central processor 100 are programmed to scan through a wide range of RF frequencies in synchronous fashion. Again, the operations of the receiver subsystems 102 (hereafter referred to as “Wideband Systems”) are exactly the same as described by U.S. patent application Ser. No. 10/829,858.
[0022] The wideband systems 102 A-C digitize large bandwidths of the RF spectrum for processing. One wideband receiver subsystem 102 A is attached to the rear antenna 26 , one wideband receiver subsystem 102 B is attached to the bottom antenna 18 , and one wideband receiver subsystem 102 C is attached to the front antenna 28 . Every time each receiver subsystem 102 A-C produces a single n-point Fast Fourier Transformation (FFT) frame of information, the flames are sent to an algorithm that quickly compares those frames. An n-point EFT frame is comprised of n number of frequency measurements, or “bins” across the entire bandwidth.
[0023] As the FFT frames are collected from antennaes 302 A, the bins of one of the ambient RF receiver subsystem 102 A, C FFT frames are compared to the corresponding bin of the RCIED receiver subsystem 102 B FFT frame that is taken at the same instant in time 304 A.
[0024] The signals that come in from the wideband receiver subsystems 102 A, C connected to the antennas 26 , 28 will be different man the signals coming from the wideband receiver subsystem 102 B connected to the bottom antenna 18 due to numerous factors. In most cases, the signals from the top antennas 26 , 28 will have higher amplitudes than the signals from the bottom antenna 18 since the bottom antenna is facing towards the ground and thus is more isolated from the surrounding RF environment. The only time the FFT bin amplitudes from the bottom antenna 18 should be higher than the bin amplitudes from the top antennas 26 , 28 will be when a leakage signal from an RCIED is detected underneath (or beside) the vehicle 200 . It is this phenomena that is exploited according to embodiments of the present invention.
[0025] Continuing forward, the system 100 calculates which bins received from the bottom antenna 18 have higher amplitudes than the corresponding top antenna's 26 , 28 FFT bins 308 . If the bins from the bottom subsystem 102 B are not higher in amplitude than the corresponding bin of the top subsystems 102 A, C, then the next FFT frames are processed 306 A.
[0026] As high-amplitude bins are detected by the system 100 , the system 100 takes those higher bins and labels them as “bins of interest”. These bins of interest, and their respective amplitudes from the bottom antenna only, are then taken to another algorithm that begins to populate “trends” 308 which are finite numerical arrays of the amplitude data from one particular frequency bin number.
[0027] The operational modification of the present method 300 A is that when bins have been seen before, it is considered to be a “Qualifying Event” 309 A. This triggers the Buffered Data to be analyzed and the Doppler profiles are created for each set of buffered data 311 A. These Doppler profiles are then used to determine the tangent position of the emitter and the tangential distance to that detected emitter 313 A. Each element in these trend arrays is a successive frequency measurement (amplitude data from the bottom antenna, for a single bin of interest) over time.
[0028] If the FFT bins of interest have been seen before, i.e. trends have already been started for those bin numbers, then the new data points are simply placed into the end of those trend's arrays 312 . If a bin of interest corresponds to a trend that has not been started before, then a new trend is begun 310 . Finally, if existing trends do not have new data to add, that means that the signal amplitude from the bottom antenna 18 have ceased to be higher than the amplitude of the corresponding signals from the top antenna 10 for those particular trend's bin numbers (i.e. the signal eventually went away or the original trend was started on bad data). In such cases of trend dissipation, the system 100 will conclude that the trend is no longer of interest after the expiration of a specified period of time, as configurable by the system user 312 .
[0029] The next step is to tag each new added element, of each trend, with a “distance tag” 314 . This distance tag number comes from the drive shaft sensor algorithm, and is based upon an input from the drive shaft sensor that includes the sensor data 24 . An algorithm calculates the relative distance the vehicle 200 traveled from when one measurement was taken to the very next. All data elements in an array that were recorded and are older man, for example, 20 meters are discarded 316 . This is because it is necessary to bind the length of the trend arrays for the next stage of the signal processing, which is adjustment, after which comes correlation.
Operation
[0030] FIGS. 3A and 3B show graphical depictions of the invention as it is traveling down a roadway and how it's physical location relative to the weak emitter, equates to the signals that it is receiving from the front and rear antennas.
[0031] When the vehicle is approaching the emitter, the detected frequency emitted by that target will exhibit a Doppler effect. That is, the wavelengths will slightly compress and the detected frequency will go up slightly by a few Hz. Conversely, when the vehicle passes the emitter, the detected frequency will go slightly down by a few Hz, also due to the Doppler effect.
[0032] FIGS. 4A and 4B show he difference between two profiles and how those can be used to further resolve the tangential distance of the detected weak emitter from the centerline midpoint of the vehicle. This additional feature of the invention provides yet another discriminator to weed out false alarms.
[0033] This reality is exploited according to embodiments of the present invention. The two data forms are plotted over time. What can be seen by the drawing of FIG. 4B is that the detected Doppler shifts will both be identical, but yet offset in time. That is because the Front Antenna 28 will pass the emitter before the Rear Antenna 26 will. The maximum difference in frequencies between the two antennas can only result when the vehicle's midpoint is perpendicular to the location of the emitter with respect to the midpoint of the vehicle (i.e. the physical separation between the front and rear antennas). Embodiments of the present invention then mark the exact time that this maximum Doppler difference occurred and the central processor can then go back and determine the exact GPS location of the vehicle when that signal was received. This will give the location of the emitter on the roadway. But it will not directly give the distance the emitter is from the vehicle's centerline motion That calculation is done by a separate algorithm.
[0034] In order to determine the tangential distance of the emitter from the vehicle's centerline requires a calculation of the vehicle's velocity when it passed the target
[0035] Again, the drive shaft sensor is used to determine the vehicle's velocity as it passed by the emitter. An algorithm is installed that calculates the maximum Doppler shift that would have been detected if the emitter was located directly on the cars centerline at the current speed and at the emitter's frequency. The further away from the centerline that the emitter is located the lower in frequency the Doppler difference signal will be. This will then give an accurate mathematical distance to the emitter's antenna from the vehicle's centerline. This calculation allows the system to weed out weak emitters mat are too tar from the vehicle to be considered a threat or “within the sphere of importance”. This will also weed out all other spurious signals that were detected as “interesting” by fee wideband detector. Thus, the invention provides a unique way to eliminate the false alarms and at the same time provides a more accurate way to determine the distance of an emitter's antenna from the centerline of the moving weak signal detection system vehicle as it drives by.
Diagram Reference Numerals
[0000]
14 GPS Antenna
16 GPS Signals
18 Bottom Flat Antenna
20 Weak Signal Energy Tom Bottom Antenna
22 Drive Shaft Sensor
24 Drive Shaft Signals
26 Rear Antenna
28 Front Antenna
30 Weak Signal Energy from Rear Antenna
32 Weak Signal Energy from Front Antenna
100 Central Processor
200 Moving Weak Signal Detection System Vehicle
[0048] Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | A Method and Apparatus for Enhancing the Detection of Weak Emitters provide an enhanced method to eliminate the fake hits of a moving weak signal detection system. The method and apparatus have the abilities stated in the previous U.S. patent application Ser. No. 11/332,801 filed by this author, to do moving detection of weak signals, even in dense urban environments. Secondly, the method and apparatus includes additional antennas and hardware boards, in order to verify authenticity of detected targets. Thirdly, the method and apparatus include appropriate DSP algorithms loaded to program the mission. Fourthly, the method and apparatus are enabled to accurately determine the tangential distance of the target from me vehicles centerline. Finally, the method and apparatus provide the ability to continually discard false targets based upon the information provided by these approaches. | 5 |
SUMMARY OF THE INVENTION
The present invention relates to hydraulic lash adjusters (tappets) and in particular to a compact lash adjuster suitable for use in modern overhead cam engines. In this environment engine oil must enter the tappet through a passageway located in the lower or mid portion of the tappet. This invention includes a flexible rubber-like seal which permits engine oil to enter the tappet, thereby forming a reservoir of hydraulic fluid, while blocking the subsequent release of such fluid. In this manner a permanent supply of hydraulic fluid is available for proper tappet operation particularly following a prolonged period of engine shut-down.
The hydraulic compression chamber is contained in a piston assembly which is positioned in the center of the overall tappet. Interchangeable piston assemblies of various lengths may be substituted thereby providing an inexpensive and flexible technique for creating a family of tappets suitable for use in a variety of engines.
A primary purpose of this invention is a compact tappet having a source of hydraulic fluid other than at the top and having a reservoir of hydraulic fluid immediately available even following periods of engine shut-down.
Another purpose is a flexible rubber-like seal which permits the entry of hydraulic fluid as required into a reservoir within the tappet during periods of engine operation while blocking the subsequent loss of such reservoir fluid particularly when the engine is shut-down.
Another purpose is a compact tappet suitable for use in modern compact engines having overhead cams, particularly where the tappet is positioned immediately between the valve stem and the cam.
Another purpose is a tappet having interchangeable piston assemblies thereby facilitating an inexpensive method for the creating of a family of tappets.
Other purposes will appear in the ensuing specification, drawings, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated diagrammatically in the following drawings wherein:
FIG. 1 is a cross section view of the upper cylinder region of an overhead cam engine utilizing the lash adjuster of this invention; and
FIG. 2 is an axial section through a lash adjuster of the type described.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention described herein relates to a self-compensating hydraulic lash adjuster ("tappet"). Specifically, this invention discloses a valve-like sealing member which functions to admit hydraulic fluid to an internal adjuster reservoir but precludes return or draining of this reservoir during engine shut-down.
Self-compensating hydraulic lash adjusters have been known to the art for many years. Most conventional adjusters contain a cylindrical plunger or body which is inserted into and is permitted to slide axially within a larger cylindrical follower member. A hydraulic fluid compression chamber is thereby formed between these members. A second fluid chamber or reservoir is usaully formed within the cylindrical interior of the plunger body, the fluid level of this reservoir being maintained by a supply of engine lubricant through appropriate channels and cavities. A biasing spring is provided which forces the plunger body outwardly from the follower housing when no external restaining forces are applied. This relative movement causes a oneway check valve located at one end of the plunger body to open thereby permitting hydraulic fluid to pass from the fluid reservoir into the hydraulic chamber as the volume of that chamber increases. A more complete description of this type of adjuster is provided below.
Conventional adjusters of this type typically utilize relatively long members, particularly the plunger body. This facilitates the inclusion of a significant fluid reservoir within the plunger which is fed from a source of motor oil at the adjuster's upper portion. Conventional adjusters are designed and mounted so that the fluid pumped into the fluid reservoir during engine operation remains in that reservoir upon shut-down. This is a necessary and desirable feature in that adjusters often require additional fluid immediately upon engine start up. This fluid will be instantaneously available in a conventional adjuster through the check valve from the adjacent fluid reservoir. In the absence of a fluid reservoir, however, or in the event that such reservoir has drained during shut-down periods, new fluid will not be available to the adjuster until the engine develops sufficient oil pressure and again pumps fluid to the adjuster. The absence of an available hydraulic fluid reservoir can result in improper adjuster length compensation for a considerable period of time upon start up, particularly in cold ambient temperatures.
With the advent of small efficient internal combustion engines and with the increased utilization of overhead cams, hydraulic lash adjusters of considerably smaller axial dimension have been mandated. Further, the placement of such adjusters within the valve train often makes it difficult or impossible to supply oil to the upper-most portion of the adjuster. FIG. 1 illustrates such a modern compact adjuster 10 positioned axially above its respective valve 21 and immediately below the overhead cam 14. In this configuration the top portion 16 of adjuster 10 extends substantially above the engine cylinder casting 18 through which oil galleys and channels 20 are formed. As a consequence, hydraulic fluid or engine oil must enter adjuster 10 at a point 22 well below the upper-most portion of the adjuster. This invention discloses a self-compensating hydraulic lash adjuster of small physical dimension and a device for maintaining a reservoir of hydraulic fluid during periods of engine shut-down.
FIG. 2 illustrates the complete lash adjuster or "tappet" of this invention. A high pressure hydraulic chamber 30 is formed between a cylindrical cup-shaped body 32 and cylindrical plunger 34. Body 32 and plunger 34 are dimensioned so as to permit relative axial movement between these members. Further, the relative diameters of these members are chosen so that a small and predetermined quantity of hydraulic fluid is permitted to escape from compression chamber 30 into the hydraulic fluid reservoir 38a along the cylindrical interface surface 36 whenever a compressive force is applied on body 32 with respect to plunger 34.
A boss 40 is formed on the lower portion of the body 32 which will receive and contact the valve stem during normal engine operation. An annular groove 56 is provided on the upper portion of body 32 to receive a retaining ring 58 which may be of the slotted compression type. Retaining ring 58 blocks the unrestrained downward movement of body member 32 thereby guaranteeing that the compete tappet, once assembled, remains an integral unit during engine assembly and, subsequently, during engine operation. Slot 56 is dimensioned so as to receive the entire cross section of retaining ring 58 thereby permitting the unrestrained insertion of body 32 into the tappet structure.
A hydraulic metering orifice 42 is provided on the center axis of plunger 34 through which hydraulic fluid is permitted to pass from the reservoir 38b to the compression chamber 30 whenever the check valve is open. The check valve is comprised of an orifice blocking check ball 44, a check ball retainer 46, and a biasing coil spring 48. Check ball 44 is normally held in its closed position as shown by the force of biasing spring 48 acting against ball retainer 46 or by the pressure of the hydraulic fluid within compression chamber 30 whenever a compressive axial force is applied to the tappet. Ball retainer 46 is provided with several openings or perforations to permit the free flow of hydraulic fluid within compression chamber 30 both above and below the retainer clip. A second and larger coil spring 50 functions to rigidly hold ball retainer 46 against plunger 34.
A second and principal function of coil spring 50 is to provide an axial biasing force between body 32 and plunger 34 thereby forcing these members into relative axial expansion. This expansion continues as the plunger 34 contacts the follower 52 which, in turn, forces the body 32 downward or outward in relation to the overall tappet assembly until the assembly engages, simultaneously, the valve stem on the bottom and the cam on the top. Slots 54 are spaced along the annular top portion of plunger 34 to facilitate the free flow of hydraulic fluid from the outer fluid reservoir 38a to the inner reservoir 38b.
Body 32, plunger 34, biasing spring 50, and the check valve components described above form an integral piston assembly which, by compressing retaining spring 58, is inserted into the overall tappet structure. This geometry permits piston assemblies of varying lengths to be inserted into a single common tappet structure. As a consequence, a family of tappets adapted to engines having differing tappet length requirements has been created merely by providing a series of piston assemblies which can be inserted into a common overall tappet structure.
This piston assembly is positioned within the center of an annular L-shaped spacer 60 containing a flange 62 along its outside perimeter. This flange is positioned along an indented portion 64 of the interior cylindrical surface of follower 52 so as to engage the non-indented stop at 66. Spacer 60 is held in this position by an annular retaining ring 68 inserted into annular slot 70. The inside cylindrical surface 72 of spacer 60 forms a close but non-interfering fit with the outside surface 74 of body 32. Body 32 is free to move upwardly to the limits permitted by the axial dimension of plunger 34 and downwardly until retaining ring 58 engages the upper surface 76 of spacer 60. Engine oil within reservoir 38a will lubricate the sliding joint between the body and spacer members but the close fit between these members precludes any significant loss of oil through this interface. In a similar manner fluid will not escape past flange 62.
The outer body or follower 52 of this hydraulic lash adjuster is a cylindrical cup-shaped member closed at the top and open at the bottom. The interior surface including an indented portion 64, a stop 66, and a slot 70 was described above. The outer diameter of follower 52 is selected so that the entire tappet assembly establishes, as shown in FIG. 1, a close but non-interfering fit with cylinder block 24. A V-shaped annular groove 22 is formed around the outside perimeter of follower 52. This groove is located so as to be in communication with a source of engine lubrication 20 as shown in FIG. 1. A passage 78 is provided through the follower side wall thereby permitting the flow of fluid from the exterior groove 22 into the internal fluid reservoir 38a.
An annular sealing member is positioned between spacer 60 and follower 52. Sealing member 84 is formed in place on spacer 60, and the dimension of surface 94 on sealing member 84 is such that when assembled into its final configuration the contact of surface 94 with surface 96 on follower or effects a snug compression fit assuring proper rotation and prevents fluid leakage between surfaces 94 and 96. This contact point is substantially below the opening of passage 78 into fluid reservoir 38a. Thus it will not block the flow of engine oil into reservoir 38a. An upper finger-like portion 92 of member 84 is biased against the interior wall of follower 52 thereby precluding the flow of oil from reservoir 38a outwardly through passage 78. Any outward pressure from within the fluid reservoir acts to increase the force acting upon member 84 thereby assuring an even tighter engagement between this member and follower 52. On the other hand, orientation of rubber member 84 is such that a positive fluid pressure acting through passage 78 upon rubber member 84 easily moves finger-like portion 92 away from the wall thereby admitting additional hydraulic fluid to reservoir 38a.
The self compensating hydraulic lash adjuster or "tappet" of this invention is installed and functions as follows. The tappet is positioned as shown in FIG. 1 within a cylindrical opening in cylinder block 24. The tappet is properly located when the top of valve stem 12 engages the boss 40 on body 32 of the tappet. The cam shaft assembly including cam 14 may then be assembled above the tappet.
Tappets may be supplied in either a "dry" or a "wet" form. A "dry" tappet is one containing no hydraulic fluid while a "wet" tappet is precharged at the time of manufacture with a quantity of hydraulic fluid. Since "dry" tappets quickly fill with hydraulic fluid in the manner described below upon initial engine start-up, only "wet" tappets will be considered at this point.
If the tappet as supplied contains the proper quantity of hydraulic fluid, the upper surface 16 of the tappet should just contact the circular portion 28 of the cam 14. This assumes that valve 21 is properly seated at 23 within the cylinder. The top of valve stem 12 will be in contact with boss 40 on tappet body 32. In this condition, there will be no play or "lash" between the tappet and either the cam 14 or the valve stem 12.
If, on the other hand, the tappet is precharged with an excess amount of fluid in compression chamber 30, the bottom portion 40 of tappet body 32 will force valve 21 downward so that it no longer seats at 23. In this condition, valve spring 26 exerts a upward or compressive force through valve stem 12 on tappet body 32. However, upward movement of the entire tappet assembly is precluded as the upper tappet surface 16 is in contact with the rigidly mounted and stationary cam 14. Instantaneous compression of the tappet piston assembly, thereby allowing the valve to seat, is precluded by the non-compressibility of the hydraulic fluid within chamber 30. Further, hydraulic fluid cannot escape through passage 42 as the increased hydraulic pressure augments the force created by check spring 48 thereby maintaining check ball 44 in tight blocking engagement with the orifice and passage 42.
The narrow cylindrical passage 36 between plunger 34 and body 32, however, does provide a slow means of escape for the fluid trapped in compressive chambers 30. Over a period of time the fluid escaping between these members permits the slow contraction of the tappet ultimately allowing valve 21 to seat at 23. Upon proper seating, the force of valve spring 26 acting on the tappet ceases which, in turn, terminates the gradual loss of hydraulic fluid from compression chamber 30. The tappet has now properly self-adjusted. The upper tappet surface 16 is in engagement with the circular portion 28 of cam 14 while the valve stem 12 is in contact with the lower portion 40 the tappet body 32.
Finally, if the tappet is precharged with an insufficient quantity of hydraulic fluid, the upper tappet surface 16 will not be in contact with the cam when the tappet is resting upon a properly seated valve.
In such event, biasing spring 50, which acts upon plunger 34 and, in turn, upon follower 52, forces the follower upwardly until it engages the cam. In order that this occur, however, additional hydraulic fluid must enter pressure chamber 30 in an amount corresponding to the increased volume of that chamber. The check valve functions as follows to admit this fluid. As the piston assembly attempts to expand, the hydraulic pressure within the compression chamber drops as compared to that of the adjacent fluid reservoir by an amount sufficient to overcome the force of check spring 48 acting upon check ball 44. The check ball then moves from tight engagement with orifice 42 thereby admitting the requisite fluid to the pressure chamber. This expansion continues only until the upper tappet surface 16 contacts the cam. At the instant of contact, further expansion ceases as the relatively weaker biasing spring 50 can not overcome the valve spring 26 which is required to unseat and force valve 21 downwardly.
In this manner, the hydraulic lash adjusters of this invention automatically adjust to properly fill any gap or "lash" while permitting the valve to properly seat. Although the above discussion was predicated upon the assumption that the engine was not in operation, the functioning of this tappet is substantially the same during normal engine operation.
Proper engine operation requires that the eccentric rotational motion of the cam be transmitted through the tappet to the corresponding valve thereby forcing it open. In order that this transfer occur, the tappet must maintain its axial dimension, that is, it can not substantially compress during any given valve opening. Such compression would allow the valve to close thereby impeding the free flow of gasses through the open valve aperture.
The tappet herein does, as discussed above, anticipate or permit some size reduction during tappet compression cycles by reason of fluid leakage at interface 36. This does not represent a limitation, however, as significant leakage requires sustained compression for durations in excess of several seconds. Thus, for example, a 50 pound compressive force sustained between 5 and 25 seconds causes only 0.05 inch axial compression of the tappet. During normal engine operation a valve remains open typically for less than a tenth of one second. Such short compressive intervals cause only insignificant tappet compression. By contrast, the tappet can expand almost instantaneously by reason of the relatively large cross sectional area of orifice 42. This permits the tappet to correct instantaneously as required for any axial contraction however minimal it may be. For this reason, successive losses of pressure chamber fluid do not accumulate. Each individual loss is replenished as soon as the valve has again closed.
Whereas the preferred form of the invention has been shown and described herein, it should be realized that there may be modifications, substitutions and alterations thereto. | A compact self-compensating hydraulic lash adjuster (tappet) particularly suited for use in internal combustion engines having overhead cams. A flexible rubber member forms a one-way valve and seal thereby creating a reservoir of hydraulic fluid. This reservoir instantaneously provides the necessary hydraulic fluid for proper tappet operation, even after sustained periods of engine shut-down. A hydraulic compression chamber is contained in a piston assembly positioned within the center of the overall tappet assembly. This construction facilitates the substitution of piston assemblies of varying axial dimension thereby permitting the basic structure to be used in engines having differing tappet length requirements. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to mobile load handling equipment such as a tractor with a backhoe and more particularly to stabilizers for such equipment.
Mobile load handling equipment such as excavators and backhoes, frequently are mounted on a self-propelled vehicle, such as a tractor, on which the load handling or excavating equipment is supported for transport on the road and for load handling operations during off the road operation.
Usually, such equipment is provided with a stabilizer which engages the ground to support the weight of the vehicle and the loads being manipulated to form a more stable operating platform than can be provided by ground engaging wheels and suspension systems of the vehicle. In the case of a backhoe, for example, such stabilizing equipment is disposed at the rear of the vehicle between the latter and the backhoe equipment and is engageable with the ground at laterally spaced points which serve to resist tilting of the vehicle. The points of engagement with the ground are formed by pads or foot members having a substantial ground engaging, load bearing surface. The structure is usually of a transverse width which will provide a maximum stability for the vehicle and the load handling equipment and at the same time will be no greater than the legal maximum vehicle width which is permitted on a highway. To increase the transverse width of the stabilizer to increase its effectiveness during off the road operation, it is usual to use hydraulically actuated equipment and linkages which are complex and costly or attachments which must be added and subsequently removed for on the road movement of the vehicle.
SUMMARY OF THE INVENTION
It is an object of the invention to provide stabilizer apparatus for load handling equipment such as a backhoe in which the stabilizing structure has one transverse width during vehicle transport and a greater ground engaging width when load handling equipment is being operated.
It is a further object of the invention to provide a stabilizer for load handling equipment employing ground engaging food members which have a given position when they are engaged with the ground and in which portions are automatically moved laterally when the foot member is raised to an elevated position for transport.
Still another object of the invention is to provide stabilizing apparatus for load handling equipment in which the ground engaging width of the stabilizing structure is greater than the transport width and in which the changes in width are automatically accomplished by movement of the foot members between ground engaging and transport positions.
Stabilizing apparatus for mobile load handling equipment has been provided in which ground engaging foot members for supporting the load of the mobile equipment on which the stabilizer apparatus is used are disposed in one position when they are being transported and in a more widely spaced position laterally of the vehicle when they are moved to engage the ground. The stabilizer structure includes vertically movable elevator members which may be manually or hydraulically actuated and to which ground engaging foot members are connected through the intermediary of toggle links so that elevation of the shoe members causes them to assume a position requiring less lateral width. When the ground engaging foot members are lowered to a ground engaging position, the foot members are automatically moved to a ground engaging position occupying a greater lateral spacing to increase the stability of the vehicle with which the stabilizing structure is being used.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a tractor mounted backhoe employing a stabilizer structure embodying the present invention;
FIG. 2 is a rearward plan view of a portion of the stabilizer structure at one side of the tractor under one condition of operation;
FIG. 3 is a view similar to FIG. 2 but showing an elevated, transport position of a portion of the stabilizing structure;
FIG. 4 is a view of a portion of the stabilizing structure taken generally on line 4--4 in FIG. 2;
FIG. 5 is a view of locking means for the stabilizer structure of FIG. 1; and
FIG. 6 is an alternate embodiment of the device in FIG. 3.
DETAILED DESCRIPTION
Referring to the drawings and particularly to FIG. 1, load handling equipment in the form of a tractor mounted backhoe is illustrated. The equipment includes a tractor 10 and a backhoe 12 mounted on the tractor with a stabilizing structure generally designated at 14 and embodying the invention, supported from the tractor to the rear of the rear driving wheels 16.
The stabilizing structure includes a relatively wide weldment or framework 18 which extends transversely of the vehicle. The framework 18 includes laterally spaced vertical members 20 which are fixed in transversely spaced relationship by upper and lower transverse members 22. The vertical members 20 are substantially identical and are disposed at the left and right side of the vehicle or tractor 10. The vertical members 20 are generally box-like in cross section and can be formed by welding plates together to form a housing for a hydraulically actuated cylinder, the rod end of which is indicated at 24. Alternately the rod end of the cylinder may be attached to a member telescoping with member 20. The hydraulic cylinders are under the control of the operator so that the rod ends 24 may be selectively extended or retracted.
Referring now to FIGS. 2, 3 and 4, a portion of the stabilizing structure at the left side of the tractor is shown, the structure at the right side being generally identical but a mirror image. The cylinder rod member 24 supports a pad or ground engaging foot member 26 which is generally rectangular in configuration and is preferably formed of a casting or heavy metal plate so that its lower surface 27 provides a large ground engaging surface to act as a bearing support for the load of the vehicle. Opposite lateral edges of the foot member are provided with upturned edge portions 27a and 27b.
As viewed in FIG. 4, the foot member 26 is provided with a bracket member 28 rigidly connected to an upper surface 29 of the foot member 26 in a position located centrally of the foot member in a longitudinal direction of the tractor and offset outwardly relative to the tractor to one side of the center of the shoe member 26.
The bracket member 28 is provided with a longitudinally extending pin receiving hole 30 which receives a pin 32 pivotally supporting the ends of a pair of link elements 36 disposed at opposite sides of the bracket 28. The opposite ends of the pair of links 36 are provided with apertures which are adapted to receive a pivot pin 42 passing through the ends of the links 36 and an aligned opening 44 in a bracket member 46 rigidly connected to the end of the rod member 24. In the alternative, the bracket member would be attached to the member telescoping into member 20.
In the position shown in FIG. 2, the foot member 26 is disposed so that the lower end of the bracket member 46 is disposed centrally of the foot member 26 in both a fore and aft and transverse direction. The bracket 28 is disposed to one side of the central location a distance determined by the length of the links 36 and the spacing of the pivot pins 32 and 42. This is the ground engaging position of the foot member 26 in which the weight of the vehicle is absorbed centrally of the foot member 26 by engagement of the end of the bracket member 46. The rod member 24 is held in a fixed position by means of the hydraulic circuit, not shown, which locks the rod 24 in a fixed position relative to its cylinder and to the vertical member 20.
To retract the pad or foot member 26 so that the vehicle can be moved to another location or operated on a highway, the piston rod 24 is retracted into its cylinder within the vertical member 20. This causes the links 36 to lift the foot member 26 vertically upwardly so that the links 36 and foot member 26 assume the position shown in FIG. 3. In this position it will be noted that the unbalanced location of the bracket 28 causes the foot member 26 to tilt downwardly relative to the links 36 and the upturned edge 27a of the foot member 26 engages an edge of the links 36. The weight of the foot member 26 and the links 36 is pivotally suspended from the pin 42 so that the links 36 and foot member 26 are disposed at an angle to each other and so that the foot member 26 is tilted inwardly and downwardly relative to a vertical plane.
In this position, the foot member 26 occupies a minimum transverse width relative to the vehicle so that none of the structure protrudes outboard or to the left of the vertical member 20 as viewed in FIG. 3. As a result, the outboard side of the vertical member 20 can define the maximum permissible projection of the stabilizer structure to one side of the vehicle. In the transport position, it will be noted that no portion of the foot member 26 projects outwardly of the stabilizer 20 defining the maximum width of the vehicle.
When the vehicle is moved to a working location and it is desired to stabilize the vehicle in a working position, the cylinder rods 24 are extended by hydraulic fluid. When the lower upturned edge 27b, as viewed in FIG. 3, engages the ground, the foot member 26, which is disposed at an angle to a vertical plane, is caused to pivot about the ground engaged edge 27b relative to the ground. Such pivotal movement causes the pivot pin 32 to swing in an arc carrying with it the lower ends of the links 36 which also are caused to swing outwardly or to the outboard side of the vehicle relative to the pivot pin 42. As the foot member 26 reaches a horizontal position the links 36 also will be disposed generally horizontally and the end of the bracket member 46 will engage the top surface of the foot member 26 so that all further hydraulic force transmitted through the rod member 24 will be transmitted directly to the foot member 26 without imposing larger loads on the links 36 and pins 32 and 42.
It will be noted that in their ground engaging positions the foot members 26 uniformly distribute the weight transferred from the vehicle through the associated piston rods 24 and that the foot members 26 can assume various angles relative to the associated piston rods 24 to accommodate variations in contour of the ground. Also the foot members will have their outer edges extending beyond the maximum transport width of the vehicle to provide a stabilizing platform wider than the vehicle.
FIG. 5 illustrates means for locking the foot member 26 in transport position in the form of lock bars 48 attached to a vertical member 20. The lock bars 48 can be fixedly attached or movable into the locking position because they are engaged naturally as the rod 24 is retracted. If gravity can be satisfactorily relied on, only one lock bar 48 (on the left in FIG. 5) need be provided. The second lock bar prevents movement of the foot member 26 upwardly. As the foot member 26 approaches the lock bar 48 on the left the edge 27a will engage the bar 48 first to deflect the foot member 26 into the position illustrated in FIG. 5 with the edge 27a adjacent the lock bar 48 and vertical member 20.
In FIG. 6 an alternate embodiment is illustrated incorporating support members in the form of support bars 50 welded to the foot member 26. The support members could be webs cast into the plate or like members attached in numerous ways such as by pinning or bolting. The support bars 50 are pivotally connected to the link elements 36 by a pin 52 to support the foot member 26 from the rod 24 in a manner similar to that illustrated in FIGS. 1-4. Additional support in the fore and aft directions is provided by the support members.
A stabilizer arrangement for mobile load handling machinery is provided in which a foot member for distributing the weight of the vehicle is connected to a vertically movable member in such a manner that in its transport position the foot member occupies a minimum transverse width to minimize the maximum width of the vehicle and in its ground engaging position occupies a maximum transverse width to add to the stability of the vehicle when it is in its machinery working position. | Stabilizer apparatus for use with a vehicle such as a tractor supporting load handling equipment such as a backhoe in which foot members disposed at opposite sides of a vehicle are engageable with the ground to stabilize the vehicle and are movable to an elevated position for transport by the vehicle. In the ground engaging position the foot members are positioned with their outer extremities projecting beyond some maximum predetermined width of the vehicle and in their transport position occupy a position in which the outer extremities are disposed within the confines of the maximum predetermined width of the vehicle. | 4 |
This is a continuation of application Ser. No. 138,590, filed on Dec. 28, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bobbin housing assembly in a sewing machine having at least one hook, and a tension spring which rests against the bobbin housing, and advantageously relates to a lockstitch sewing machine of this type.
2. Description of Related Art
A lockstitch sewing machine having a hook, a bobbin housing assembly which includes the hook, and a spring bar, is disclosed in Federal Republic of Germany Patent 34 46 547, having a U.S. counterpart U.S. Pat. No. 4,691,650. In this device, the spring bar rests against the bobbin housing. The spring bar is fastened to a carrier which, in turn, is fastened to the base plate of the lockstitch sewing machine. The carrier furthermore has two cams which are arranged essentially in the center region of the loop press-off side of the bobbin housing and which receive the spring bar between them. The obliquely directed spring bar assumes a position with respect to the cam which is towards the rear in the direction of rotation of the hook body, so that a larger clearance is always present between the free end of the spring bar and the surface of the rear cam facing it.
This device has the following disadvantage. In a lockstitch sewing machine operating with a high stitching rate, the spring bar begins to oscillate, and as a result, the position of the bobbin housing, which itself is held by the spring bar, becomes unstable. As a result of this, defects can arise in the sewing.
Another lockstitch sewing machine having a hook and a spring bar resting against the bobbin housing is disclosed in Federal Republic of Germany Patent 26 16 738, having U.S. counterpart U.S. Pat. No. 4,137,858. In this device, the bobbin housing has a holding finger which is received by two stops provided on a bottom side of the throat plate of the lockstitch sewing machine. Because of the relatively narrow passage clearances between the two stops and the holding finger, passage of the loop of the needle thread (top thread) can be impeded. Furthermore, the manner of operation of this spring bar is also not substantially vibration-free.
SUMMARY OF THE INVENTION
The principal object of the invention is to develop a tension spring bar assembly for the bobbin housing of a lockstitch sewing machine having at least one hook, with vertically mounted hook shaft, which operates substantially free of vibration.
In accordance with the invention, this is achieved by a sewing machine, comprising a base having a throat plate mounted therein; a rotating hook mounted in the base below the throat plate for holding and looping a top thread in a looping direction, the hook enclosing a bobbin housing for accommodating a bottom thread; spring means mounted in the base having a free end for bearing against the bobbin housing and said free end being displaceable by said top thread held in said hook; and cam means disposed in the base closely adjacent to said free end of the spring means, for preventing displacement of said free end, beyond a predetermined range of displacement. The cam means is for preventing uncontrolled oscillation movement of said free end of said spring means.
Advantageously, said cam means comprises a cam secured to said base; said spring means comprises a spring bar secured at a first end to said cam and bearing at said free end against said bobbin housing; and said cam has a resting surface disposed closely adjacent to said free end of said spring bar, and effective for positively guiding the free end of the spring means. The resting surface is preferably disposed at most substantially 0.3 mm from said free end.
The spring bar of the invention is provided with a leg having a free end, which is movable through a maximum clearance of about 0.3 mm, to come against a stop surface of a cam and thereby be quieted. With this device, vibration-free operation is now possible.
Furthermore, according to the invention, the rotation of the bobbin housing in the direction of rotation (GD) is prevented if the needle thread sticks in the hook race. This feature prevents the bobbin housing from being jammed in this situation.
An arrangement of the invention comprises a sewing machine including: a base having a throat plate mounted therein; a rotating hook mounted in the base below the throat plate for holding and looping a top thread in a looping direction, the hook enclosing a bobbin housing for accommodating a bottom thread; spring means mounted in the base having a free end for bearing against the bobbin housing and said free end being displaceable by said top thread held in said hook; and cam means disposed in the base closely adjacent to said free end of the spring means, for preventing displacement of said free end, beyond a predetermined range of displacement, said cam means comprising a cam secured to said base; said spring means comprising a spring bar secured at a first end to said cam and bearing at said free end against said bobbin housing; and said cam having a resting surface disposed closely adjacent to said free end of said spring bar, said resting surface being effective for positively guiding said free end of said spring means.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be appreciated from the following detailed description of embodiments thereof, with reference to the drawings, in which:
FIG. 1 is a simplified side view of a two-needle lockstitch sewing machine having two verticalshaft hooks;
FIG. 2 is a top view of a hook of a single-needle lockstitch sewing machine, a free end of a spring bar being enclosed within a V-shaped notch in a cam;
FIG. 3 is a sectional view along the section line III--III in FIG. 2, shown on a larger scale;
FIG. 4 is a top view of the hook of a single-needle lockstitch sewing machine, wherein the free end of the spring bar comes against an obliquely extending edge of a cam at the end of its swinging movement;
FIG. 5 is a sectional view along the section line V--V of FIG. 4, shown on a larger scale;
FIG. 6 is a top view of the hook of a single-needle lockstitch sewing machine, wherein the free end of the spring bar is held laterally by two plates which are arranged on a cam;
FIG. 7 is a sectional view along the section line VII--VII of FIG. 6, shown on a larger scale;
FIG. 8 is a top view of the hook of a lockstitch sewing machine, wherein the spring bar is received in a hole in a cam; and
FIG. 9 is a sectional view along the section line IX--IX of FIG. 8, shown on a larger scale.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the reference number 1 designates a known lockstitch sewing machine, comprising an arm 2, an arm head 3, a stand 4 and a base plate 5. In the arm head 2, there is mounted a needle bar 6 which can move up and down. On the end of the needle bar 6 is fastened a needle holder 7 which receives two sewing needles 8. A throat plate 9 is mounted in the base plate 5. In a known manner, the sewing needles 8 and the toothed transport ribs of a feed dog 10 pass through the throat plate 9.
As the broken-away portion in FIG. 1 shows, mounted in the base plate 5 are two hooks 11, the drive shafts 12 of which are arranged vertically. For this reason, they are also referred to as vertical-shaft hooks.
Referring now to FIG. 2, each hook 11 comprises a rotating hook body 13 and a bobbin housing 14 therein, which, in turn, comprises an upper part 15 and a lower part 16. Within the latter is mounted, in a known manner, a bobbin 36 which receives a hook thread (bottom thread) 17.
The drive of the hooks 11 is of a known type. The manner in which a needle thread (top thread) loop 33 is received by a hook point 34 which forms part of the hook body 13, and the moving of the needle thread loop 33 around the bobbin housing 14, are also sufficiently well-known that a more extensive description thereof can be dispensed with here.
Below the throat plate 9, there can be provided a thread cutting device 18, shown schematically in FIG. 1, the manner of action of which is well known. The thread cutting device 18 comprises a stationary cutting knife (not shown) and a swingable thread catcher 19, shown in FIG. 6. The manner of operation of an appropriate thread cutting device 18 is described, for example, in Federal Republic of Germany Utility Model 86 30 911.
In order to hold the bobbin housing 14 fast during the rotating movement of the hook body 13, a spring bar 20 is provided. In the various embodiments of this invention, the spring bar 20 has a non-spring part which is received by a portion of a cam 21, 21a, 21b or 21c (hereinafter jointly identified as cams 21) for example, a notch 38 (FIGS. 2-7), or a hole 39 (FIGS. 8-9). The spring bar 20 is fastened by a screw 24 to any of the cams 21 so that the free end of a leg 22 forming part of the spring bar 20 rests against a holding nose 23 on the upper housing part 15.
A slot 26 in any of the cams 21 permits the displacement of the spring bar 20 relative to the holding nose 23 after loosening a screw 25. Each of the cams 21 is firmly attached by a screw 25 to the base plate 5.
Between the free end of the leg 22 and a resting surface of any of the cams 21, which faces it, there is provided a small clearance of at most about 0.3 mm.
The portion of each of the cams 21 for receiving the free end of the spring bar can take several forms. In accordance with FIGS. 2 and 3, a V-shaped notch 27 is provided in the cam 21 in the region of the resting surface.
In the embodiment of FIGS. 4 and 5, an obliquely extending edge 28 on the cam 21a and a plate 30 are provided there, together forming the resting surface.
In FIGS. 6 and 7, a plate 30 is provided on a lower side 29 of the cam 21b and another plate 32 is provided on an upper side 31. The plates 30 and 32, which are firmly connected in any suitable manner to the cam 21b by bonding or soldering, receive the leg 22 of the spring bar 20 between them, as shown in FIG. 7. The plate 32 is so developed that it does not prevent the swinging motion of the thread catcher 19, which forms part of the thread-cutting device 18.
With the embodiment shown in FIG. 8, a bent-off leg 40 of the spring bar 20 fastened to the cam 21c extends into a hole 41 provided in the cam 21c, as a result of which the leg 40 is guided laterally during its swinging motion.
The manner of operation of the spring bar 20, in combination with any of the cams 21, will now be described:
At the start of the formation of a stitch, the needle thread loop 33 is taken up in known manner by the hook point 34, and then moved around the bobbin housing 14. When the loop 33 has completed at least about 70 percent of its passage around the bobbin housing 14, it lies directly in front of the narrow space between the leg 22 of the spring bar 20 and the holding nose 23. At this time, the amount of top thread required for the needle thread loop 33 to completely wrap around the bobbin housing 14 has already been withdrawn from a thread lever (not shown), which is movable up and down and provided in known manner in the arm head 3. The corresponding part of the needle thread loop 33 now comes between the holding nose 23 and the leg 22 at the free end of the spring bar 20, the leg 22 moving for a short time away from the holding nose 23; i.e., the leg 22 carries out a slight swinging motion.
Towards the end of this swinging motion, the free end of the leg 22 rests, as shown in FIG. 3, against the V-shaped notch 27 of the cam 21; or, as shown in FIG. 5, against the obliquely extending edge 28 of the cam 21a and against the inside of the plate 30; or, in accordance with FIG. 7, against the edge 37 of the cam 21b; or, in accordance with FIGS. 8 and 9, the bar 40 is girded between the resting surfaces on the cams 21c. Each of these supports is located at most about 0.3 mm behind the leg 22. By each of the supports which have just been described, the leg 22 of the spring bar 20 is immediately quieted again after its swinging motion, so that no undesired oscillation of the spring bar 20 or instability of the bobbin housing can occur.
In the event the needle thread sticks in the hook race, and thus the hook body 13 and the bobbin housing 14 are blocked, the holding nose 23 first of all presses the leg 22 against the resting surface on any of the cams 21. Thereupon, in the embodiment shown in FIGS. 4 and 5, the holding nose 23 comes against a stop edge 35b provided on the cam 21a, and as a result, further rotation of the bobbin housing 14 in the direction of rotation (GD) of the hook body 13 is prevented. In the embodiments in accordance with FIGS. 2, 3 and 6-9, upon such sticking of the needle thread, the bobbin housing 14 is held fast in the manner that the holding nose 23 presses via the leg 22 against the stop edge 35a (FIG. 3) or 35c (FIG. 7) or 35d (FIG. 9).
If, upon the replacement of an empty bobbin 36 by a full bobbin, the lower part 16 of the bobbin housing 14 should, by mistake, be shifted, then -- in order to be able to insert the upper part 15 again in functionally correct position -- the lower part 16 must be rotated into a position which is indicated by a marking provided on the lower part 16.
Although illustrative embodiments of the invention have been disclosed herein, it is to be understood that the invention is not limited to such embodiments. Rather, modifications and variations thereof may occur to one of ordinary skill in the art, still within the scope of the invention, as defined in the claims. | A sewing machine has at least one rotating top thread hook, the hook enclosing a bobbin housing which accommodates a bottom thread. A spring bar is mounted in the base of the sewing machine and has a free end for bearing against the bobbin housing. The free end of the spring bar is displaceable by the top thread as it is being looped. To prevent unwanted displacement or oscillation of the spring bar, a cam is disposed in the base closely adjacent to the free end of the spring bar. The cam prevents displacement of the free end beyond a predetermined range of displacement. | 3 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation of PCT/EP2015/056733, filed Mar. 27, 2015, which claims priority to European Application No. 14162348.8, filed Mar. 28, 2014, the entire teachings and disclosure of which are incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The invention relates to an aluminium alloy for the manufacture of semi-finished products or components of motor vehicles, a method for the manufacture of a strip made of an aluminium alloy according to the invention, a corresponding aluminium alloy strip or sheet as well as a structural component of a motor vehicle consisting of a sheet of aluminium alloy.
BACKGROUND OF THE INVENTION
[0003] Semi-finished products and components for motor vehicles need to meet different requirements depending on the location in which they are used within the motor vehicle and the purpose for which they are used. The forming properties of the aluminium alloy or the strips and sheets are of decisive importance during the manufacture of the semi-finished products and components for motor vehicles. The strength properties, but also in particular the corrosion-resistance properties play an important role during the later use in the motor vehicle.
[0004] For example, in the case of structural components of a motor vehicle, for example interior door parts, the mechanical properties are primarily determined through their rigidity, which depends above all on the shape of the interior door parts. In contrast, tensile strength for example has more of a secondary influence. However, the materials used for an interior door part may not be too soft. In contrast, good formability is particularly important for the introduction of aluminium alloy materials in motor vehicle applications, since the components and semi-finished products undergo particularly complex forming processes during manufacture. This applies in particular to components which are manufactured in a single piece as a formed sheet metal shell, for example sheet metal interior door parts with integrated window frame region. By dispensing with joining operations, such components offer significant cost advantages in comparison with, for example, a joined aluminium profile solution for the window frame. The aim is for example to be able to manufacture semi-finished products or components in a single piece of an aluminium alloy, using as few forming operations as possible. This requires an optimization of the forming behaviours of the aluminium alloy which is used. The aluminium alloy of the type AA5005 (AlMg1) occasionally used for similar applications does not fulfill these requirements, since it does not possess sufficient forming capacity due to hardening which takes place during forming.
[0005] A further important role is played by corrosion resistance, since components of motor vehicles are frequently exposed to perspiration, condensation and sprayed water. The aluminium alloy which is used must therefore be as corrosion-resistant as possible, in particular resistant to intercrystalline corrosion and filiform corrosion in the painted state. Filiform corrosion is understood to mean a corrosion type which occurs in coated components and which displays a filamentary pattern. Filiform corrosion occurs at high atmospheric humidity in the presence of chloride ions. Although the aluminium alloy of the type AA8006 (AlFe1.5Mn 0.5) exhibits sufficient strength and very high formability, it is susceptible to filiform corrosion. The alloy AA8006 is therefore less suitable for coated, in particular painted components such as interior door parts.
[0006] An aluminium alloy is known from the applicant's as yet unpublished patent application PCT/EP2014/053323, as an alternative to the aluminium alloy of the type AA8006, which contains the following alloy components in % by weight:
Fe≦0.8%, Si≦0.5%, 0.9%≦Mn≦1.5%, Mg≦0.25%, Cu≦0.20%, Cr≦0.05%, Ti≦0.05%, V≦0.05%, Zr≦0.05%,
the remainder aluminium, unavoidable accompanying elements individually ≦0.05%, in total ≦0.15%, whereby the total of the Mg and Cu contents fulfils the following relationship:
[0000] 0.15%≦Mg+Cu≦0.25%.
[0016] It has been found that also this aluminium alloy offers scope for improvement, in particular with respect to its forming behaviour. Moreover, the high Mn content leads to problems in recycling this aluminium alloy when it is mixed, in the scrap cycle, with the Al—Mg—Si alloys of the alloy type AA6XXX usually used in automobile applications.
[0017] Starting out from this prior art, the present invention is therefore based on the problem of providing an aluminium alloy for the manufacture of semi-finished products or components for motor vehicles which is highly formable, of medium strength and highly corrosion-resistant. In addition, a method for the manufacture of a strip made of a corresponding aluminium alloy, an aluminium strip or sheet, its use and a structural component of a motor vehicle are suggested.
BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION
[0018] According to a first teaching of the present invention, the aforementioned problem is solved through an aluminium alloy for the manufacture of semi-finished products or components of motor vehicles which contains the following alloy components in % by weight:
0.6%≦Si≦0.9%, 0.6%≦Fe≦1.0%,
Cu≦0.1%,
0.6%≦Mn≦0.9%, 0.5%≦Mg≦0.8%,
Cr≦0.05%,
the remainder Al and impurities, individually up to a maximum of 0.05% by weight, in total up to a maximum of 0.15% by weight.
[0025] Unlike the previous approaches, the present aluminium alloy is based on the knowledge that Al—Mg—Si alloys of the alloy type AA6XXX display very good formability in their soft-annealed state. However, they were too soft for the previous applications. The lower limits of the essential alloy elements of 0.6% by weight for Si, 0.6% by weight for Fe, 0.6% by weight for Mn and 0.5% by weight for Mg guarantee that the aluminium alloy can display sufficient strengths in a soft-annealed state. The upper limits of 0.9% by weight for Si, 1.0% by weight for Fe, 0.9% by weight for Mn and 0.8% by weight for Mg prevent the elongation at break to decrease and to thus adversely affect the forming behaviour. For the same reason, the content of the alloy element Cu is limited to a maximum of 0.1% by weight and that of Cr to a maximum of 0.05% by weight. The combination of the alloy components Si, Fe, Mg and Mn ensures that, on the one hand, the very good forming behaviour of the Al—Mg—Si alloys is combined with an increased strength, without suffering from excessive losses in ductility. Tests showed that the described aluminium alloy in its soft-annealed state fulfills the requirements in terms of formability and in particular corrosion-resistance and is thus suitable for the manufacture of semi-finished products or components in motor vehicles. With the specified ranges of the essential alloy elements Si, Fe, Mn and Mg, the aluminium alloy according to the invention falls into the class of Al—Mg—Si alloys of the alloy type AA6XXX. This makes possible an improved recyclability of this aluminium alloy when it is mixed, in the scrap cycle, with the Al—Mg—Si alloys of the alloy type AA6XXX usually used in automobile applications.
[0026] According to a first embodiment of the aluminium alloy according to the invention, the alloy components Si, Fe, Mn and Mg have the following contents in % by weight:
0.7%≦Si≦0.9%, 0.7%≦Fe≦1.0%, 0.7%≦Mn≦0.9% and 0.6%≦Mg≦0.8%.
[0031] Increasing the lower limits for Si, Fe, Mn and Mg further increases the strength of the aluminium alloy without adversely affecting the forming behaviour or the elongation at break of the soft sheets or strips manufactured from the aluminium alloy.
[0032] A further improvement of the aluminium alloy according to the invention in terms of a maximum elongation at break is achieved in that the alloy components Si, Fe, Mn and Mg have the following contents in % by weight:
0.7%≦Si≦0.8%, 0.7%≦Fe≦0.8%, 0.7%≦Mn≦0.8% and 0.6%≦Mg≦0.7%.
[0037] It has been found that, through this narrow range of essential contents in terms of the alloy components Si, Fe, Mn and Mg, a very good compromise between strength and elongation at break properties, i.e. the forming properties of the aluminium alloy, is achieved.
[0038] Although the aluminium alloy according to the invention displays good corrosion-resistant properties, according to a further embodiment of the aluminium alloy the resistance to intercrystalline corrosion can be further improved in that the Si content of the alloy exceeds the Mg content by a maximum of 0.2% by weight, preferably a maximum of 0.1% by weight.
[0039] According to a further embodiment of the aluminium alloy according to the invention, the elongation at break of the aluminium alloy can be further improved in that the Cr content is further reduced to a value of maximum 0.01% by weight, preferably to a maximum of 0.001% by weight. It has been found that chromium already has a negative effect on the elongation at break properties in very low concentrations.
[0040] The reduction of the Cu content to a maximum of 0.05% by weight, preferably to a maximum of 0.01% by weight, also has a similar effect, whereby at the same time the tendency to filiform corrosion or intercrystalline corrosion is generally reduced through the reduction in the Cu content.
[0041] According to a second teaching of the present invention, the aforementioned problem is solved by a method for the manufacture of a strip made of an aluminium alloy according to the invention with the following method steps:
casting of a rolling ingot, homogenization at a temperature of between 500° C. and 600° C. for at least 0.5 h hot rolling of the rolling ingot at temperatures of 280° C. to 500° C., preferably at temperatures of 300° C. to 400° C., to a thickness of 3 mm to 12 mm, cold rolling with or without intermediate annealing with a degree of reduction of at least 50%, preferably at least 70%, to a final thickness of 0.2 mm to 5 mm and final soft annealing at 300° C. to 400° C., preferably 330° C. to 370° C. for at least 0.5 h, preferably at least 2 h in a chamber furnace.
[0047] Following casting, the homogenization at a temperature of 500° C. to 600° C. for at least 0.5 h, preferably at least 2 h ensures that a homogenous structure is provided for the further processing of the rolling ingot. The hot-rolling temperatures thereby make possible a good recrystallisation during the hot rolling, so that the microstructure is as fine-grained as possible after the hot rolling. This fine-grained microstructure is merely elongated by the cold rolling and is recrystallized once again during the final soft-annealing. If produced without intermediate annealing, a particularly high number of displacements are created in the microstructure through the cold rolling which creates a very fine-grained fully recrystallized microstructure during the final soft annealing. For this purpose, the degree of reduction to final thickness before the final soft annealing must be at least 50%, preferably at least 70% in relation to the desired final thickness.
[0048] A further positive influence on the fine-grained nature of the microstructure can be achieved in that, according to a further embodiment of the method according to the invention, the homogenization takes place in two stages, whereby the rolling ingot is first heated to 550° C. to 600° C. for at least 0.5 h and then the rolling ingot is kept at 450° C. to 550° for at least 0.5 h, preferably at least 2 h. The rolling ingot is then hot rolled.
[0049] The corrosion-resistance properties can be improved in that the rolling ingot is milled on the upper side and underside after casting or after homogenization in order to exclude impurities on the upper side and underside of the rolling ingot which could have a negative influence on corrosion resistance.
[0050] According to a further embodiment of the method according to the invention, at least one intermediate annealing takes place, after a first cold rolling, at a temperature of 300° C. to 400° C., preferably at a temperature of 330° C. to 370° C., for at least 0.5 h, whereby before and after the intermediate annealing the degree of reduction amounts to at least 50%, preferably at least 70%. As a result of the chosen degrees of reduction before the intermediate annealing or after the intermediate annealing it is ensured that the microstructure recrystallises sufficiently during the intermediate annealing. The intermediate annealing duration amounts to at least 0.5 h, preferably at least 2 h.
[0051] If the intermediate annealing takes place at a temperature of 330° C. to 370° C., due to the increased lower temperature of 330° C. it is ensured that a sufficient recrystallisation takes place and at the same time it is ensured, through the reduction in the upper limit, that an efficient intermediate annealing is carried out which requires as little thermal energy as possible.
[0052] According to a third teaching of the present invention, the aforementioned problem is solved by an aluminium alloy strip or sheet manufactured from an aluminium alloy according to the invention, whereby the strip has a thickness of 0.2 mm to 5 mm and in the soft-annealed state has a yield strength R p0.2 of at least 45 MPa as well as a uniform elongation A g of at least 23% and an elongation at break A 80mm of at least 35%. In particular, with the specified thickness of the strip in combination with the composition of the alloy and the resulting mechanical properties in the soft-annealed state, the prerequisites are fulfilled that the aluminium alloy strip or sheet can be used for components in a motor vehicle, which in addition to very good forming properties also include a very good resistance to intercrystalline corrosion or filiform corrosion. This also applies in particular to painted or coated components.
[0053] In this respect, the use of the aluminium alloy strip according to the invention for the manufacture of semi-finished products or components of a motor vehicle, in particular structural components of a motor vehicle, also solves the aforementioned problem. In particular, structural components can be manufactured with very high degrees of deformation and assume very complex forms without requiring particularly complicated forming operations. In particular, these are also particularly corrosion-resistant in painted form, in particular to intercrystalline corrosion and filiform corrosion.
[0054] According to a further teaching of the present invention, the aforementioned problem is solved by a structural component of a motor vehicle, in particular an interior door part of a motor vehicle comprising at least one formed sheet of an aluminium alloy according to the invention. As stated above, tests have shown that the aluminium alloy according to the invention not only displays the necessary forming properties in a soft-annealed state but at the same time guarantees the necessary corrosion resistance and strength of the structural components.
[0055] In order to achieve the optimum degrees of deformation, the structural component according to the invention is manufactured from a strip which has been produced by means of the method according to the invention. It has been found that, with the method according to the invention, the forming properties as well as the strength properties of the structural components can be achieved in a reliable manner, so that an economical production of the structural components which fulfill the aforementioned prerequisites is possible.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0056] The invention is explained in more detail in the following with reference to exemplary embodiments in combination with the drawing. In the drawing:
[0057] FIG. 1 shows a flow chart of a first exemplary embodiment of the method according to the invention for the manufacture of an aluminium alloy strip;
[0058] FIG. 2 shows a flow chart for a further exemplary embodiment of the method according to the invention; and
[0059] FIG. 3 shows a diagrammatic representation of an exemplary embodiment of a structural component of a motor vehicle.
DETAILED DESCRIPTION OF THE INVENTION
[0060] FIG. 1 shows a first exemplary embodiment in the form of a schematic flow chart. In a first step 2 the rolling ingot is cast, for example using the DC continuous casting method or using the strip casting method. In the method step 4 , the ingot is then heated to a temperature of 500° C. to 600° C. and held at this temperature for at least 0.5 h, preferably at least 2 h for homogenization. The rolling ingot homogenized in this way is then hot rolled at a temperature of 280° C. to 500° C., preferably 300° C. to 400° C. to a final thickness of 3 to 12 mm. Then, in the step 8 a cold rolling to final thickness takes place, followed by a recrystallising final soft annealing according to step 10 . During the cold rolling to final thickness in one or more passes, the degree of reduction must amount to at least 50%, preferably at least 70%, in order to create a sufficiently fine-grained microstructure during the final soft annealing. The final soft annealing, during which the strip is again recrystallized, takes place in the chamber furnace at 300° C. to 400° C., preferably at 330° C. To 370° C. in step 10. Despite the alloy components of Mg, Si, Fe and Mn according to the invention it is not possible to use a continuous furnace for the manufacture of the aluminium alloy strip according to the invention, since different microstructures would be created due to the different heating and cooling rates.
[0061] Alternatively to producing the aluminium alloy strip without intermediate annealing, an intermediate annealing can also be carried out according to step 14 in a chamber furnace at 300° C. to 400° C., preferably at 330° C. to 370° C., whereby a degree of reduction of at least 50%, preferably at least 70%, should be guaranteed both before the intermediate annealing and after the intermediate annealing in order to have a positive effect on the fine-grained nature of the microstructure after the recrystallising final soft annealing. Optionally, after the casting of the rolling ingot in step 2 , a milling according to step 12 of the upper side and underside of the rolling ingot can take place in order to minimize the influence of impurities occurring on the edges of the ingot during production of the rolling ingot on the finished product. In particular, this has a positive influence on the corrosion resistance of the components.
[0062] FIG. 2 shows a further flow chart which, alternatively to step 4 , shows the step 16 of homogenization. The homogenization has an influence on the fine-grained nature of the desired final microstructure of the strip or finished component. In order to further improve the fine-grained nature of the microstructure, the homogenization is carried in multiple stages. Thus, instead of the step 4 in FIG. 1 , in FIG. 2 a homogenization step 16 is carried out. The homogenization step 16 first involves a first homogenization phase, step 18 , in which the milled or unmilled rolling ingot is heated to a temperature of 550° C. to 600° C. for at least 0.5 h, preferably at least 2 h. In a next step 20 the rolling ingot heated in this way is cooled to a temperature of 450° C. to 550° C. and held at this temperature for at least 0.5 h, preferably at least 2 h, as shown in FIG. 2 in step 22 .
[0063] Alternatively, after the first homogenization step 18 the rolling ingot can also be cooled to room temperature in a step 24 and, in a following step 26 , heated to the temperature for the second homogenization. This is for example necessary if the rolling ingot needs to be stored between the homogenization steps. Optionally, this phase at room temperature can be used to mill the rolling ingot on its upper side and underside, step 28 . After the second homogenization step 22 the hot rolling takes place as represented in FIG. 1 with the parameters shown there. It has been found that the multi-stage homogenization, in particular the two-stage homogenization, leads to a finer microstructure in the end product.
[0064] The effect according to the invention of providing a medium-strength and very highly formable aluminium alloy or aluminium alloy strip was proved on the basis of 10 exemplary embodiments.
[0065] First, 10 different rolling ingots consisting of different alloys were cast using the DC continuous casting method. The upper sides and undersides of the rolling ingots were milled after casting according to step 12 . A two-stage homogenization was then carried out in which the rolling ingots were first kept for 3.5 h at 600° C. and then for 2 h at 500° C. Directly following homogenization, the rolling ingots were directly hot rolled at approximately 500° C. into an aluminium alloy hot strip with a thickness of 8 mm. The 8 mm thick hot strip was in each case finally cold-rolled, without intermediate annealing, to a final thickness of 1.5 mm, i.e. with a degree of reduction of more than 70%. The recrystallising final soft annealing of the cold-rolled aluminium alloy strips with a thickness of 1.5 mm took place for 1 h at 350° C. in a chamber furnace. The different tested aluminium alloys are shown in Table 1.
[0000]
TABLE 1
Var-
(C): Comparison
Aluminium alloy components in % by weight,
iant
(I): Invention
Si
Fe
Cu
Mn
Mg
Cr
1
C
0.66
0.66
0.26
0.7
0.62
0.14
2
C
0.53
0.46
0.19
0.52
0.44
0.13
3
C
0.67
0.66
0.27
0.69
0.61
0.0005
4
C
0.73
0.68
0.0016
1.0
0.67
0.0002
5
I
0.72
0.69
0.0016
0.74
0.66
0.0006
6
I
0.67
0.65
0.07
0.69
0.61
0.0005
7
I
0.72
1.0
0.0017
0.72
0.66
0.0004
8
I
0.8
0.68
0.0015
0.72
0.63
0.0003
9
C
0.4
0.41
0.004
0.47
0.41
0.001
10
C
0.5
0.27
0.0013
0.66
0.42
0.0008
[0066] The variants 1 to 4 as well as 9 and 10 are comparison examples which do not correspond to the aluminium alloy according to the invention. In contrast, the exemplary embodiments 5 to 8 correspond to the aluminium alloy compositions claimed according to the invention.
[0067] As well as the yield strength R p0.2 , the tensile strength R m , the uniform elongation A g , the elongation at break A 80mm and the SZ 32 cupping in millimetres achieved during stretch forming of cold-rolled aluminium alloy strips produced in this way were measured. The values for the yield strength R p0.2 as well as the tensile strength R m were measured in the tensile test perpendicular to the rolling direction of the sheet according to DIN EN ISO 6892-1:2009. The uniform elongation A g as well as the elongation at break A 80mm in per cent were measured according to the same standard, in each case perpendicular to the rolling direction of the sheet, using a flat tensile test specimen according to DIN EN ISO 6892-1:2009, Annex B, Form 2. In addition, the forming behaviour can for example be measured in an SZ 32 stretch forming test by means of an Erichsen cupping test (DIN EN ISO 20482), in which a test body is pressed against the sheet, so that a cold deformation occurs. During the cold deformation, the force as well as the punch movement of the test body are measured until a drop in load, caused by the formation of a crack, occurs. In the present exemplary embodiments, the cupping test was carried out with a stamping head diameter of 32 mm, matched to the thickness of the sheet and a die diameter of 35.4 mm, using a Teflon drawing foil to reduce friction. An overview of the results is provided in Table 2.
[0000]
TABLE 2
Var-
(C): Comparison
R p0.2
R m
A g
A 80 mm
SZ32
iant
(I): Invention
N/mm 2
N/mm 2
%
%
mm
1
C
65
145
19.6
26.5
15.8
2
C
52
131
21.9
30.3
16.2
3
C
60
135
22.7
30.3
16.4
4
C
51
122
22.3
33.5
15.6
5
I
48
112
23.1
35.3
16.0
6
I
47
118
23.5
35.0
16.5
7
I
50
120
23.4
36.2
16.1
8
I
47
112
23.8
36.6
15.0
9
C
41
98
23.6
37.9
16.5
10
C
41
102
24.2
38.0
16.3
[0068] Comparing the variant 2 for example with the variants 5 to 8 according to the invention, the exemplary embodiments show that too great a reduction in the content of Si, Fe, Mn, Mg combined with an increase in the content of Cu and Cr means that, while the yield strength values remain above 45 MPa, the elongation at break is reduced significantly to around 30%. This effect can be proved if the Mn content alone amounts for example to 1.0%, which already reduces the elongation at break A 80mm to below 35%, variant 4. The variants 9 and 10 show the effect of reduced contents of Si, Fe, Mn and Mg. While the comparison examples 9 and 10 display a very good elongation at break A 80mm , with more than 35%, the yield strength is, at 41 MPa, below that of the exemplary embodiments 5 to 8 according to the invention.
[0069] The exemplary embodiments according to the invention displayed very good forming behaviour, in particular under high degrees of deformation, which can be seen from the very good SZ 32 stretch forming results and the high elongation values both for uniform elongation A g as well as the elongation at break A 80mm .
[0070] These results show that, overall, the critical factor is the interrelationship between the alloy contents of Si, Fe, Mn, Mg, whereby the contents of the components Cr and Cu must be kept particularly low; preferably, the Cu content is ≦0.05% by weight, preferably ≦0.01% by weight and the chrome content is ≦0.01% by weight, preferably ≦0.001% by weight. Coupled with the very good corrosion-resistance of the exemplary embodiments, semi-finished products and components for vehicles, in particular structural components such as interior door parts, can be provided which not only meet the specifications required within this field of application in terms of mechanical and chemical properties, but can also be manufactured economically using few forming operations.
[0071] The aluminium alloy strips produced according to the invention are therefore ideally suitable for providing, for example, structural components of a motor vehicle, such as the interior door parts 30 illustrated in FIG. 3 , or for use in their manufacture. The interior door part is manufactured from a sheet of an aluminium alloy according to the invention with a thickness of 1.5 mm which provides a window frame simply through forming operations, but without joining operations.
[0072] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0073] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0074] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | An aluminium alloy for the manufacture of semi-finished products or components of motor vehicles, a method for the manufacture of a strip made of an aluminium alloy according to the invention, a corresponding aluminium alloy strip or sheet as well as a structural component of a motor vehicle consisting of an aluminium alloy sheet which includes the following alloy components in % by weight: 0.6%≦Si≦0.9%, 0.6%≦Fe≦1.0%, Cu≦0.1%, 0.6%≦Mn≦0.9%, 0.5%≦Mg≦0.8%, Cr≦0.05%, the remainder Al and impurities, individually up to a maximum of 0.05% by weight, in total up to a maximum of 0.15% by weight. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to U.S. Provisional Application No. 60/426,302 filed Nov. 14, 2002 which is hereby incorporate herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to vapor compression systems, and more specifically to a vapor compression apparatus with a charging element for electrically stimulating the refrigerant, and a method for enhancing the performance of heat pump and refrigeration equipment and the efficiency of vapor compression systems.
BACKGROUND
[0003] In the present state of the art, vapor compression systems are used in a number of applications to cool an environment. Vapor compression is used in air conditioners, refrigerators, freezers, blast freezers and other cooling systems. Cooling is achieved by evaporating a refrigerant or refrigeration media under reduced pressure to lower the temperature of the refrigerant and absorb heat from an environment.
[0004] In conventional vapor compression systems, refrigerants or refrigerant mixtures with low boiling points are used as the working fluid. The refrigerant is pumped to a compressor which elevates the temperature and pressure of the refrigerant. The hot refrigerant is discharged to a first heat exchanger, or condenser, to remove heat from the refrigerant. As heat is removed in the condenser at elevated pressure, the refrigerant converts to the liquid phase. The refrigerant is then conveyed to an expansion valve that rapidly reduces the pressure of the refrigerant. The rapid pressure reduction causes the refrigerant to flash into a liquid and vapor mixture having a very low temperature. The refrigerant is discharged to a second heat exchanger, or evaporator, where the refrigerant absorbs heat. The added heat converts a substantial portion of the remaining liquid phase to the vapor phase. The refrigerant is cycled back to the compressor, where the foregoing process is repeated.
[0005] A significant problem with present vapor compression systems is the excessive cost of operation. Vapor compression consumes a significant amount of energy. Energy efficiency in vapor compression systems is often limited by incomplete or inefficient evaporation and condensation of the refrigerant. When evaporation is incomplete, some of the refrigerant enters the compressor shell in the liquid phase. The compressor must consume additional energy to boil the liquid refrigerant that enters the compressor shell. This reduces the coefficient of performance (COP) of system components and overall efficiency of the system.
SUMMARY OF THE INVENTION
[0006] In a first aspect of the present invention, a vapor compression apparatus is provided that efficiently evaporates a working fluid to cool an environment. A compressor is operable to increase the pressure and temperature of the working fluid. The system also includes a condenser that is operable to absorb heat from the working fluid. An expansion valve is operable to decrease the pressure of the working fluid. An evaporator is operable to transfer heat to the working fluid, and a charging element is operable to apply an electric charge to the working fluid.
[0007] In another aspect of the invention, a refrigeration system is provided that includes a working fluid operable to absorb heat, a fluid path comprising a conduit through which the work flows, and a triboelectric charging element positioned along the fluid path so that the working fluid flows over a surface of the charging element. The charging element is formed of a material having a triboelectric working function that is substantially different than the triboelectric working function of the working fluid, so that the working fluid is triboelectrically charged by flowing over the charging element.
[0008] In another aspect of the present invention, a method for operating a vapor compression system is provided. A working fluid is compressed to elevate the pressure and temperature of the working fluid. The working fluid is discharged to a condenser to release heat from the working fluid and convert the fluid to a liquid phase. The working fluid is discharged from the condenser to an expansion device to convert the working fluid to a vapor phase. The working fluid is discharged from the expansion device and heat is transferred to the working fluid. In addition, an electrical charge is applied to the working fluid to improve the efficiency of the process
[0009] The present invention may be constructed and operated without the need for a highly skilled technician. In operation, the present invention increases the cooling capacity and COP of the evaporator. Specifically, the present invention improves the expansion of the working fluid in the evaporator, thereby improving the efficiency of the overall system. The enhanced performance of the system and reduced cycling lowers overall power consumption in the system, conserving energy and lowering greenhouse gas emissions to the environment.
DESCRIPTION OF THE DRAWINGS
[0010] The foregoing summary as well as the following description will be better understood when read in conjunction with the figures in which:
[0011] FIG. 1 is a block diagram of a refrigeration system embodying aspect of the present invention;
[0012] FIG. 2 is a section of the system illustrated in FIG. 1 detailing an implementation of a triboelectric dielectric material;
[0013] FIG. 3 illustrates possible location of the triboelectric generating station on an evaporator circuit; and
[0014] FIG. 4 illustrates refrigerant lines from refrigerant distributor to evaporator circuits with electrostatic triboelectric union.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIGS. 1-4 in general, and to FIG. 1 specifically, a schematic view of a vapor compression system in accordance with the present invention is shown and designated generally as 20 . The system 20 is operable to condense and evaporate a working fluid which flows through the system. A magnetic field is generated through the working fluid to enhance the coefficient of performance and energy efficiency of the system 20 .
[0016] The vapor compression system 20 comprises a compressor 22 , a condenser 24 , an expansion valve 26 and an evaporator 28 . Depending on operating conditions, the system 20 may also incorporate other components used in vapor compression, including but not limited to a pre-condenser, post-condenser, pre-evaporator, post-evaporator, reversing valve, suction accumulator, and other components. The system 20 may use any type of heat exchanger in the condenser 24 and evaporator 28 , including but not limited to refrigerant/air, refrigerant/water or refrigerant/anti-freeze exchangers.
[0017] A charging element 30 is connected to the system to apply an electric charge to the working fluid. The electric charge is applied to the working fluid in the liquid phase to disrupt intermolecular forces in the working fluid and enhance expansion of the working fluid molecules. This reduces the amount of residual liquid that is boiled in the compressor shell, lowering the power consumption of the compressor and improving the overall efficiency of the system. The direction of flow of the working fluid in the system 20 is represented by the arrows in FIG. 1 .
[0018] The system 20 is intended to enhance the performance of a number of working fluids in vapor compression systems, including but not limited to pure refrigerants and multi-component HFC mixtures. The type of working fluid is dependent on, among other things, the desired application and operating temperatures for the condenser and evaporator. The present invention may enhance performance of working fluids at condenser temperatures between 20° C. and 90° C., and evaporator temperatures between −85° C. and 25° C. The system 20 may be used with any pure refrigerant or refrigerant mixture, including but not limited to R-12, R-22, R-502, R-11, R-114, R-134a, R-507 (R-125/R-143a:50/50%), R-404A (R-125/R-143a/R-134a:44/52/4%), R-410A (R-32/R-125:50/50%), and R-407C (R-32/R-125/R-134a:23/25/52%). In addition, ammonia methane, ethane, propane, butane, pentane and carbon dioxide may be used as working fluids in the present invention. The foregoing list of refrigerants represents just some of the possible refrigerants that may be used, and is not intended to be exhaustive or exclude other refrigerants not explicitly mentioned. In the description that follows, the system 20 will be described simply as using a refrigerant, with the understanding that this may include a variety of pure refrigerants, multi-component HFC refrigerant mixtures, and other working fluids suitable for different applications.
[0019] Preferably the refrigerant is a multi-component HFC refrigerant mixture, and ternary refrigerant mixtures are most preferred. However, binary mixtures and pure refrigerants such as R-134A may also be used. Alternatively, the system may use R-404A and R-410A refrigerant mixtures.
[0020] Referring now to FIGS. 1-2 , the system 20 will be described in greater detail. The system 20 is a closed loop system, in which the refrigerant is recycled. A fluid line 40 connects the compressor 22 , condenser 24 , expansion valve 26 and evaporator 28 in the closed loop.
[0021] The charging element may comprise a conductive element that provides an electrical charge from an external source. However, preferably the charging element is operable to triboelectrically charge the working fluid. Triboelectric effects are experienced when electrostatically different materials are rubbed or come in physical contact with each other. For instance, the rubbing of silk material of a glass rod has been known to the scientific community for centuries as a triboeictric or electrostatic producing effect. The triboelectric working function of a material relates to the tendency to appropriate electrons from other materials. More specifically, a material that has a higher work function than a second material will tend to appropriate electrons from the second material when the two materials are brought into contact. The effect is increased when the two elements are rubbed together. Still further, the greater the dissimilarity between the working function of two materials, the greater the triboelectric effect.
[0022] Although not exhaustive, the following list ranks a series of elements from most likely to give up an electron to least likely. The element at the top of the list has the lowest work function, the element at the bottom of the list has the highest work function.
Dry human skin Asbestos Leather Rabbit fur Acetate Glass Human hair Nylon Wool Lead Silk Aluminum Paper Cotton Steel Wood Amber Sealing wax Hard rubber MYLAR Nickel, Copper Brass, Silver Gold, Platinum Sulfur Polyester Celluloid Styrene (Styrofoam) Orion Acrylic Saran Wrap Polyurethane Polyethylene (like Scotch Tape) Polypropylene Vinyl (PVC) Silicon Teflon Silicon Rubber
[0060] In other words, the further apart two elements are from one another along the Triboelectric series shown in the list above, the greater the triboelectric effect (i.e. the greater the triboelectric charging).
[0061] According to the chart the highest electrostatic generating capabilities come from selecting materials near the ends of the series. Glass and teflon are materials that are capable of generating high triboelectric effect when frictional contact is made. It should be noted that teflon is basically a polymerized refrigerant gas and that teflon and CFC and HFC refrigerant mixtures have this common chemical origin.
[0062] In order to generate the maximum charge on a refrigerant or working fluid, it is advisable to select materials from the extreme positions of Triboelectric chart. The triboelectric chart represents a sample of dissimilar materials, but it should not be construed as a comprehensive list. As an example, glass used in combination with a Refrigerant of CFC, HCFC or HFC origin is chosen. Other materials with the same work function can be chosen. Another example would be Asbestos in connection with a CFC, HCFC or HFC refrigerant. The use of materials with similar charge properties is not desirable (e.g. Teflon and silicon rubber) since they possess similar electric properties.
[0063] The effect of electrostatically charging a fluid can result in altering or disrupting the intermolecular forces of the refrigerant as well as providing greater thermal heat transfer through the full use of the latent heat of evaporation. Electrostatically voltages generated by such means can exceed 70 Kilo-Volts or more. Each single triboelectric generating station produces electrostatic charges causing a mutual repulsion between molecules and reduces the covalent bonds between the molecules. This in turn, reduces the Van de Wales forces that bond the refrigerant molecules and increases the rate of nucleation and bubble generation of refrigerant vapor subject to boiling.
[0064] In FIG. 1 , a block diagram of a refrigeration system is provided and FIG. 2 shows the possible position of triboelectric generating stations.
[0065] In order to create an electrostatic charge on the refrigerant molecule, a charging element, such as a glass sleeve or Positive End of Series PES (materials with lower work function) serves as the triboelectric material. The choice of PES depends upon the many parameters including but not limited to type of the refrigerant, chemical composition, electrical properties and friction factors. A glass sleeve is desired since the glass is not only capable of rendering the refrigerant charged as the fluid passes through, but it also serves as a dielectic union. The charging element may be an insert positioned within the conduit through which the refrigerant flows. Alternatively, the charging element may be in-line with the conduit. In other words, the conduit abuts the charging element and the charging element is essentially a section along the length of the conduit. Configured in this way, the conduit would appear as a length of conduit, the a length of glass (or other material) and then another length of conduit.
[0066] As refrigerant 45 passes over or through the triboelectric element a charge is generated. The glass also reduces pressure drop of refrigerant across the triboelectric element. If the conduit is formed of a conductive material, such as a metal, it may be desirable to utilize an insulating element adjacent the triboelectric element; More specifically, by charging the working fluid, there may be a tendency for the charge to create sparking between the working fluid and the conduit if the conduit is conductive. Accordingly, preferably the insulating element is formed of a material that has a similar or substantially similar triboelectric working function as the working fluid. In this way, the triboelectric charging does not increase as the working fluid passes over or through the insulating element. As with the triboelectric element, the insulating element may be disposed within the conduit (like a liner) or the insulating element can be in-line with the conduit.
[0067] The triboelectric elements can be installed at any point of the heat exchanger to enhance the thermal capacity. However, it is most advantageous to have the triboelectric generating section located after the heat exchanger distributor 50 at the inlet to the heat exchanger as the refrigerant enters the evaporator circuits 55 . Evaporators have many circuits and each circuit acts as an evaporating length as shown in FIG. 3 .
[0068] Electrostatic charges in the refrigerant or refrigerant mixture passing through the sleeve as presented in FIG. 4 and enhances rate of nucleation, heat transfer rate, heat flux and increases the thermal capacity of the heat exchanger thus increasing the cooling capacity. This in turn reduces compressor power, enhances the system performance and coefficient of performance. Other benefits include but not limited to increase of compressor life span and less system maintenance.
[0069] Accordingly, it may be desirable to locate other dielectric sections 30 at various distances along the heat exchanger evaporator length depending upon various design parameters including but not limited to the length of the heat exchanger and the boiling point of the refrigerant. The use of various triboelectric stations will enhance the rate of nucleation along the boiling length of the evaporator and reduce the liquid refrigerant that is carried over to the compressor chamber.
[0070] The aforementioned series of dielectric unions electrostatically isolates the evaporator from the rest of the refrigeration equipment since only the evaporator is electrostatically charged. In FIG. 2 a grounding strap 60 is located at the end of the evaporator section 55 . This allows the charges to dissipate after the tribolectric charge as the refrigerant passes through the final section of the evaporator to the compressor.
[0071] The triboelectric generating stations can be used for other types air and liquid cooled heat exchangers where boiling takes place in many applications including but not limited to refrigeration, air conditioning, freezing, blast freezing, heating, steam boilers, waste heat boilers, co-generation systems and combined cycles.
[0072] The triboelectric unions will be placed at the entrance to the heat exchangers evaporating lengths or/and circuits. At certain applications it is also advantageous to use more than one triboelectric union in the heat exchanger circuits. The net benefit of the use of triboelectric in the aforementioned applications is to enhance the thermal capacity, the performance of equipment and to reduce specific fuel consumption rate of equipment.
[0073] The terms and expressions which have been employed are used as terms of description and not of limitation. There is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof. It is recognized, therefore, that various modifications are possible within the scope and spirit of the invention. Accordingly, the invention incorporates variations that fall within the scope of the following claims. | A vapor compression apparatus and a method for operating a vapor compression system are provided. A working fluid is conveyed through a vapor compression system having a fluid line. A charging element is connected to the fluid line to direct an electric charge into working fluid. The electric charge is operable to disrupt intermolecular forces and weaken intermolecular attraction to enhance expansion of the working fluid to the vapor phase, increasing the capacity, performance and efficiency of the system components, and reducing system cycling mechanical wear and energy consumption. | 5 |
TECHNICAL FIELD
[0001] The present embodiments relate to generally to swimming pools and more specifically to swimming pool skimmers.
BACKGROUND
[0002] Swimming pools have become popular for both recreation and exercise. FIG. 1 is an illustration of a conventional above ground swimming pool 10 . Outdoor swimming pools such as above ground swimming pools 10 naturally accumulate a large amount of debris. In order to mitigate the debris from fouling a circulating water system, many pools incorporate a swimming pool skimmer.
[0003] FIG. 2 is a perspective view of an example of a pool skimmer 20 of a conventional above ground swimming pool 10 . The pool skimmer 20 has a large rectangular opening 28 with a weir door 24 that controls how water enters the pool skimmer 20 . The pool skimmer 20 generally includes a basket (not shown) for catching some of the larger surface debris and a cylindrical discharge cylinder 26 at the bottom of it which connects to filter hoses of a circulating water system. The pool skimmer 20 also includes an access lid 22 that allows access to the basket for removal of debris.
[0004] FIG. 3 is an illustration of a pool skimmer 20 attached to an above ground swimming pool 10 . A pool skimmer 20 in an above ground swimming pool 10 is attached to the wall 32 of the pool 10 by installing a faceplate (not shown) on the inside of the above ground swimming pool 10 and the pool skimmer 20 on the outside of the swimming pool 10 .
[0005] FIG. 4 is a sectional view of the pool skimmer 20 illustrating water entering the pool skimmer 20 . FIG. 4 illustrates a pool skimmer 20 in use in an in-ground swimming pool. Water enters the pool skimmer 20 while a pump (not shown) for circulating water is running and the water flows inward, the top of the weir door 24 pulls in a bit and forces more water to enter the pool skimmer 20 more from the surface 42 rather than from below the surface 44 . The weir door 24 floats at the water level, causing a suction action to speed up the water flow and to pull in debris that accumulates at the surface 42 . Greater flow from the surface 42 of the water translates to greater removal of surface, floating debris that would not be taken out as effectively without the weir door 24 , thus, enhancing the debris removal process. This effect is desired in a swimming pool 10 and results in the skimming action of the pool skimmer 20 that removes floating debris (leaves, insects, pine needles, pollen, etc.).
[0006] FIG. 5 is a sectional view of the pool skimmer 20 that includes the skimmer basket 52 for catching debris. Because large surface debris received by pool skimmer 20 is caught in the skimmer basket 52 , an access lid 22 which opens into an open chamber 56 to allow removal of the skimmer basket 52 for emptying the caught debris. The access lid 22 covers an access opening 54 allowing access to the open chamber 56 into which a quantity of the pool water enters the pool skimmer 20 . Access opening 54 may be, for example, cylindrical in shape to complement a circular shaped access lid 22 . The access lid 22 may include a central hole 58 by which the access lid 22 may be removed to access the skimmer basket 52 . Access hole 58 has the purpose of enabling a user to insert a finger or tool into the access hole 58 to pull access lid 22 up for removal of the access lid 22 and allowing access to skimmer basket 52 . Access lid 22 may be configured with the access hole 58 in alternative configurations other than that shown in FIG. 5 or access lid 22 may include more than one access hole 58 .
[0007] FIG. 6 is an illustration of an example of activity in a conventional above ground swimming pool 10 causing turbulence on the surface of the above ground swimming pool 10 .
[0008] Referring again to FIGS. 4 and 5 , the pool skimmer 20 receives water primarily from the surface 42 . Thus, the increased activity in the above ground pool 10 as shown in FIG. 6 results in more turbulent water entering the pool skimmer 20 . Consequently, the turbulent water has the result of expelling water from the pool skimmer 20 through the access hole 58 of the access lid 22 . This discharge of excess water can result in the wasteful loss of water and results in more frequent resupply of water. This situation can have a more amplified effect in regions where draughts are frequent and water loss more important to prevent. Such regions also generally experience a high population of swimming pools.
[0009] Thus, there is a need for a device to prevent the excess loss of water through pool skimmers during times when excessive turbulence leads to a higher loss of water.
SUMMARY
[0010] A water conservation device is disclosed. The water conservation device includes a membrane and an uninterrupted flange comprising a cross sectional cylindrical shape that is attached to an entire outer edge of the membrane. The membrane is configured to completely cover a top of a swimming pool skimmer access opening and further configured to accept an access lid of the swimming pool skimmer opening over the membrane wherein the access lid holds the water conservation device in place when the access lid is attached to the access opening by which the membrane acts to prevent water from expelling from the access lid.
DRAWINGS
[0011] The following figures set forth embodiments of the invention in which like reference numerals denote like parts. Embodiments of the invention are illustrated by way of example and not by way of limitation in the accompanying figures.
[0012] FIG. 1 is an illustration of an example of a conventional above ground swimming pool;
[0013] FIG. 2 is a perspective view of an example of a pool skimmer of a conventional above ground swimming pool;
[0014] FIG. 3 is an illustration of an example of the pool skimmer attached to the swimming pool;
[0015] FIG. 4 is a sectional view of the pool skimmer in an in-ground swimming pool showing water entering the pool skimmer;
[0016] FIG. 5 is a sectional view of the pool skimmer that includes the skimmer basket;
[0017] FIG. 6 is an illustration of an example of activity in a conventional above ground pool;
[0018] FIG. 7 is an exemplary perspective view of a water conservation device of an embodiment of the present invention;
[0019] FIG. 7A is a perspective view of an exemplary flange attached to the water conservation device according to embodiments of the present invention;
[0020] FIG. 8 is a cut-away perspective view of an exemplary placement of the water conservation device onto the pool skimmer according to the present embodiments;
[0021] FIG. 9 is an exemplary operation of the water conservation device according to the present embodiments;
[0022] FIG. 9A is an exemplary scenario of the pool skimmer without the water conservation device;
[0023] FIG. 9B is an exemplary scenario of the pool skimmer including the water conservation device;
[0024] FIG. 10 is an exemplary perspective view of an alternate shape of a water conservation device of an embodiment of the present invention;
[0025] FIG. 10A is a perspective view of an exemplary flange attached to the alternate shaped water conservation device according to embodiments of the present invention;
[0026] FIG. 11 is an exemplary cut-away perspective view of a water conservation device in an alternative embodiment of the present invention;
[0027] FIG. 12 is an exemplary water conservation device applied to a pool skimmer of an in-ground pool.
DETAILED DESCRIPTION
[0028] The description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts and features described herein may be practiced. The following description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details. In some instances, well known, structures, techniques and components are shown in block diagram form to avoid obscuring the described concepts and features.
[0029] FIG. 7 is an exemplary perspective view of a water conservation device 70 in an embodiment of the present invention. FIG. 7 is meant as an example only to illustrate an embodiment of the invention but is not intended as a limitation of the present subject matter or its implementation. The water conservation device 70 includes a flexible central membrane 72 which may be made, for example, of a flexible vinyl fabric material. The vinyl fabric material may be, for example, polyethylene (PE), polyvinyl chloride (PVC), polyvinyl acetate (PVac) or polyvinyl fluoride (PVF), for example. The vinyl material may be, for example, between 16 and 24 mils in thickness.
[0030] The water conservation device 70 further includes a flange 74 which is encompasses the entire outside edge uninterruptedly and which can be seen in an enlarged view in FIG. 7A . FIG. 7A is a perspective view of an exemplary flange 74 attached to the entire circumference of membrane 72 according to embodiments of the present invention. Flange 74 may be made for example of a durable slightly rigid plastic material. The plastic material may be made of, for example, polyethylene, PVC or nylon. The flange 74 is configured to maintain the membrane 72 in a consistent shape and provide for easy handling. The flange 74 may, for example, have a cross section that is cylindrical in shape where the cylinder may have a cross sectional diameter of ⅛-¾ inches. The flange 74 is attached to the membrane 72 by, for example, a water proof flexible vinyl cement. The water proof flexible vinyl cement may include, for example, Weld-On 66 . In other embodiments, various other water proof flexible vinyl cements may be employed to attach the membrane 72 to the flange 74 . In still other embodiments, the membrane 72 may be attached to the flange 74 through use of a heat application device such as a heat welding gun.
[0031] As shown in FIG. 7 , the membrane 72 is circular in shape. However, the membrane 72 may be made in any shape that would provide for the water conservation of the present subject matter. As discussed in further detail below, the access lid 22 is placed over the water conservation device 70 as shown by dotted line 78 .
[0032] FIG. 8 is a cut-away perspective view of an exemplary placement of the water conservation device 70 onto the access opening 54 of the pool skimmer 20 according to the present embodiments. Water conservation device 70 is placed over the access opening 54 where membrane 72 completely covers the access opening 54 . The membrane 72 is made to completely encompass the diameter of the access opening 54 and further may be formed in a size that is between ½ and 1 inch larger than the diameter of the access lid 22 to allow “play” in the water conservation device 70 in the center of the water conservation device 70 and to permit easy placement under access lid 22 . The “play” in the center of water conservation device 70 is sufficient to allow a user to place a finger or tool in the access hole 58 when necessary to remove the access lid 22 but secure enough so that there is little of the membrane 72 that protrudes from the access opening 54 . A typical access lid 22 of a pool skimmer 20 may, for example, have a diameter of 10 inches. In this case, the membrane 72 may be between 10½ inches and 11 inches in diameter. Because the access hole 58 is required to open the pool skimmer 20 so that the skimmer basket 52 may be removed, the play allowed in water conservation device 70 maintains access to the access hole 58 and thus allows removal of access lid 22 for access to the skimmer basket 52 in the access chamber 56 . Furthermore, water conservation device 70 , due to its unique design may be easily removed when the activity in the swimming pool 10 causes little turbulence or when the swimming pool 10 is vacant. The play in the water conservation device 70 allows easy opening of the access lid 22 through the access hole 58 and easy handling by use of the attached flange 74 for removal.
[0033] The user may easily manipulate the placement of water conservation device 70 by handling the water conservation device 70 by the flange 74 . Once placed over the access opening 56 , the access lid 22 is placed over water conservation device 70 . The Access lid 22 and the access opening 56 are assembled tongue-in-groove 82 fashion. Water conservation device 70 is placed such that the membrane 72 fits inside the tongue-in-groove 82 of the access lid 22 and the access opening 54 assembly. Again, the play is sufficient to allow a user to place a finger in the access hole 58 but secure enough so that there is little of membrane 72 that protrudes from the access cylinder 56 and the access lid 22 .
[0034] The swimming pool skimmer 20 may include access opening 54 and access lid 22 that are shaped other than circular. In that case, water conservation device 70 would be configured to compliment the shape of access opening 54 and access lid 22 and membrane 72 would be configured to maintain the dimensions that are between ½ and 1 inch larger than dimension of the swimming pool skimmer access opening 54 .
[0035] FIG. 9 is an exemplary water conservation device 70 in operation in a pool skimmer 20 of an above ground swimming pool 10 . FIG. 9A illustrates a scenario in which turbulent activity in the swimming pool 10 is present and the water conservation device 70 is absent from the pool skimmer 20 , water easily expels from access hole 58 . Water is therefore lost to evaporation or seepage into the soil and must be replenished in swimming pool 10 resulting in needless water loss.
[0036] FIG. 9B illustrates the same scenario as FIG. 9A except that water conservation device 70 is present in pool skimmer 20 . When placed as described above with respect to FIG. 8 , the water conservation device 70 completely covers access hole 58 , thus preventing water from being expelled from the access hole 58 when activity causing turbulent water conditions occur. Water in the scenario of FIG. 9B thus results in the prevention of water loss from the swimming pool 10 .
[0037] FIG. 10 is an exemplary perspective view of an alternate shape of a water conservation device of an embodiment of the present invention. As illustrated in FIG. 10 , one possible alternate shape of water conservation device 100 is square. Similar to the circular water conservation device 70 shown in FIG. 7 , the water conservation device 100 includes a flexible central membrane 102 that is square and which may similarly be made, for example, of a flexible vinyl fabric material. The vinyl material may be, for example, between 16 and 24 mils in thickness.
[0038] The water conservation device 100 further includes a flange 104 which is encompasses uninterruptedly the entire outside edge and which can be seen in an enlarged view in FIG. 10A . FIG. 10A is a perspective view of an exemplary flange 104 attached to the entire circumference of the membrane 102 according to embodiments of the present invention. Flange 104 may be made for example of a durable slightly rigid plastic material. The plastic material may be made of, for example, polyethylene, PVC or nylon. The flange 104 is configured to maintain the membrane 102 in a consistent shape and provide for easy handling. The flange 104 may, for example, have a cross section that is cylindrical in shape where the cylinder may have a cross sectional diameter of ⅛-¾ inches. The flange 104 is attached to the membrane 102 by, for example, a water proof flexible vinyl cement.
[0039] FIG. 11 is a cut-away perspective view of an exemplary alternative embodiment of the water conservation device 70 placed in a swimming pool skimmer 20 . In the embodiment illustrated in FIG. 11 , the access opening 54 and the lid 22 include a circumferential tongue-in-groove 116 on the circumference of the outer portion of the access opening 54 and the circumference of the outer portion of the lid 22 (not shown). In this embodiment, the water conservation device 70 is placed over the access opening 54 in which the flange 74 is configured with a circumferential dimension that corresponds to the circumference of the circumferential tongue-in-groove 116 of access opening 54 in order to fit precisely within the groove of circumferential tongue-in-groove 116 . The membrane 72 continues to cover the access opening 54 completely encompassing the diameter of the access opening 54 and further may be formed in a size that is between ½ and 1 inch larger than the diameter of the access opening 54 to allow “play” in the water conservation device 70 in the center of the water conservation device 70 and to permit easy placement under access lid 22 as described above. In the embodiment of FIG. 11 , the flange 74 includes a notch 114 corresponding to the notches of the tongue-in-groove 82 of the access lid 22 and access opening 54 . The flange 74 is also configure to have a cross sectional diameter sufficient so that the flange 74 does not interfere with the circumferential tongue-in-groove 116 of access opening 54 and lid 22 . The cross sectional diameter of the flange 74 may be, for example ¼ inches in diameter.
[0040] Although the above description has been made for above ground swimming pools, the described apparatus can be used for in-ground pools as well. FIG. 12 is an exemplary pool skimmer 120 for an in-ground pool. Pool skimmer 120 includes a large rectangular opening 122 with a weir door 124 that controls how water enters the pool skimmer 120 . Pool skimmer 120 also includes an access lid 126 covering the access opening 128 of the pool skimmer 120 . Similar to the description above (See, for example, FIGS. 8 and 11 ), water conservation device 70 is placed over the cylindrical opening 128 and secured by access lid 126 . Thus, water is prevented from being expelled when activity causing turbulent water conditions occurs.
[0041] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | A water conservation device is disclosed. The water conservation device includes a membrane and an uninterrupted flange comprising a cross sectional cylindrical shape that is attached to an entire outer edge of the membrane. The membrane is configured to completely cover a top of a swimming pool skimmer access opening and further configured to accept an access lid of the swimming pool skimmer opening over the membrane wherein the access lid holds the water conservation device in place when the access lid is attached to the access opening by which the membrane acts to prevent water from expelling from the access lid. | 4 |
CROSS REFERENCE TO RELATION APPLICATIONS
[0001] This application claims priority from U.S. provision application No. 62/056,513, filed on Sep. 27, 2014, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the field of washing and restoration of hard-to-restore items including soiled soft objects, and in particular to a system for monitoring restoration quality to a third party certified standard of soft objects being washed remotely.
BACKGROUND OF THE INVENTION
[0003] There are many examples where articles of clothing and other fabric or otherwise “soft” goods become soiled to the extent that often they are thrown away or used in a soiled condition because the goods cannot conventionally be returned to a clean state. To give one example: firefighters use outer wear which is of a fire-retardant fabric, better described below, which loses some of fire retardant properties as the fabric becomes soiled, notably with organics, smoke, soot, ash, mud, etc. Washing firefighting clothing must be done carefully so as to not disrupt the integrity of seams etc., and to a repeatable standard of cleanliness so that degradation of fire retardant capability is minimized and the fabric's fire retardancy restored to a predetermined and verifiably acceptable and safe level.
[0004] Washing such clothing has been accomplished using specialized large-object washing machines such as those provided commercially by Esporta Wash Systems Inc., the applicant herein. Descriptions of such machines are found in U.S. Pat. Nos. 6,374,644 and 6,732,553, which issued on Apr. 23, 2002, and May 11, 2004, respectively, for an Equipment Washer, and which are incorporated by reference herein. Such machines are also described in United States published patent applications 2004/0089030 A1, 2004/0231063 A1, and 2005/0193500 A1 published in May 13, 2004, Nov. 25, 2004 and Sep. 8, 2005, respectively, for an Equipment Washer, and which are incorporated by reference herein. In such machines the objects to be washed may be secured in bins or other means for immobilizing the object in a porous cage. An array of such cages may be formed around the perimeter of a porous rotary drum. The drum is mounted in a water-tight wash housing. Wash fluid; typically a combination of water, detergent, and other ingredients according to present formulas determined in accordance with the objects being washed, is introduced into the wash housing and the drum circulated through the wash fluid whereby hydraulic wash fluid pressure provides the cleaning medium as it is forced through and around the items being cleaned. Pre-set washing, rinsing, spinning, and extraction cycles are employed to remove the soilant from the objects, to then remove the detergents, etc. from the objects, and then to remove the moisture from the objects.
[0005] To give another example, restoration of objects salvaged from a fire, such as a residential home fire, or restoration of objects salvaged from flooding of a residence has been limited to date, hampered by lack of a trustworthy standard of cleanliness and a means to accomplish this within a verifiable monitoring system, so that presently often the objects are merely discarded and, to the extent possible, replaced with the proceeds of insurance coverage. Insurance companies thus are motivated to see such replacement more limited than is presently the case, so as to reduce the cost of insurance payouts, and the insured home-owners are motivated to see restoration in cases where replacement of soiled objects cannot be accomplished, for example, in the cases of irreplaceable clothing, or a child's loved stuffed animal toys, or heirlooms—the list goes on, as better described below.
[0006] In applicant's view it is preferable for the restoration industry, and in some instances, such as in the firefighting example, also a safety concern, to attempt to standardize standards of cleanliness which can be repeated and, importantly, verified including verified remotely, so as to allow the proliferation of restoration facilities employing the standards.
[0007] For items such as protective clothing worn by first responders such as firemen, the level of cleanliness and the manner of washing will affect the safety of first responder. For example, fire retardant clothing provides fire protection to specification when clean, for example when new, but with degraded fire retardency when soiled. Further, if not washed in a specialized washing machine such the applicant's washing machine mentioned above or for example such as the washing machine described below, then there is a risk of damage to seams and fabric that may degrade the safety of the clothing. It is thus in these cases a matter of safety for the first responder that the operator of the washing machine not cut corners by for example using different wash fluid consumables such as different detergent than those recommended and supplied by the applicant for its washing machines.
[0008] In the case of a remotely operated washing facility, it is very difficult to monitor washing operation or to monitor an otherwise remotely located washing machine operator so as to detect when the pre-set and certified washing protocols are not being followed. Again, if the protocols are not followed, then the cleanliness standard may not be met, and thus the insurance company customers and the restoration company customers may be dissatisfied with goods which have been returned to them which have allegedly been cleaned and restored to the desired standard.
SUMMARY OF THE INVENTION
[0009] One mechanism for avoiding the cutting of costs or the otherwise cutting of corners by operators of remotely located washing facilities is to monitor consumption of the consumables that are to be used in the washing protocols. The operators have to elect which washing recipe they will use for a particular item or set of items. The system described herein records that election, and records when the washing has been done. Each recipe will require a unique set of consumables be used. Tracking the consumables actually used and comparing that to the washing recipes that have been used, and the number of times those washing recipes have been cycled, allows the tallying of use, comparison to on-site inventory of consumables, and thus the detection by the monitoring system of any shortcuts being taken by the operators.
[0010] Tracking the consumables that have actually been used has proven to be difficult where tracking relies solely on a fluid metering system, for example working in conjunction with the fluid pumps assigned to each type of fluid consumable (for example detergents, etc.). In applicant's experience, fluid flow and volumetric meters which are available commercially are sufficiently inaccurate at the lower viscosities associated with preferred consumables, that tracking of overall consumption of consumables by an operator using such meters is at present undesirable. Advances in fluid flow rate metering and fluid flow volume metering may allow the future use of such tracking, which may then be monitored by the networked system described herein below.
[0011] In the meantime, the system presently knows an initial level of each consumable associated with each machine, knows the wash load/recipe types that a particular washing machine has washed, and the number of those loads. The amount of consumable consumed for each such wash is thus known, as it has been pre-measured for each load type/wash recipe how much consumable is consumed by the operation of a particular pump for its pre-set run-time as prescribed for each wash recipe.
[0012] Consumables are shipped from the system administrator to an operator as the consumables are ordered and re-ordered by the operator. The system tracks the consumables for a particular machine, for example using bar coding on the consumables which matches a serial number or other unique identifier to the serial number or unique identifier on the particular washing machine in need of re-supply. For example, the consumables may be shipped in 20 liters pails, or in larger containers. So long as the system knows the volume of each consumable which is shipped to the operator for a particular washing machine and so long as the on-going tally of consumable consumption is maintained and monitored by the system and system administrator, the comparison to usage may also be maintained to thereby assist in verifying that the certified standard of cleanliness is being maintained.
[0013] In a preferred embodiment the system is advised of, for example tracks in real time, the arrival of consumables at an operator's premises. Tracking may for example be done by the scanning of barcodes on the containers of consumables for upload to the system by, RFID, by feedback from the shipper, etc., or any combination of these. The object is to seamlessly track the balance between the consumption of consumables for each washing machine, and the timely re-supply of consumables and input of those re-supplied consumables into the washing machines. In this fashion any use of un-authorized consumables, for example a potentially inferior detergent, by an operator will be detected by the system and the particular machine may then be shut-down remotely by the administrator.
[0014] The insurance industry is not in, and to applicant's knowledge has no interest in being in, the restoration business. The insurance industry needs to be able to rely, in every instance of restoration, on the standard to which difficult to restore items are being restored. If in extreme circumstances where an insured claimant commences litigation against the insurance company alleging failure of the company to abide by its contractual obligations to cover the claimant's loss, then in such circumstances the insurance company likely must be able to show and prove sufficient due diligence in performance of its obligations. How the insurance company meets its standard of care owed to the claimant, and how it proves that it has met its standard of care required by law, is likely critical if the insurance company is, firstly, to avoid unhappy claimants in the first place; and, secondly, avoid liability in the unavoidable few instances of unhappy insured claimants who either intractably perceive they have been wronged by inadequate restoration when damaged goods should rightfully have been replaced and not restored, or when the insured claimants are fraudulently attempting to collect a windfall from the insurance company based on a specious claim.
[0015] In the system described herein, the insurance company meets its standard of care by having pre-approved, or by having a third party pre-approve on its behalf, protocols for restoration of categories of goods to be restored, where the pre-approval is based on independent assessment and verification of the restoration protocols. That is, for example, an independent third party, trusted by the insurance industry, and who is a proven expert in restoration, tests restoration protocols in specific instances, especially where restoration has in the past been difficult or next to impossible, and verifies that the restoration protocols that have been tested, including the process and consumables being used and the corresponding equipment being used, consistently achieve restoration of the specified goods to a high level or otherwise certified level. In the present instance the certified level of cleanliness is known as food-grade-safe.
[0016] Restoration to food-grade-safe has proven in applicant's experience to be a safe, high-level standard that can be tested for using an ATP tester which reads so-called Relative Light Units (RLUs). Thus whether restoration to food-grade-safe has been achieved is easily tested and verified using an ATP tester. One such ATP tester is provided by Hygiena/Medical Packaging of Camarillo, Calif. USA. It may to some seem strange to be restoring goods such as textiles in clothing, etc. to a standard literally sufficient to eat off (i.e. food-grade-safe), as in reality, prior to the damage event (example: flooding, sewage leakage, fire, etc.) the insured claimant's goods would not likely have been food-grade-safe. However, the present system described herein provides for attaining food-grade-safe levels of cleanliness and restoration. That standard in applicant's opinion likely exhibits the insurance company's required standard of care in restoration of insured claimant's goods, and may in fact exceed the required standard of care to which an insurance company will be held. Using an ATP tester, in applicant's experience a food-grade-safe level of cleanliness is indicated by a reading of substantially equal to ten RLUs.
[0017] So having the insurance industry embrace food-grade-safe as the required standard for restoration, allowing the insurance industry to save costs by restoring goods rather than replacing them as was done in the past, then begs the question of how to implement on a mass market scale, restoration centers which will meet the food-grade-safe standard in every instance of restoration in a virtually fail-safe method. This is a very difficult thing to do, where the number of restoration centers operating daily will be in the hundreds, if not thousands globally. Overseeing such a network so as to substantially guarantee to the insurance industry that in most if not all cases the food-grade-safe standard is being met is not possible without:
a) automated oversight and administration provided by networked computers, for example networked over the internet; b) the use of rigorously applied and enforced cleaning protocols including machine use procedures, recipes, and detergents and other consumables; c) the use of standardized automated cleaning machines which interface and cooperate with the operator and, via computer network, the central administrator of the system; d) the monitoring and analysis on a short-interval basis, for e.g. in real-time, of data received from every operational automated cleaning machine in every operational restoration center; and e) providing both-short interval reports summarizing the received short-interval, e.g. real time data, and other feedback to the central administrator to allow oversight and management by the central administrators as a fail-safe check on whether the food-grade-safe standard is being met by the operators.
[0023] In summary, the system for the remote monitoring of cleanliness to a pre-certified standard being achieved by washing machines as described herein may be characterized in one aspect as including:
[0024] At least one washing machine wherein each washing machine has a wash processor, and is adapted to wash items according to pre-determined pre-certified recipes using pre-certified consumables, which include pre-certified detergents. The consumables may be provided in removably couplable containers removably couplable to the washing machines. Each wash processor is adapted to communicate over the internet. An administrator processor, remote from the washing machines, adapted to communicate over the internet with each wash processor and to receive information from each wash processor on a repeating, short-time interval. Each said wash processor is adapted to provide to the administrator processor the volumetric consumption of consumables by its corresponding washing machine over successive wash loads according to the recipes. The recipes correspond to characteristics of the wash items in each corresponding wash load and the corresponding nature of the spoilage. The characteristics of the wash items may include what the items are made of; e.g., plastic, fabric, leather, foam/padding or otherwise puffy, etc., or any combination of such materials whether they are specialty wash items such as PPE, and whether the items are heavily, moderately or lightly soiled by various spoilants, for example from provider of insurance over the wash items against damage to the wash items by reason of at least one of the group of spoilants. The certification standard of cleanliness may be advantageously be food-grade-safe, for example defined as a measured RLU reading of substantially ten RLUs.
[0025] The administrator processor may use the information from the wash processor for each washing machine to track the consumption of the consumables by each washing machine, to track the available volume of the consumables available at each washing machine, and to compare the consumption of the consumables to the available volume of the consumables at each said washing machine, and to determine therefrom status information including an anticipated re-supply request for consumables from an operator of each washing machine. Upon failure to receive a re-supply request for any one washing machine the administrator or administrator processor may execute and deliver a remote warning, and/or shut-down of the corresponding washing machine.
[0026] In one embodiment the information provided to the administrator or administrator processor also includes tracking the re-supply of the re-supply consumables to determine an estimated arrival of the re-supply consumables at each washing machine. The information provided may include for example information updating the available volume of the consumables at each washing machine, and comparing a rate of consumption of the consumables to the available volume of consumables at each washing machine to determine an estimation of when the consumables will be substantially completely consumed by each washing machine and to thereby determine an anticipated re-supply request.
[0027] Where the group of wash items being washed includes heavy soiled items, the wash processor may reduce operator control of wash variables controlled by said wash processor for the corresponding washing machine. For example, the wash processor may substantially eliminate operator control of the wash variables for wash items.
[0028] In using the system, a method of use includes employing the pre-certified recipes and the pre-certified consumables that have been independently pre-certified by a third party certifier in each washing machine so as to clean and restore the wash items to a pre-determined certification standard of cleanliness approved by the provider of insurance over the wash items against damage to the wash items by reason of at least one of the group of spoilants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] In the following illustrations like reference numerals denote corresponding parts in each view, wherein:
[0030] Washing Machine Embodiments
[0031] FIG. 1 is, in front, left-side perspective view, a washing machine according to one embodiment, with its front door closed.
[0032] FIG. 1 a is, in left perspective view, a further embodiment of a washing machine
[0033] FIG. 2 is, in front elevation view, the washing machine of FIG. 1 with the front door being swung open and items for washing being held waiting for loading into the washing machine.
[0034] FIG. 3 is the washing machine of FIG. 2 wherein the exposed compartment of the rotating cage or drum contained within the washing machine is shown with the cage or drum door open and the items to be washed being loaded into the compartment.
[0035] FIG. 4 is the view of FIG. 3 showing the internal basket having been slid from inside the compartment receiving the items to be washed.
[0036] FIG. 4 a is, in front-view, looking into one embodiment of a compartment of the rotating cage or drum mounted in the washing machine.
[0037] FIG. 5 is the view of FIG. 4 with the items to be washed having been loaded into the basket and the basket being reinserted into the compartment of the rotating cage or drum.
[0038] FIG. 6 is the view of FIG. 5 with the basket fully reinserted into the compartment of the rotating cage or drum.
[0039] FIG. 7 is the view of FIG. 6 with the compartment door being closed.
[0040] FIG. 8 is the view of FIG. 7 with the compartment door fully closed and the rotating drum or cage being rotated so as to expose the next adjacent compartment ready for loading.
[0041] FIG. 9 is the view of FIG. 8 wherein the rotating cage or drum has been rotated, stopped and the next adjacent compartment opened, its basket slid outwardly of the compartment, and further items to be washed inserted into the basket.
[0042] FIG. 10 is the view of FIG. 9 with the items to be washed fully inserted into the basket and the basket being return into the compartment of the rotating cage or drum.
[0043] FIG. 11 is the view of FIG. 10 with the basket fully inserted.
[0044] FIG. 12 is the view of FIG. 11 with the compartment door closed, ready for the rotating cage or drum to be rotated to the next adjacent compartment, showing further items to be washed held waiting for loading.
[0045] FIG. 13 is the view of FIG. 12 showing the third load of items being inserted into the corresponding third compartment basket.
[0046] FIG. 14 is the view of FIG. 13 with the third load of items to be washed having been fully inserted into the basket and the basket being returned into its compartment.
[0047] FIG. 15 is the view of FIG. 14 wherein the compartment has been loaded and the compartment door closed and latched.
[0048] FIG. 16 is the view of FIG. 15 with the front door of the washing machine being closed.
[0049] FIG. 17 is the view of FIG. 16 with the front door in its closed and latched position.
[0050] FIG. 18 is, in right-side perspective view, the washing machine of FIG. 17 with the front-face of the washing machine housing pulled away from the machine.
[0051] FIG. 19 is the view of FIG. 18 with the front-face of the washing machine housing removed so as to expose the front-face of the sealed wash housing.
[0052] FIG. 20 is the view of FIG. 19 with the front-face of the wash housing removed so as to expose the front-face and compartment doors of the rotating cage or drum mounted within the sealed wash housing.
[0053] FIG. 21 is the view of FIG. 20 with the compartment doors removed so as to show the front openings of the compartments of the rotating cage or drum.
[0054] FIG. 22 is, in enlarged, left perspective view, two of the compartments of the rotating cage or drum of FIG. 21 showing various items held, separated, within the compartments during agitation of the compartments through wash fluid contained within the wash housing.
[0055] Data Flow
[0056] FIG. 23 is, in diagrammatic view, the various data flow paths between the system administrator and two remote washing locations.
[0057] Washing Machine Graphical User Interface
[0058] FIG. 24 is a map of graphical user interface screens according to one example for the operation of a washing machine showing, diagrammatically, the inter-relationship between each of the screens.
[0059] In the following figures, individual screens taken from FIG. 24 are shown enlarged and wherein:
[0060] FIG. 25 is a system initializing screen,
[0061] FIG. 26 is an enter button screen,
[0062] FIG. 27 is a home screen,
[0063] FIG. 28 is a rotate cage screen,
[0064] FIG. 29 is a wash type screen,
[0065] FIG. 30 is an alarms screen,
[0066] FIG. 31 is an emergency stop information screen,
[0067] FIG. 32 is an alarms active screen,
[0068] FIG. 33 is a first internet connection error screen,
[0069] FIG. 34 is a second internet connection error screen,
[0070] FIG. 35 is a final internet connection error screen,
[0071] FIG. 36 is a control panel screen,
[0072] FIG. 37 is a machine information screen,
[0073] FIG. 38 is a maintenance screen,
[0074] FIG. 39 is a configuration screen,
[0075] FIG. 40 is an hour meter screen,
[0076] FIG. 41 is a water meter screen,
[0077] FIG. 42 is a wash cycle counter screen
[0078] FIG. 43 is a detergent inventory screen
[0079] FIG. 44 is a set pail volume screen,
[0080] FIG. 45 is a water valve test screen,
[0081] FIG. 46 is a drain valve test screen,
[0082] FIG. 47 is a pump calibration screen,
[0083] FIG. 48 is a water level and drain check screen,
[0084] FIG. 49 is a set points screen,
[0085] FIG. 50 is a language screen
[0086] FIG. 51 is a screen configure screen,
[0087] FIG. 52 is a time set-up screen,
[0088] FIG. 53 is a units screen,
[0089] FIG. 54 is a machine serial screen,
[0090] FIG. 55 is a log-in screen,
[0091] FIG. 56 is a leather contamination screen,
[0092] FIG. 57 is a wash temperature screen,
[0093] FIG. 58 is a spin cycle speed screen,
[0094] FIG. 59 is a finishing agent screen,
[0095] FIG. 60 is a machine load screen,
[0096] FIG. 61 is a job number screen,
[0097] FIG. 62 is a wash cycle summary screen,
[0098] FIG. 63 is a PPE wash screen,
[0099] FIG. 64 is a pre-rinse screen,
[0100] FIG. 65 is a sanitize screen,
[0101] FIG. 66 is a water-in step screen,
[0102] FIG. 67 is a detergent step screen,
[0103] FIG. 68 is a rotation step screen,
[0104] FIG. 69 is a drain step screen,
[0105] FIG. 70 is an extract step screen,
[0106] FIG. 71 is a pause screen,
[0107] FIG. 72 is a water-in details screen,
[0108] FIG. 73 is a detergent details screen,
[0109] FIG. 74 is a rotation details screen,
[0110] FIG. 75 is a drain details screen,
[0111] FIG. 76 is an extract details screen,
[0112] FIG. 77 is a wash-complete first screen,
[0113] FIG. 78 is a wash-complete second screen,
[0114] FIG. 79 is a wash-complete final screen,
BRIEF DESCRIPTION OF THE TABLES
[0115] Table 1 is a list of items that may be washed in the present system, broken down by category type.
[0116] Table 2 is a data flow legend.
[0117] Table 3 is a device content legend.
[0118] Table 4 is a list of parts and corresponding reference numerals.
[0119] Table 5 is a listing of 14 recipes for standard PPE washing and listing the recipes by name and table number, wherein:
Table 5.01 is for light washing. Table 5.02 is for medium washing. Table 5.03 is for heavy washing. Table 5.04 is for extra heavy washing. Table 5.05 is for sewage washing. Table 5.06 is for leathers, light soil washing. Table 5.07 is for leathers, sewage washing. Table 5.08 is for washing firefighter thermal moisture barrier. Table 5.09 is for washing firefighter thermal moister barrier with prerinse. Table 5.10 is for washing firefighter outer shell. Table 5.11 is for washing firefighter outer shell with prerinse. Table 5.12 is for washing firefighter helmet. Table 5.13 is for washing firefighter helmet with prerinse. Table 5.14 is for a washing machine flush. Table 6 is a brief description of Stage 1-3 detergents.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0135] The wash system as described herein is capable of cleaning both standard garments and textiles that conventionally may be cleaned in traditional washing machines, and is also capable of cleaning many other items that would never conventionally be washed in a regular or conventional washing machine. A list of such items, which is not intended to be exhaustive, of soft objects or other items (collectively referred to herein as soft objects or items) that may be washed in accordance with the wash system described herein is listed in Table 1 herein. The objective for washing of soft objects and other items which are not conventionally washed in conventional washing machines is to obtain cleanliness of the items to a certified standard. In the wash system described herein the example is provided of restoring soiled items to a certified standard referred to as “food-grade-safe”.
[0136] The wash system restores wash items from all categories of insured losses including what would have been in the past replacement loss claims to soft wash items due to contamination by heavy smoke, soot, mold, blood, as well as category 2 and 3 (grey and black sewage) soiled water. The washing and restoration system as described herein may include processes as described by way of example herein-below, in conjunction with for example the use of the applicant's washing machines, one example of which is also described herein and another incorporated by reference above, where the washing is according to pre-certified washing and restoration protocols which have been certified by third party testing organizations such as for example Wonder Makers Environmental Inc., located in Kalamazoo, Mo., USA, who provide third party testing for compliance with certification standards.
[0137] Other certification testing may be performed by for example Caro Environmental Services of Kelowna, British Columbia, Canada, and by Northwest Labs of Calgary, Alberta, Canada.
[0138] In the case of testing done by Wonder Makers Environmental, Inc., an experimental study (“the Wonder Makers study”) was undertaken to compare the effectiveness of a pre-curser wash system to the present wash system with cleaning procedures used by dry cleaning contractors of the Certified Restoration Dry-cleaning Network. The Wonder Makers study was to provide testing of a worst-case scenario where items where intentionally contaminated with smoke, sewage, mold, and blood. The intentionally contaminated representative items were sampled prior to cleaning. The items were them provided as a standard loss to contractors who have specialized in cleaning soft goods for the restoration industry so as to conduct a blind test by the contractors. The clean items were evaluated by a physical assessment and post-cleaning samples.
[0139] The physical assessment of the clean items along with laboratory sampling data generated during the study led to the conclusions that: (a) a large percentage of contaminated soft goods can be recovered after fires, floods, and bodily traumas if they are cleaned properly, (b) a substantial percentage of even intentionally difficult contaminated items can be successfully salvaged based on 3-part criteria of the cleaning contractors internal quality assessment standards, a detailed physical review, and sample results, (c) a stringent visual/odours evaluation of the clean items provided a relative accurate indicator of scientifically obtained results, (d) using stringent subjective standards regarding acceptability of stained residues and odour, and notwithstanding the dry-cleaning contractor declared the entire batch of contaminated items to be unsalvageable due to odour or staining, the wash system under study provided greater success in regards to salvageable items as compared to the cleaning processes used by the dry-cleaning contractors. These results were obtained in four different categories; namely, regular fabrics, bulky or quilted, that is, “puffy” materials, leather goods, and materials designated as “dry clean only”. The four forms of contamination used represented the most common kinds of damage to soft goods recovered by restoration contractors; namely, sewage, mold, blood, and smoke.
[0140] Example of Washing Machine
[0141] A sequence of views in FIGS. 1-25 illustrate a washing machine, and the use of that washing machine, capable of the required protocols within the wash system described herein.
[0142] In FIG. 1 , the front face of the front housing 10 a of washing machine 10 is shown with its front door 12 in its closed and latched position. An alternative embodiment of a washing machine 10 is shown in FIG. 1 a.
[0143] In FIG. 2 front door 12 has been swung open in direction A on its hinges 12 a so as to expose a perforated cage door 14 which, when stationary, is aligned behind door 12 when door 12 is closed. That is, both front door 12 and cage door 14 are aligned with the same opening in front housing 10 a so as to provide access from the front of machine 10 into the cage behind the cage door 14 .
[0144] In FIG. 4 , items to be restored 16 , which may include soft items, hard items, or combinations of soft and hard items, are shown by way of example suspended in front of machine 10 awaiting insertion into the washing machine.
[0145] In FIG. 3 , cage door 14 is in its open position having been swung open in direction B about its corresponding hinges to thereby expose the opening 18 into the corresponding perforated basket 20 . Basket 20 is snugly, slidably mounted in the cage behind the corresponding cage door 14 . The cage is better described below.
[0146] In FIG. 4 , basket 20 is shown pulled from within the corresponding cage, and items 16 are inserted into basket 20 .
[0147] In FIGS. 5 and 6 basket 20 containing items 16 has been slid back into the corresponding cage within segmented rotary drum 22 seen for example in FIG. 21 .
[0148] As seen in FIG. 4 a , the inside of basket 20 is significantly ventilated or perforated by extensive rows of apertures or cut-outs 20 a , which allow the circulation of washing fluids under pressure into, and through, the basket 20 . The washing fluids also circulate through any items 16 contained within the basket. The extensive number of apertures or cut-outs 20 a provide, for example, openings in the sidewalls 20 b of basket 20 which may be equal to or greater than 50 percent of the area of the sidewalls 20 b.
[0149] Basket 20 is fully reinserted into the corresponding cage, hereinafter also referred to as a cage segment 24 , in rotary drum 22 . In the illustrated example, which is not intended to be limiting, rotary drum 22 has a cross sectional circumference, shown in front elevation view, in the shape of an octagon. The octagonal shape of the circumference is due to the triangular shaped cross section of each cage segment 24 . Rotary drum 22 provides eight triangular compartments; that is, eight cage segments 24 into which corresponding baskets 20 are snugly received in their sliding engagement therein.
[0150] With the basket 20 containing the items 16 returned fully into the corresponding cage segment 24 as seen in FIG. 6 , cage door 14 is closed as seen in the sequence in FIGS. 7 and 8 . With door 12 closed as seen in FIG. 17 , the variable speed motor (not shown) drives a transmission (not shown), for example a geared or pulley transmission, mounted for example within the rear of machine 10 . The motor and transmission is engaged according to machine instructions from a programmable logic controller (PLC) and corresponding processor described better below or other wash processor so as to rotate rotary drum 22 . Rotary drum 22 may rotate for example clockwise in direction C. Rotary drum 22 is rotated by the operation of the motor and corresponding transmission so as to rotate drum 22 about axis of rotation D on drive axle 26 . Axis of rotation D is better seen in FIG. 1 a , but is similarly aligned with respect to the washing machine 10 of FIG. 1 . That is, FIG. 1 a is an illustration of a further alternative embodiment of a washing machine 10 showing more clearly axis of rotation D.
[0151] Continuing with the sequence described above, in FIG. 8 rotary drum 22 is rotated in direction C. In FIG. 9 , rotary drum 22 has been rotated so as to align the next adjacent cage segment 24 with opening 18 behind door 12 .
[0152] As seen in FIG. 10 , further items 16 are loaded into a second basket 20 corresponding to the second cage segment 24 . Then, with items 16 within basket 20 , again basket 20 is slid entirely into the correspondent cage segment 24 as seen in FIG. 11 , and the corresponding cage door 14 is closed as seen in FIG. 12 .
[0153] Advantageously, a pin and receiver or other positive locking mechanism is provided for each cage door 14 on each cage segment 24 of rotary drum 22 so as to prevent inadvertent opening of a cage door 24 during rotation of rotary drum 22 , for example during wash, rinse, spin or extract cycles. Such a positive locking mechanism is provided so that an operator of machine 10 , once the cage door 14 exposed in opening has been shut, may positively lock that cage door 14 in its closed position. Locking pins 14 a are illustrated diagrammatically by way of example in FIG. 20 . Locking pins slide into, for example a female receiver (not shown).
[0154] In FIG. 14 , further items 16 , including in the illustrated example a stuffed toy animal 16 c and purses 16 d , are shown suspended waiting for placement into the next available basket 20 in the next adjacent cage segment 24 . In FIG. 15 , items 16 are being inserted into basket 20 , and, as before, basket 20 is then inserted in direction E as to slide the basket completely back into its corresponding cage segment 24 within rotary drum 22 . In FIGS. 16 and 17 respectively, cage door 14 has been closed and locked shut, and door 12 is closed and latched, or otherwise locked, so as to enable the operation of the washing, rinsing, spinning and extraction cycles better described below.
[0155] In FIG. 18 , the front housing 10 a of washing machine 10 is shown pulled away from the front face of the rigid internal wash support structure 28 . As seen in FIG. 20 wash housing 30 is mounted behind the front face of support structure 28 as seen in FIG. 19 . Support structure 28 supports the front of wash housing 30 . Wash housing 30 contains the various wash fluids during the various wash cycles while rotary drum 22 , and its corresponding cage doors 14 , are rotated through the wash fluids. The wash and rinse fluids are selectively pumped into (and drained from) wash housing 30 according pre-programmed, operator selectable, operation of the washing machine via its processor. It is understood that wash housing 30 when mounted to support structure 28 at the front of wash housing 30 , and when mounted to other support structure (not shown) within washing machine 10 , provides a sealed wash tub environment in which rotary drum 22 may be rotated through wash fluids in the tub or in which rotary drum 22 as seen in FIG. 21 may be rotated at high speed to force fluids out by centrifugal force so that the fluids may be drained from the wash housing.
[0156] It is also understood, although not shown, that various replaceable containers of detergent and other wash fluids, for example, fragrances, sanitizers, etc. would ordinarily be located adjacent washing machine 10 , for example to the rear of the machine, or in some embodiments located within washing machine 10 so as to be easily replaced as the fluids are consumed from within the containers. The fluid containers may advantageously be removably mounted to for example, corresponding hoses having corresponding pumps (not shown). The pumps pump the various fluids under pressure into wash housing 30 . The fluid containers are removably coupled to their corresponding hoses or other fluid conduits and are thus removably coupled so as to be in fluid communication with the washing machine, and in particular with rotary drum 22 .
[0157] One of the desired cleaning mechanisms provided by the wash system is that the items 16 within baskets 20 within the porous cage segments 24 of rotary drum 22 are impinged by the various wash fluids which are injected or sprayed under pressure into rotary drum 22 . The various wash fluids impinge items 16 through various and numerous apertures in the cage segments 24 (wherein cage segments 24 and rotary drum 22 may for example be a very sturdy segmented wire cage), and through apertures 20 a in baskets 20 , so as to permeate the bulk of the various soft or hard wash items 16 to thereby more effectively clean the wash items.
[0158] In some instances hard wash items may themselves contain soft items requiring cleaning. For example, sports helmets are rigid on the outside and contain soft or spongy materials on the inside, and it is often the case that it is the interior soft and spongy materials that require cleaning, in many cases more than the rigid materials on the exterior. A balance must be achieved between, firstly, vigorously circulating the soft materials of items 16 through the wash fluids as they are injected or sprayed in wash housing 30 or as the wash fluids are turbulently tumbling in wash housing 30 as rotary drum 22 is rotated within wash housing 30 , and secondly, inhibiting damage to the rigid or hard items or components of the items.
[0159] With the correct sizing of baskets 20 and corresponding cage segments 24 , or for example by the use of inserts such as mesh holders or bags on folding or rigid frames (not shown), wash, items 16 may be held sufficiently snuggly and separated within their corresponding basket 20 so as to not only be cleaned but also to inhibit damage to the various items 16 caused by the items moving around within basket 20 . Advantageously basket 20 may be constructed of soft or compliant plastics so as to minimize damage to items 16 . In some cases, item 16 may have further containment within baskets 20 , for example porous bags, etc. (not shown) to assist in the holding of the various items 16 within their corresponding basket 20 .
[0160] In FIG. 20 the front support structure 28 has been removed so as to expose the interior of wash housing 30 and the front faces of cage doors 14 . The positive locking pins 14 a are shown slidably mounted to the front of each cage door 14 . Pins 14 a may engage for example latching apertures or the like mounted to, or formed in, the corresponding spokes on the front face of rotary drum 22 , for example, the illustrated spokes which define the front openings of each cage segment 24 .
[0161] In one preferred embodiment, not intended to be limiting, the washing machine motor and corresponding transmission, for example a pulley system, for rotationally driving drive axle 26 is adapted to provide not only relatively slow rotational agitation cycles but also high rate of rotation fluid extraction cycles. Slow rotational agitation cycles may be provided for example when each cage segment 24 is to be rotated through washing fluid 32 which has been pumped into wash housing 30 , during which the combined fluid resistance and the weight of the tumbling fluids passing through the cages segments 24 , baskets 20 , and items 16 within wash housing 30 , combined with the wet weight of items 16 may put significant loading and strain on the drive system including the motor and transmission. In the illustrated embodiment, which is not intended to be limiting, the total dry weight of items 16 held in all cage segments 24 may, collectively, be in the order of 120 pounds. Advantageously, during loading of items 16 , their dry weight is somewhat evenly distributed around rotary drum 22 .
[0162] During wash fluid extraction and spin cycles, in order to obtain sufficient centrifugal separation of wash and rinse fluids from items 16 , which may be highly retentive of fluid, rotary drum 22 may have to be rotated on drive axle 26 at high rotational speeds, for example at speeds exceeding 200 rpm, so as to generate for example centrifugal forces, measured as multiples of the force of gravity (g's), in the order of 50-70 g's acting on items 16 . The motor loading, and strain on the transmission, at these speeds may, consequently, again be high. At such high rotational speeds, and creating such high centrifugal g forces, it has been found that the framework supporting wash housing 30 etc. must be significantly robust.
[0163] As seen in closer detail in FIG. 22 , wash water 30 is driven under pressure through the apertures in the bars of cage segments 24 and through apertures 20 a in baskets 20 so as to impinge as a spray or flow of droplets of various wash fluids driven through the apertures under pressure as the cage segments 24 and their items 16 being carried in the baskets 20 therein are subjected to spray. Items are sprayed for example when they are in upper most portions of the rotational trajectory of the items being washed. The items 16 are turbulently mixed in the collected wash fluids while being continuously circulated when in the lower portions of the rotational trajectories of the items being washed.
[0164] Pumps may be those provided by Knight Canada™ of Mississauga, Ontario, Canada. Metering may be meters such as those provided by Burkert Fluid Control Systems™ of Burlington, Ontario, Canada.
[0165] Example of Data Flow within Washing System
[0166] A diagrammatic representation of the data flow in one embodiment of the washing system is illustrated in FIG. 23 . In FIG. 23 the ovals 100 denote the remote locations of the operators of one or more of washing machines 10 . As used herein, each operator also referred to as a Customer. Although only two remote locations 100 are illustrated in FIG. 23 , it is understood that this is by way of example only as, and as stated above, the number of remote locations 100 may run into the hundreds or thousands.
[0167] Each washing machine 10 at each remote location 100 has a data connection between the remote location 100 and a system administrator 102 and/or corresponding administrator processor (collectively system administrator 102 ) which may be located at great distance from any one of remote locations 100 . Some form of contractual arrangement may exist between the system administrator 102 , or the corporate entity for whom the system administrator 102 works, and the Customers or operators at remote locations 100 . Under such contractual arrangement the Customers or operators, or their corporate legal entities, are bound to follow the protocols set out below by way of example, and thus provide restoration of items 16 to a certified standard such as the food-grade-safe standard or such other standard as may be required by the insurance industry from to time-to-time.
[0168] In FIG. 23 , each of the data flow paths is indicated by separate lines which denote different data flows as set out in the Data Flow Legend in Table 2.
[0169] The dashed data flow lines 104 , as set out in Table 2, denotes a two way communication link that allows the administrator 102 to remotely monitor machine activity of machines 10 at remote locations 100 , perform machine diagnostics remotely, install program updates remotely, and, as necessary, remotely turn washing machine 10 on or off as better described below.
[0170] The solid data flow lines 106 , as set out in Table 2, denotes a two way communication link between the system administrator 102 or its employees, for example machine technicians and cleaning technicians, and the remote Customer or operator at remote locations 100 , using for example instant messaging, voice calls, video calls, etc.
[0171] The hash mark data flow lines 108 , as set out in Table 2, denotes a two way communication link that allows the Customer at remote location 100 to view and report specific wash system machine analytics provided by the administrator 102 , for example, the number of wash loads, the detergent usage, the cost to the Customer per wash loads, the number of washes etc. Data flow 108 allows the Customer to review and report the Customer's machine analytics from any internet browser through a secure administrator machine web User Interface (UI) 110 .
[0172] The data flow lines 112 , which consist of a row of “+” symbols as set out in Table 2, denote a one way communication that sends machine analytic data, (for example date, time, wash load number, detergents usage (for example, in millilitres), water temperature, water usage, etc. by email (for example in “csv” file format) to the administrator email server 128 which is then parsed and deposited into the administrator data base 114 .
[0173] The data flow lines 116 , which consist of a row of dots as set out in Table 2, denotes a two way communication link that allows an administrator employee to view, add, edit, delete administrator wash system machines analytics, for example, the number of wash loads, the detergent usage, the cost per wash load, the number of washes etc. from any internet browser through a secure machine web user interface 110 .
[0174] The data flow lines 118 , which consist of a row of dashes alternating with “x's” as set out in Table 2, denotes a two way communication link that allows the administrator 102 to remotely view, edit, add, delete, and report the analytic data generated by each Customer wash system at remote location 100 and also to view, edit, add and delete the content (for example the frequently ask questions (FAQ), the training videos, the maintenance videos, etc.) provided by the administrator 102 and access by the Customers at remote locations 100 though either the machine tablet 120 or any browser enabled device.
[0175] The data flow line 122 , which is denoted by a corrugated line as set out in Table 2, denotes a two way communication that provides touch screen operated instructions from the human machine interface (HMI) 124 to the wash processor including the programmable logic controller (PLC) 126 which operates the components of the washing machine 10 (for example, to run or stop the washing machine motor, to open or close various drain valves, to open or close pumps, etc.).
[0176] Again with reference to FIG. 23 , although not intending to be limiting, the following may be provided by administrator 102 for the use of the employees of administrator 102 : email server 128 which interfaces between internet 130 and data base 114 , web server 132 which interfaces between internet 130 and data base 114 , and in the case of data flows 116 and 108 , via machine web user interface 110 . Email server 128 and web server 132 interfaces directly between internet 130 and data base 114 by data flows 112 and 118 respectively.
[0177] HMI software 214 a , PLC software 126 a and E-catcher software 134 are enabled on PC 136 and interface with Talk2M server 138 via internet 130 and firewall 140 , with the exception that data flow 116 bypasses Talk2M server 138 .
[0178] The Customers or operators at remote locations 100 may access machine web user interface 110 using any internet browser 142 so as to thereby interface with the administrator web server 132 via machine web user interface 110 and firewall 140 . At remote locations 100 , data flows 106 , 104 , and 118 exchange data between tablet 120 , used by the operator to control, in one preferred embodiment, washing machine 10 via WIFI router 144 , and the “EWON” virtual private network router 146 .
[0179] In one embodiment of the present system the above network may be employed, modified as need be and as would be known to one skilled in the art, to help avoid the cutting of costs or the otherwise cutting of corners by operators of the remotely located washing facilities by monitoring consumption of the consumables that are to be used in the washing protocols. The operators have to elect which washing recipe they will use for a particular item or set of items. The system records that election, and records when the washing has been done. Each recipe requires a unique set of consumables be used. Tracking by the administrator of the consumables actually used and comparing that to the washing recipes that have been used, and the number of times those washing recipes have been cycled, allows the tallying of use, comparison to on-site inventory of consumables, and thus the detection by the administrator of shortcuts being taken by the operators.
[0180] Tracking the consumables that have actually been used has proven to be difficult where tracking relies solely on a fluid metering system, for example working in conjunction with the fluid pumps assigned to each type of fluid consumable (for example detergents, etc.). In applicant's experience, fluid flow and volumetric meters which are available commercially are sufficiently inaccurate at the lower viscosities associated with preferred consumables, that tracking of overall consumption of consumables by an operator using such meters is at present undesirable such meters may however be employed as the technology improves. Thus, advances in fluid flow rate metering and fluid flow volume metering may allow the future use of such tracking, which may then be monitored by the networked system.
[0181] In the meantime, presently the administrator in this embodiment of the system knows an initial level of each consumable associated with each machine, knows the wash load/recipe types that a particular washing machine has washed, and the number of those loads. The amount of consumable consumed for each such wash is thus known, as it has been pre-measured for each load type/wash recipe how much consumable is consumed by the operation of a particular pump for its pre-set run-time as prescribed for each wash recipe.
[0182] Consumables are shipped directly or indirectly from the system administrator to an operator as the consumables are ordered and re-ordered by the operator. The system tracks the consumables for a particular machine, for example using bar coding on the consumables which matches a serial number or other unique identifier to the serial number or unique identifier on the particular washing machine in need of re-supply. For example, the consumables may be shipped in 20 liters pails, or in larger containers. So long as the system knows the volume of each consumable which is shipped to the operator for a particular washing machine and so long as the on-going tally of consumable consumption is maintained and monitored by the system and system administrator, the comparison to usage may also be maintained to thereby assist in verifying that the certified standard of cleanliness is being maintained.
[0183] In a preferred embodiment the system is advised of, for example tracks in real time or other more intermittent intervals, but advantageously no longer than short-intervals such as several times per day for example, the arrival of consumables at an operator's premises. Tracking may for example be done by the scanning of barcodes on the containers of consumables for upload to the system by, RFID, by feedback from the shipper, etc., or any combination of these. The object is to more or less seamlessly track the balance between the consumption of consumables for each washing machine, and the timely re-supply of consumables and input of those re-supplied consumables into the washing machines. In this fashion any use of un-authorized consumables, for example a potentially inferior detergent, by an operator will be detected by the administrator and the particular offending machine may then be shut-down remotely by the administrator.
[0184] Washing Machine Operator Control
[0185] FIG. 24 is a diagrammatic representation of the interrelationships between the various user interface screens which an operator would see and interact with on tablet 120 so as to control the operation of washing machine 10 . As seen in FIG. 24 , upon initial start-up of washing machine 10 and its corresponding controller, a system initializing screen, as seen in better detail in FIG. 25 , is displayed. In FIG. 24 the system initializing screen is denoted by a reference numeral 210 . FIG. 24 also illustrates one example of a system fault. Other system faults which may occur, as would be known to one skilled in the art, are not shown.
[0186] Once the system is initialized, the “enter” screen 212 , as better seen in FIG. 26 , is displayed. Once the operator has entered into the system according to a pre-established verification protocol, such as a password or the like, home screen 214 , better seen in FIG. 27 is displayed. At home screen 214 , the operator may select to rotate the cage using the “rotate cage” button, that is, so as to rotate rotary drum 22 to a desired load or unload position, which then takes the operator to the rotate cage screen 216 . The use of the rotate cage function is described above for loading and unloading the washing machine 10 . The operator may then select either the “counter-clockwise” button or the “clockwise” button on the touch screen to rotate the cage, as described above, so as to load or unload items 16 into, or from, another basket 20 . The operator may then select the “back-arrow” button, in the lower left-hand corner of the screen, so as to return to home screen 214 . The rotate cage screen 216 is better seen in FIG. 28 .
[0187] From the home screen 214 , the operator may select the “run” button which then takes the operator to wash type screen 218 , better seen in FIG. 29 . From wash type screen 218 , the operator may then select the details of the desired wash load as better described below.
[0188] Using the “back” button on wash type screen 218 , the operator is returned to home screen 214 . If the operator selects the “alarms” button on the home screen the operator is taken to the alarms screen 220 , better seen in FIG. 30 . The operator may then select the “E-stop” button at any time the washing machine is operating, which then takes the operator to the emergency stop information screen 222 , better seen in FIG. 31 . If the E-Stop button is depressed the machine motor brake will be activated and all functionality will be stopped and not usable until the Estop is pulled out and the alarm on the HMI is reset. On return to the alarms screen 220 the operator may select the “reset alarms” button which then takes the operator to the alarms active screen 224 , better seen in FIG. 32 . As indicated in FIG. 24 , the alarms may become present at any time during a particular wash cycle.
[0189] As also indicated in FIG. 24 , if at any time connection to internet 130 is lost the Customer is given, for example, a further two washes for that disconnected machine 10 , after which that machine 10 will automatically lock itself and ask the operator for a code. As seen in internet connection error screen 226 , better seen in FIG. 33 , upon loss of internet connection from machine 10 to internet 130 , screen 226 is displayed which asks the operator to reconnect to the internet and gives the operator the option to bypass screen 226 to allow the operator to run a wash without internet connection. The operator is warned of the number of bypasses remaining upon selection of a first bypass. In the event of selection of a first bypass, the operator screen 226 is replaced with screen 226 a which warns the operator that, in one embodiment not intended to be limiting, only a single bypass remains. The operator may select the “bypass” button again to operate the washing machine 10 one further time without internet connection following which internet connection error screen 226 b is displayed which prompts the operator for a password key or the like which may be obtained by contacting the administrator 102 . The screen also prompts the operator to simply reconnect to the internet. The screens 226 a and 226 b are better seen in FIGS. 34 and 35 respectively.
[0190] If the operator returns to home screen 214 , or had remained at home screen 214 , and had selected the “run” button, then the operator is taken to the “control panel” screen 228 , better seen in FIG. 36 . Once in the control panel screen 228 , the operator may select from three choices; namely, the machine “information” button which takes the operator to the machine information screen 230 , better seen in FIG. 37 ; or the operator may select the “maintenance” button in which case the operator is taken to the maintenance screen 232 , better seen in FIG. 38 ; or the operator may select the “configuration” button in which case the operator is taken to the configuration screen 234 , better seen in FIG. 39 .
[0191] In the instance that the operator had selected the machine information screen 230 , the operator may then select one of four buttons; namely the “detergent inventory” button, the “hour meter” button, the “water meter” button, or the “wash cycle counter” button. If the operator selects the “hour meter” button, then the operator is taken to the hour meter screen 236 better seen in FIG. 40 . If the operator selects the “water meter” button, then the operator is taken to the water meter screen 238 , better seen in FIG. 41 . If the operator selects the “wash cycle counter” button then the operator is taken to the wash cycle counter screen 240 , better seen in FIG. 42 . If the operator selects the “detergent inventory” button then the operator is taken to the detergent inventory screen 242 , better seen in FIG. 43 . The operator may return to the machine information screen 230 from any of these screens 236 , 238 , 240 , and 242 , by selecting the “back” button, denoted by the return arrow in the lower left-hand of each screen.
[0192] When the operator is in the detergent inventory screen 242 , the operator is presented with a stacked array of “reset” buttons, in the illustrated embodiment which is not intending to be limiting, six reset buttons corresponding to six displayed “Stages”. Each reset button, labelled “reset inventory” in screen 242 takes the operator to a corresponding “set pail volume” screen 244 better seen in FIG. 44 . Each of these Stages 1-6 correspond to the various consumable fluids, for example the detergent fluid used in each of Stages 1-3 of a particular cycle of the washing cycle as determined by the recipe as selected by the operator, and better described below. The detergents etc. in stages 1-3 are described by way of example in Table 6. The operator selects the recipe according to the category of goods to be restored. Depending on the recipe, the fluid pump (not shown) associated with consumables container, for example a pail, for a particular Stage is engaged, so, depending on the recipe, as to supply a select combination of fluids from the various pails corresponding to the various Stages at any particular time in a cycle during the entire wash, rinse, spin or extraction cycles. Thus in the illustrated example the operator has viewed the volume in pail 2 which corresponds to Stage 2, and having reviewed the amount of Stage 2 detergent left in the pail, swapped the pail out for a full pail of Stage 2 detergent and reset the inventory for that pail so that the system knows that a full pail is available.
[0193] Returning now to the instance where the operator has selected the maintenance screen 232 from the control panel screen 228 , the operator in maintenance screen 232 has a selection of six buttons to choose from; namely, a “water valves”, a “drain valve”, a “brake” button, a “pump calibrate” button, a “detergent flush” button and a “water level drain check” button. The “brake” button engages the brake which arrests rotation of rotary drum 22 . The detergent “flush” button flushes the detergent from the system. The “water valves” button takes the operator to the water valve test screen 246 , better seen in FIG. 45 . The “drain valve” button takes the operator to the drain valve test screen 248 , better seen in FIG. 46 . The “pump calibrate” button takes the operator to the pump calibration screen 250 , better seen in FIG. 47 . The water “level drain check” button takes the operator to the water level and drain check screen 252 , better seen in FIG. 48 .
[0194] In the instance that the operator when at the control panel screen 228 , selects the “configuration” button, the operator is take to configuration screen 234 and presented with six buttons to select from; namely, a “set” button, a “language” button, a “screen configure” button, a “time set-up” button, a “units” button and a “machine serial” button. If the operator selects the “set point” button, then the operator is taken to the set point screen 254 , better seen in FIG. 49 . If the operator selects the “language” button then the operator is taken to the language screen 256 , better seen in FIG. 50 . If the operator selects the screen “configure” button then the operator is taken to the configure screen 258 , better seen in FIG. 51 . If the operator selects the “time set-up” button, then the operator is taken to the time setup screen 260 , better seen in FIG. 52 . If the operator selects the “units” button, then the operator is taken to the units screen 262 , better seen in FIG. 53 . If the operator selects the “machine serial” button, then the operator is taken to the machine serial screen 264 , better seen in FIG. 54 . Upon the operator selecting from the options available on the machine serial screen 264 the operator is taken to a log-in screen 266 , better seen in FIG. 55 , and is prompted for a name and password.
[0195] If from the home screen 214 the operator has selected the “run” button, the operator is taken to wash type screen 218 , better seen in FIG. 29 . The operator then has the choice to select from, without intending to be limiting, eight buttons; namely the “light” button, the “medium” button, the “heavy” button, the “extra-heavy” button, the “sewage” button, the “leathers” button, the “machine rinse” button, and the “PPE” button. In the event that there has been an alarm, the operator also has the option to select the “reset alarms” button.
[0196] If the operator selects the “leather” button, the operator is taken to the leather contamination screen 268 , better seen in FIG. 56 . In the leather contamination screen 268 , the operator has the choice of a “light” soil button or a “sewage” button. Once the operator has selected whether the leather contamination is a light soil or sewage, the operator is taken to a machine load screen 276 described below.
[0197] In the event that the operator selects the “light”, “medium”, or “heavy” buttons in the wash type screen 218 then the operator is taken to the wash temperature screen 270 and presented with the choice of wash fluid temperatures by use of corresponding “cool”, “warm” or “hot” buttons, as better seen in FIG. 57 . Once the wash temperature has been selected, the operator is taken to spin cycle speed screen 272 , better seen in FIG. 58 wherein the operator is given the choice of low, medium, and high spin cycle speeds which the operator selects by the corresponding buttons on the screen. Once the spin cycle speed has been selected, the operator is taken to the finishing agent screen 274 where the operator may select from a fragrance button, a softener button, or a “none” button which deselects the use of a finishing agent, as better seen in FIG. 59 .
[0198] Once the operator has selected the finishing agent (or no finishing agent), the operator is taken to the machine load screen 276 , which is also the machine load screen that the operator is taken to upon selection of the leather contamination in leather contamination screen 268 , as better seen in FIG. 60 . In the machine load screen 276 , the operator selects from either a “¼” button, a “½” button, a “¾” button or the “full” button, as better seen in FIG. 60 , so as to select whether the volume of the items 16 , which has been loaded into machine 10 , are approximately ¼, ½, ¾ or full. For example, “full” means that, in one embodiment, 120 lbs of items 16 have been inserted into baskets 20 so as to symmetrically distribute the load around rotary drum 22 . Once the operator has selected the machine load, the operator is taken to job number screen 278 , better seen in FIG. 61 , wherein the operator is prompted for the operator job number to be associated with that particular wash. Upon entry of the job number, and pushing the “continuing” button, the operator is taken to the wash cycle summary screen, better seen in FIG. 62 .
[0199] In the wash cycle summary screen the operator is presented with a summary of the operator selections in teems of wash type, load size, wash temperature, finishing agent, and spin speeds. The selections made by the operator are matched by the wash processor to a corresponding recipe, for example as described below, and from that recipe the volume of the various consumables are determined and multiplied by the presently stored cost of each consumables, and those costs amount are summed and a total cost for the selected wash is presented in wash cycle summary screen 280 in the “to run” field. The predetermined run times for the various cycles associated with the selected wash are then also summed and the results in minutes and seconds are displayed adjacent to the cost field in the wash cycle summary screen. The operator is then prompted to initiate the selected wash cycle by a prominent “run” button located on the screen adjacent to the wash cycle summary information.
[0200] If in the wash type screen 218 the operator has selected the “PPE” button, that is, the button associated with the washing Personal Protective Equipment, then the operator is taken to the PPE wash screen 282 , better seen in FIG. 63 . Within the PPE wash screen 282 , the operator may select from various buttons corresponding to the type of PPE being washed, the example in FIG. 63 being given of a “TL MB” button (which stands for Thermal Liner Moisture Barrier), a “SFF OS” button (which stands for Structural Fire Fighter Outer Shell), and a “SFF helmet” button (which stands for Structural Fire Fighter helmet).
[0201] Once the operator selects the appropriate type of PPE to be washed by selecting the corresponding button on the PPE wash screen 228 , the operator is taken to the pre-rinse screen 284 , better seen in FIG. 64 , wherein the operator is given the choice as to whether to use a wash pre-rinse by corresponding “yes” and “no” buttons. Once a pre-rinse has been selected or deselected, the operator is taken to machine load screen 276 , and thereafter continues through job number screen 278 , and wash cycle summary screen 280 as previously described.
[0202] In the event that the operator has selected the “extra-heavy” or “sewage” buttons in wash type screen 218 then the operator is taken to the sanitize screen 286 , better seen in FIG. 65 wherein the operator selects whether or not the operator wishes fluid sanitizer to be added to the wash load by selecting either the “yes” or “no” buttons. Once the operator has selected or deselected using sanitizer fluid, the operator is taken to job number screen 278 , and thereafter taken to wash cycle summary screen 280 as described above.
[0203] Once the operator is satisfied with the wash cycle that has been selected as displayed in wash cycle summary screen 280 , and the operator then selects the “run” button on wash cycle summary screen 280 , the operator is taken through a sequence of five “step” screens, namely; the water-in screen 288 , better seen in FIG. 66 , the detergent screen 290 , better seen in FIG. 67 , the rotation screen 292 , better seen in FIG. 68 , the drain screen 294 better seen in FIG. 69 , and the extract screen 296 better seen in FIG. 70 . Each of the step screens 288 , 290 , 292 , 294 , and 296 , have in the lower left-hand corner, a “pause” button which takes the operator to the “paused” screen 298 , better seen in FIG. 71 .
[0204] Each of the five step screens 288 , 290 , 292 , 294 , and 296 also have a “+” button in the lower right-hand corner which, when selected, takes the operator to a corresponding “details” screen as seen in the corresponding “water-in” details screen 288 a as seen in FIG. 72 ; a “detergent” details screen 290 a as better seen in FIG. 73 ; a “rotation” details screen 292 a as seen in FIG. 74 ; a “drain” details screen 294 a as seen in FIG. 75 , and an “extract” details screen 296 a as seen in FIG. 76 . As with the corresponding step screens, the details screen each have, in the lower left-hand corner a “pause” button which, again, takes the operator to the paused screen 298 . In the lower right-hand corner of the detail screen, a “−” button takes the “operator” back to the corresponding step screen.
[0205] Thus in operation, once an operator has selected the “run” button in the wash cycle summary screen 280 , the selected displayed wash will cycle through the five step screens, showing the operation of the wash during each step in the corresponding step screen. Each step screen; whether it be the water step, the detergent step, the rotation step, the drain step, or the extract step, shows which steps is presently engaged and how far the machine is presently into that particular step. During the display of each of sequential steps screens, the operator may select to look at the corresponding details screen. Thus for example while the water-in screen 288 is displayed, the operator is told the length of time for that particular step, the elapsed time of the execution of that step and the predicted total time to finish all of the steps. If the operator selects the water-in detail screen 288 a then, for example, the water temperature, both the set point desired for that step, and the current water temperature is displayed, and the water level, including the set point for that step, and the current water level is also displayed. Whether the water-in is hot or cold can also be displayed. By way of further example, if the operator selects the detergent details screen 290 a , the following information may be displayed; the water flush time, the volume of detergent required the current volume of detergent which has been used during the present wash step, and the elapsed time of the detergent step. Also which may advantageously be displayed is a graphic representation as to which of the pumps are engaged. In the illustrated example six pumps are shown and one is indicated as activated (corresponding to which of the six Stages in the recipe is being pumped). If the pumps are being flushed then that status may be provided also.
[0206] In the rotation details screen 292 a , the speed of rotation of rotary drum 22 within wash housing 30 is displayed, for example in the revolutions per minute (RPM). Thus, depending on the type of wash which was selected by the operator, the desired wash speed set point is displayed, the current rotation speed is displayed, the rotation time is displayed, and the wait times may also be displayed. Further, indicators may be provided to tell the operators whether the rotation is presently clockwise or counter-clockwise, as the cage may be rotate back and forth both clockwise and counter-clockwise to provide efficient agitation of items 16 through the wash fluids 32 contained in wash housing 30 .
[0207] In the drain details screen 294 a , the operator may be provided with the drain time's set point or estimated drain times, and also the presently elapsed time during the drain step. The operator may also be provided with an indication whether the drain valve is presently open or closed. In the extract details screen 296 a , the operator may be provided the presently requested water extract RPM for rotation of rotary drum 22 , the currently obtained RPM of the rotary drum and the final RPM speed of the rotary drum, which in the example illustrated, maybe as high as 209 RPM for final water extraction from item 16 when they are subjected to very high g-loadings within baskets 20 . Again an indicator may be provided it to the operator as to whether the drain valve is open or not.
[0208] Once the five steps have been completed, a sequence of views entitled “wash-complete” are presented to the operator. In particular, by way of example, a wash complete first screen 300 a better seen in FIG. 77 may summarize again the wash summary that was chosen by the operator; that is, so as to for example show the wash type, machine load, water temperature, spin cycle, agent and the wash cost. The wash complete first screen 300 a may be followed in sequence by a wash complete second screen 300 b , better seen by way of example in FIG. 78 , wherein the wash run time is displayed, including the time of the wash start and the time of the wash end. The wash complete second screen 300 b may be followed by the display of the wash complete final screen 300 c , better seen by way of example in FIG. 79 wherein the amount of water consumed is displayed, the amount of Stage one detergent is displayed, the amount of Stage 2 detergent, if any, is displayed, the amount of Stage three detergent, if any, is displayed, the amount of fragrance, if any, is displayed, the amount of softener, if any, is displayed, and the amount of PPE cleaner, if any, is also displayed. A “home” button illustrated by a “house icon” button located in the lower left-hand corner of the wash complete screens may be selected by the operator to return the operator to the home screen 214 .
[0209] Standard and PPE Wash Recipes
[0210] Table 5 lists thirteen washing recipes which are provided herein by way of example for use within the present system. Each recipe listed in Table 5 is set out in detail in corresponding Tables 5.01-5.13. Each of Tables 5.01-5.13 provide numbered steps which corresponds to a described action, a recipe group, a list of detailed headings, the corresponding variable amounts, and finally the amount of the anticipated time for that step. In the action column of each table the description of the action may be for example “water-in”, which comprises the step of filling the wash housing to its predetermined level. “classic Stage 1” refers to a first detergent which would be located in a first pail or other container associated with a first pump and flow lines into the wash housing. “classic Stage 2”, which may be a penetrator detergent, is located in a second pail or container associated with a second pump and its flow lines into the wash housing. A “classic Stage 3” may be a force additive detergent located in a third pail or container having a third associated pump for pumping the third Stage detergent via dedicated flow lines into the wash housing. The described action in the action column may also include “rotation” for the relatively slow rotation of the rotary drum through the wash fluids according to the details listed in the detail column. The action in the action column may be “drained” for the draining of the wash fluids from the wash housing. A first wash and drain cycle may be followed by a rinse cycle wherein again the action column will include a water-in step, then, as called for, a softener or fragrance finishing agent, a rotation step, and then an extraction step. The extraction steps may include a first, medium speed rotational extraction, and a second, high-speed rotational extraction of the remaining water in items 16 held within baskets 20 within the rotary drum.
[0211] Where reference is made to Stage 4, in one embodiment that is a reference to fragrance fluids contained in a pail or other container which has its own associated pump and flow lines into the wash housing. Similarly Stage 5 may be softener fluids contained in a further pail or container and having an associated pump and flow lines into the wash housing. Stage 6 may refer to PPE cleaner contained in its own pail or other container and having its own associated pump and flow lines into the wash housing.
[0212] In certain recipes the variable amount may be chosen by the operator, for example in the water-in steps in the light, medium and heavy recipes (Tables 5.01-5.03 respectively). Where a variable may be varied by an operator the symbol “VV” is found in the variable column. In more control critical recipes such as the sewage recipe of Table 5.05, less control is given to the operator. For example, in the sewage recipe, the water in temperature is pre-set to 35° C. in step one, and 200° C. in Step 14 .
[0213] Where the variable settings are not to be tampered with by the operator, for example the amounts of Stage 1 and 2, and in applicable instances, Stage 3 detergents, the volumes are pre-set as for example in the heavy recipe of Table 5.03. In the heavy recipe the Stage 1 detergent has a volume of 340 ml, the Stage 2 detergent has a volume of 480 ml and the Stage 3 detergent has a volume of 390 ml. As set out in the tables most of the variables are pre-set so as to meet the cleaning certification required to consistently obtain the food-grade-safe standard of cleanliness. Thus for example in the leathers recipe of Tables 5.06 and 5.07 the final extract speed which is operator variable in light washing is predetermined and pre-set at 196 rpm so as to generate very high g-loadings on items 16 held in the rotary drum. The amount of time for each step is also controlled so, that for example the high final extraction speed of 196 rpm called for in the leathers sewage recipe is only 10 minutes for the entire extraction step, whereas the extraction step, again at 196 rpm for the final extraction speed lasts 25 minutes for water extraction from a firefighter thermal liner moisture barrier as set out in Table 5.08.
[0214] Thus as will be appreciated by those skilled in the art, the present system is characterized by high levels of control over the washing machinery, the system architecture, data flow, data polling, reporting, overview, administration, and feed-back and over the wash processor controlled recipes so that operator input is minimized to thereby optimize the consistent restoration of soft items to a food-grade-safe level of cleanliness.
[0215] As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims. | A system for the remote monitoring of washing machines cleanliness to a pre-certified cleanliness standard includes washing machines having wash processors to wash items according to pre-determined pre-certified recipes using pre-certified consumables. The wash processors are adapted to communicate over the internet with a remotely located administrator processor, to exchange information on a repeating, short-time interval. The wash processors provide to the administrator processor the volumetric consumption of consumables over successive wash loads. In each of said at least one washing machine according to said recipes, wherein said recipes correspond to characteristics of the wash items in each corresponding wash load and the corresponding nature of the spoilage. The recipes and the consumables have been independently pre-certified for use in the washing machines so as to clean and restore the wash items to a pre-determined certification standard of cleanliness. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application relates to and claims priority from PCT/CN2010/079620 filed Dec. 9, 2010, the entire contents of which are incorporated herein by reference, and which further claims priority from CH Ser. No. 200910250703.9 filed Dec. 9, 2009.
FIELD OF THE INVENTION
The present invention is directed to a seed-specific expression vector and its construction methods and applications, and in particular to a seed-specific expression vector and its construction methods and a method for producing apolipoprotein A-I- Milano (AIM) in oil sunflower with this vector.
BACKGROUND OF THE INVENTION
Cardiovascular disease (CVD) is the leading cause of human deaths worldwide. It is estimated that, by 2015, approximately 20 million people will die from cardiovascular disease (CVD). Numerous cardiovascular diseases (CVDs) (such as myocardial infarction and apoplexy) are the leading complications of atherosclerosis (AS). So far, the pathogenesis of atherosclerosis has not been fully understood. Abnormal lipid metabolism is one of the main risk factors that cause this disease. High-level of low density lipoprotein (LDL) and low-level of high density lipoproteins (HDL) are the two most important risk factors. Traditional strategies of treatment are to reduce the content of total cholesterol (TC) and low density lipoproteins cholesterol (LDL-C) in blood plasma. Statins are the preferred lipid-lowering drug at present. However, they cannot eliminate existing plaques deposited on artery wall, or fundamentally cure atherosclerosis (AS). More and more scientists in different countries have turn to the other risk factor, low-level of high density lipoprotein (HDL). Epidemiological studies indicate that, the level of high density lipoproteins (HDL) in blood plasma is in negative correlation to the incidence of coronary diseases. It is believed that high density lipoprotein contributes to the prevention of atherosclerosis. Treating atherosclerosis through improving the level of high density lipoprotein is a new approach for treating acute coronal atherosclerosis diseases that is emerging in pharmaceutical industry. It is called high density lipoprotein targeted therapy. Apolipoprotein A-I (apo A-I) is the main proteic component of high density lipoproteins. Apolipoprotein A-I is synthesized in liver and small intestine. The primary translation product is the preproprotein (preproapo A-I) containing 267 amino acid residues. Preproprotein is then processed into the proprotein (proapo A-I), through the cleavage of an octadeca peptide by signal peptidase. The proapo is secreted and processed into mature plasma apolipoprotein A-I through cleavage of a hexapeptide (Arg-His-Phe-Trp-Gln-Gln) by specific extracellular converting enzymes. The mainly mechanism of action of apolipoprotein A-I is to promote the cholesterol efflux, antioxidation, and to decrease platelet aggregation.
Apolipoprotein (apolipoprotein A-IM, apoA-IM) is a natural mutant of apolipoprotein A-I (Arg173-Cys). Compared with apolipoprotein A-I, the loss of Arg173 leads to the reduction of content of α-helix and the enhancement of the capability to bind lipid. Apolipoprotein A-I- Milano tends to form a dimer (A-IM/A-IM). This dimer stimulates the reverse transport of cholesterol, and thus the clearance of cholesterol, more efficiently than apolipoprotein A-I. Compared with apolipoprotein A-I, apolipoprotein A-I- Milano more efficiently decrease the oxidation of low density lipoprotein. At present, apolipoprotein A-I- Milano is the only pharmaceutical protein that is shown to remove the thrombus deposited on artery wall, with broad application prospect.
It is reported in the Journal of the American Medical Association (JAMA) recently that, apolipoprotein A-I- Milano effects changes of artery atherosclerosis lesion with unprecedentedly speed and amplitude and little side effect. With various application prospects, it has become the focus of pharmaceutical research and industrial competition worldwide. Pfizer, the largest pharmaceutical company in the world, estimates that any drug reversing artery plaque may be a billion dollar business. Therefore, the development of apolipoprotein A-I- Milano will definitely bring about enormous economical and social benefits, as well as enhance the competitive strength in the field of drug development against cardiovascular diseases and atherosclerosis diseases.
In addition, data obtained from small-scale clinical trials reveal that the clinical dosage of apolipoprotein A-I is 5-6 g per treatment course. The high therapeutic dosage of apolipoprotein A-I and the high prevalence of atherosclerosis suggest huge market demand and also an opportunity for the development of apolipoprotein A-I- Milano . At present, apolipoprotein A-I- Milano is produced by Eperion, US by means of biosynthesis, which is of high cost and low yield and undesirable for large-scale production. The recombinant expression of the protein in bacterial system is generally attractive. However, the yield is low, and Escherchia coli endotoxin tends to form tight complex with apolipoprotein A-I- Milano . Besides, the protein purification method is expensive and poor in safety. Therefore, there is the need for a method of producing apolipoprotein A-I- Milano with high yield and efficiency.
Plant bioreactor, also called molecular medicine farming, refers to the large-scale production of heterologous proteins of importance and commercial value, especially medical proteins used for the treatment or diagnosis of diseases, by a plant biological system. Mammalian antibodies were successfully expressed in transgenic plants for the first time in 1989. Both the heavy and light chains were expressed and correctly assembled in transgenic tobacco, demonstrating for the first time the possibility to use plant as a bioreactor. Since then, researches directed to transgenic plants have been rising. Many other medical proteins have been expressed in different plants sooner or later, such as hirudin, interferon, human albumin, and functional antibodies. Plants already used in plant bioreactor research include tobacco, Arabidopsis thaliana , soybean, wheat, rice, rape, potato and tomato, etc.
SemBioSys Genetic, Inc, a Canadian biotechnology company developing protein drug combinations for metabolic and cardiovascular diseases, filed a patent application in China (CN1906296A) regarding the method for producing apolipoprotein A-I and apolipoprotein A-I- Milano with transgenic Carthamus tinctorius and Arabidopsis thaliana , in which a chimeric nucleic acid construct is introduced into Arabidopsis thaliana or Carthamus tinctorius . Apolipoprotein A-I and apolipoprotein A-I- Milano is expressed in seeds upon seed setting. Arabidopsis thaliana is an annual or biennial herb. It has the smallest genome among all plants. Due to its high generic homozygosity, high mutation rates may be achieved upon physical or chemical treatments, providing various metabolic deficiency phenotypes. Thus Arabidopsis thaliana represents a good material for genetics research, and is called “the fruit fly of the plant world”. Though Arabidopsis thaliana is widely used in experimental contexts, it is not utilized in large-scale production. Carthamus tinctorius is an annual herb. Its seed can be used for oil extraction, and thus it is an important oil crop. It is distributed in the temperate zone. In China, it is mainly distributed in the Northwest (in particular Xinjiang and Tibet), and then North China and Northeast regions. Carthamus tinctorius suffers from the disadvantage of relatively low yield per mu (120-150 kg) and suboptimal oil content of the achene (34˜55%), resulting in low productivity of the end product protein and a high cost.
Therefore, there is still the need for a method for producing apolipoprotein A-I and apolipoprotein A-I- Milano with stable and high yield, low cost, and simple procedures.
BRIEF DESCRIPTION OF THE INVENTION
The inventor, upon extensive investigation and creative work, accomplished the invention by stably and high-efficiently producing apolipoprotein A-I and apolipoprotein A-I- Milano through the construction of a specific expression vector and utilizing oil sunflower as bioreactor.
The present invention is directed to a method for producing apolipoprotein A-I or apolipoprotein A-I- Milano by recombinant DNA technology, in particular a method for producing apolipoprotein A-I or apolipoprotein A-I- Milano using oil sunflower as the host. Specifically, the invention involves the expression of the gene of a fusion protein consisting of Arachis hypogaea oleosin and apolipoprotein A-I or apolipoprotein A-I- Milano in oil sunflower oil body, thereby producing the important drugs apolipoprotein A-I and apolipoprotein A-I- Milano preferably apolipoprotein A-I- Milano , used for treating atherosclerosis and the related cardiovascular diseases.
In one aspect, the invention provides a seed-specific expression vector comprising apolipoprotein A-I- Milano gene fused with Arachis hypogaea oleosin gene or apolipoprotein A-I gene fused with Arachis hypogaea oleosin gene, preferably apolipoprotein A-I- Milano gene fused with Arachis hypogaea oleosin gene, in which the promoter of the said vector is the Brassica napus oleosin gene promoter. The above vector is used for producing apolipoprotein A-I or apolipoprotein A-I- Milano , preferably apolipoprotein A-I- Milano in oil sunflower.
In another aspect, the invention provides a method for the construction the above high-efficient seed-specific expression vector, including the following steps:
1) Isolating and cloning of Brassica napus oleosin gene promoter and Arachis hypogaea oleosin gene;
2) Designing and synthesizing an apolipoprotein A-I- Milano gene or apolipoprotein A-I gene according to the codon preference of the plant;
3) Constructing a plant expression vector in which the fusion of Arachis hypogaea oleosin gene with apolipoprotein A-I- Milano or apolipoprotein A-I gene is driven by Brassica napus oleosin gene promoter.
The details of the steps are explained as follows:
1) Isolating and cloning of Brassica napus oleosin gene promoter and Arachis hypogaea oleosin gene: The 20 kD oleosin gene promoter is amplified by PCR from Brassica napus genome DNA, and cloned into pUC19 (purchased from MBI), obtaining a recombinant plasmid pUCN. The Arachis hypogaea oleosin gene lacking the stop codon is amplified by PCR using Arachis hypogaea genome DNA as template. The specific rape variety may be one that is published or used in the art, such as Qingyou 14, Hufeng 101, cold-resistance king of high oil, Early Oil 100-Day, Qingyou 2, etc., preferably Qingyou 14. The Brassica napus oleosin gene promoter may be cloned between the appropriate sites of pUC19, and preferably between the HindIII and BamHI sites of pUC19. The Arachis hypogaea variety may be one that is already published or used in the art, such as Jihua 4, Jiyou 7, Baisha, Luhua 11, Haihua, Fenghua 1, etc., preferably jihua 4.
2) Designing and synthesizing an apolipoprotein A-I- Milano gene or apolipoprotein A-I gene according to the codon preference of the plant: This is to optimize apolipoprotein A-I- Milano or apolipoprotein A-I gene (preferably the former) according to the codon usage of Helianthus animus. All codons with the usage frequency of less than 10% shall be regarded as rare codons and thus abolished, while the remaining codons shall be optimized according to the frequency of Helianthus annuus codon usage. The molecular weight of gene before optimization is 451.4. The sequence identity of the sequences before and after optimization is higher than 60%, preferably higher than 65%, even preferably higher than 72%. The preferable molecular weight of gene after optimization is 451.3. For the usage frequency of Helianthus annuus codons, reference may be made to http://www.kazusa.or.jp/codon/cgi-bin/showcodon.cgi?species=4232.
3) Constructing a plant expression vector in which the fusion of Arachis hypogaea oleosin gene with apolipoprotein A-I- Milano or apolipoprotein A-I gene is driven by Brassica napus oleosin gene promoter: The fusion gene of Arachis hypogaea oleosin gene with apolipoprotein A-I- Milano gene or apolipoprotein A-I gene is constructed by overlapping PCR. Preferably, Arachis hypogaea oleosin gene is fused with apolipoprotein A-I- Milano gene, obtaining the fusion gene Ole/apoA-I M . The fusion gene is linked into pUCN, preferable between the BamHI and SacI sites, obtaining recombinant plasmid pUCNOA. The recombined plasmid pUCNOA is subjected to double digestion, preferably with HindIII and SacI, to recover the exogenous fragment of 2202 bp. The exogenous fragment is subsequently inserted between the HindIII and SacI of pBI121, a binary plant expression vector commonly used in plant transgenic engineering, obtaining pBINOA, the plant expression vector in which the fusion gene of Arachis hypogaea oleosin with apolipoprotein A-I- Milano is driven by Brassica napus oleosin gene promoter, or in which the fusion gene of Arachis hypogaea oleosin gene with apolipoprotein A-I is driven by Brassica napus oleosin gene promoter.
In another aspect, the invention provides a method for producing apolipoprotein A-I- Milano or apolipoprotein A-I with the above seed-specific plant expression vectors, including the following steps:
1) introducing the above construction expression vectors into an explant of a receptor plant;
2) cultivating the above receptor plant materials into a complete plant and obtain seeds thereof;
3) isolating apolipoprotein A-I- Milano or apolipoprotein A-I from the seeds.
Preferably, the receptor plant is oil sunflower. Preferably, apolipoprotein A-I- Milano is produced.
The specific procedures include the following details.
1) A seed-specific plant expression vector carrying apolipoprotein A-I- Milano gene or apolipoprotein A-I gene is introduced into the explant of a oil sunflower restoring line. The method for introducing the seed-specific plant expression vector into the restoring line of oil sunflower may be a conventional introduction method in the art, including but not limited to gene gun bombardment, pollen-tube pathway, ovary injection, and Agrobacterium -mediated transformation, preferably Agrobacterium -mediated transformation. In Agrobacterium -mediated transformation, the seed-specific plant expression vector carrying apolipoprotein A-I- Milano gene or apolipoprotein A-I gene is introduced into Agrobacterium , which mediates the transformation of the explants of the restoring line of oil sunflower. The explants include shoot apexes excised from sterile seedling, cotyledon, cotyledon node, and seedlings with one cotyledon detached. Preference is made to seeding plant stripped of one cotyledon.
2) Resistance seedling is obtained through resistance selection of the regenerated plants obtained after transgenesis, and is transplanted into greenhouse after rootage for cultivation until maturity to harvest seeds. The resistance seedling is transplanted into greenhouse after taking root for vermiculite and nutritional soil mixture cultivation. PCR test and southern blotting test shall be conducted during the Seedling Stage. Western blotting test shall be conducted after harvest against the fusion protein of oleosin and apolipoprotein A-I- Milano ;
3) The seed containing apolipoprotein A-I- Milano or apolipoprotein A-I is ground in buffer solution. The oil body is separated from other components of the seed by centrifugation and washed. Apolipoprotein A-I- Milano or apolipoprotein A-I is released from the oil body surface through digestion, purified by HPLC, and subjected to identification.
In the vector and method of the invention, Brassica lupus oleosin promoter is used. Experimental research indicates that this promoter can greatly improve the expression efficiency of apolipoprotein A-I- Milano gene. Preferably, Kozak consensus sequence may be positioned near the initiator codon of oleosin gene, further improving the expression efficiency.
In the vector and method of the invention, the apolipoprotein A-I- Milano or apolipoprotein A-I is expressed as fusion protein with oleosin. The protein of interest is specifically expressed in transgenic plants in the oil body as fusion with oleosin. Taking advantage of the hydrophobic/lipophilic characteristic of the oil body, the seeds of the transgenic plant is subjected to grind, extraction, centrifugation, and recovery of the upper oil phase, thereby separating the fusion protein from other components in the cell. More than 90% of seed proteins can be removed. Preferably, a thrombin recognition site is positioned between oleosin and apolipoprotein A-I- Milano or apolipoprotein A-I for releasing apolipoprotein A-I- Milano from oil body, thereby simplifying the purification process of the expression product and improving the purification efficiency. The preferred oleosin is Arachis hypogaea oleosin. The fusion expression of Arachis hypogaea oleosin and apolipoprotein A-I- Milano or apolipoprotein A-I is optimal in terms of quality and quantity.
In the vector and method of this invention, in order to improve the expression efficiency of apolipoprotein A-I- Milano gene or apolipoprotein A-I gene, the apolipoprotein A-I- Milano gene or apolipoprotein A-I gene is optimized according to apolipoprotein A-I- Milano or apolipoprotein A-I gene sequence, the preference of codon usage of Helianthus annuus and GC content, and is fully synthetic.
In the methods of apolipoprotein A-I- Milano or apolipoprotein A-I production disclosed by this invention, the preferable plant bioreactor is oil sunflower. As an important oil crop in China, oil sunflower has a long planting history and irreplaceable advantages relative to other crops. With high yield and as a drought tolerance crop, oil sunflower can be planted in severe environment such as alkali soils, arid areas, and even in deserts. It is therefore suitable for large-scale planting. The planting of oil sunflower does not conflict with alimentary crops, and is beneficial in terms of improving the utilization of mountain ridges and dry and unfruitful area, alleviating the insufficiency of cultivated land. Therefore, it is particularly beneficial in China to use oil sunflower as bioreactor for the large-scale production of apolipoprotein A-I- Milano . A most significant advantage is the greatly improved production efficiency and productivity achieved by oil sunflower as bioreactor, compared with prior art methods using Carthamus tinctorius as the bioreactor for the production of apolipoprotein A-I- Milano or apolipoprotein A-I.
The following advantages are achieved by the method of producing apolipoprotein A-I- Milano of the invention.
1. The heterologous protein expressed in plant is similar to the protein expressed in mammals and can be correctly fold. This is of particular importance for the production of medical proteins with in vivo activity.
2. The apolipoprotein A-I- Milano produced in plant bioreactor is safer, because it avoids the contamination of E. coli endoxin or pathogens.
3. The oil body expression system of transgenic plant used for expressing apolipoprotein A-I- Milano greatly simplifies the purification process, reduces cost, and facilitates the industrialization, compared with Arabidopsis thaliana and Carthamus tinctorius systems already adopted by SemBioSys Genetics.
4. The seed-specific plant expression vector and preparation method introduced by this invention can greatly improve the expression quantity of apolipoprotein A-I- Milano or apolipoprotein A-I, which can reach 1.5% of the total protein content of seed.
5. Agrobacterium -mediated transformation is used, which not only reduce cost and improves transformation efficiency, but also improves the genetic stability of the transgenic plant.
This invention utilizes transgenic technology to develop a high expression efficiency plant bioreactor. The resultant product, apolipoprotein A-I- Milano or apolipoprotein A-I, is an potent drug for the treatment of cardiovascular diseases and atherosclerosis diseases.
Definitions:
Unless specially defined otherwise, all terms referred in this invention shall have the common meanings in the field, wherein the meaning of abbreviations are provided as follows:
LDL: Low density lipoprotein (LDL)
HDL: High density lipoproteins (HDL)
TC: Total cholesterol (TC) in blood plasma
LDL-C: Low density lipoproteins cholesterol (LDL-C)
apoA-I: Apolipoprotein A-I
apoA-IM: Apolipoprotein A-I- Milano (AIM)
A-IM/A-IM: apolipoprotein A-I- Milano dimer
pUC19: a common E. coli cloning vector, obtained from MBI
pBI121: a common plant expression vector in plant transgenic engineering
pUCN: pUC19 vector carrying Brassica napus oleosin promoter (NOP) inserted between the HindIII and BamHI sites
Ole/apoA-IM: Fusion gene of Arachis hypogaea oleosin with apolipoprotein A-I- Milano
pUCNOA: pUC19 vector carrying the fusion gene of Brassica napus oleosin gene promoter (NOP), Arachis hypogaea oleosin gene and apolipoprotein A-I- Milano , inserted between the HindIII and SacI sites
pBINOA: pBI121 vector carrying the fusion gene of Brassica napus oleosin promoter (NOP), Arachis hypogaea oleosin gene and apolipoprotein A-I- Milano , inserted between the HindIII and SacI sites.
DESCRIPTION OF FIGURES
FIG. 1 Schematic Drawing of the Seed-specific plant expression vector pBINOA;
FIG. 2 Schematic Drawing of the Construction Process of Seed-specific plant expression vector pBINOA;
FIG. 3 pUCN vector Restriction Enzyme Digestion Identification and PCR Detection;
FIG. 4 Construction of Ole/apoA-IM Fusion gene;
FIG. 5 pUCNOA vector Restriction Enzyme Digestion Identification;
FIG. 6 Restriction Enzyme Digestion Identification of Seed-specific Plant Expression Vector pBINOA;
FIG. 7 PCR Detection of npt II Gene in Transgenic Oil Sunflower;
FIG. 8 PCR Detection of apolipoprotein Gene in Transgenic Oil Sunflower;
FIG. 9 PCR-Southern Blotting Results of Transgenic Oil Sunflower;
FIG. 10 Western Detection of the oleosin-Apolipoprotein A-I- Milano Fusion Protein in Transgenic Oil Sunflower Kernel Oil Body; and
FIG. 11 Western Detection of the trans-apolipoprotein A-I- Milano gene oil sunflower seed and carthamus tinctorius seed to obtain apolipoprotein A-I- Milano protein by separation and purification.
DETAILED DESCRIPTION OF THE INVENTION
The following embodiments are provided for further description of this invention, and are not construed as limiting to the scope of the invention. Given the present disclosure, alterations may be made to this invention without departing from the spirit of this invention. All these alterations are within the scope of the present invention.
Unless otherwise specified, the methods referred to in the following embodiments are practiced according to general practice in this field.
Example 1: Seed-Specific Plant Expression Vector
Brassica napus oleosin gene promoter (NOP) was amplified by PCR, inserted into pUC19 between the HindIII and BamHI sites, obtaining pUCN. Apolipoprotein gene was designed according to apolipoprotein A-I- Milano (AIM) gene sequence and the codon usage of Helianthus annuus , synthetically produced, and inserted at the 3′ end of the Arachis hypogaea oleosin gene (Ole), obtaining the fusion gene of Arachis hypogaea oleosin and apolipoprotein A-I- Milano . Thrombin cleavage site was added between the Arachis hypogaea oleosin gene and the apolipoprotein A-I- Milano gene. The fusion gene was inserted into pUCN between the BamHI and SacI sites to obtain pUCNOA. pUCNOA was double digested with HindIII and SacI. The 2202 bp exogenous fragment was collected on agarose gel, and inserted between the and SacI sites of plant binary expression vector pBI121, obtaining the plant expression vector pBINOA of the invention. The expression cassette of pBINOA is the Ole/apoA-I M fusion gene driven by Brassica napus oleosin promoter. The structure of pBINOA is shown in FIG. 1 . 1: Brassica napus oleosin gene promoter; 2: Arachis hypogaea oleosin gene; 3: thrombin cleavage site; 4: apolipoprotein A-I- Milano gene. By sequencing of pBINOA, the sequence of the expression cassette is obtained as shown in SEQ ID NO: 15, with the length of 2202 bp.
Example 2: Construction of Seed-Specific Plant Expression Vector pBINOA
The construction of the plant expression vector pBINOA is shown in FIG. 2 . The specific procedures are provided as follows.
Cloning of Brassica napus oleosin gene promoter: Brassica napus is an important oil crop. The oil content is up to 42˜45%. The 20 kD oleosin in Brassica napus oil body is 10 times the amount of 24 kD oleosin. Forward primer pBINOA-1: CCC AAG CTT TTC AAC GTG GTC GGA TCA TGA CG (SEQ ID NO:1) and reverse primer pBINOA-2: CGC GGA TCC GAA TTG AGA GAG ATC GAA GAG (SEQ ID NO:2) for the PCR amplification of Brassica napus 20 kD oleosin gene promoter were designed according to the nucleotide sequence of Brassica napus oleosin gene promoter (Genbank No. AF134411) in which HindIII and BamHI cleavage sites were introduced (the underlined section). Using the genome DNA of Brassica napus Qingyou 14 variety as the template and pBINOA-1 and pBINOA-2 as primers, Brassica napus oleosin gene promoter was amplified by PCR with the following conditions: 94° C. 1 min, 63-73° C. 1 min, and 68° C. 1 min, and 10 min of extension at 68° C. after 30 cycles. The amplification product was recovered by agarose gel electrophoresis, double digested with HindIII and BamHI, and connected to pUC19 digested with HindIII and BamHI. The ligation product was mixed with 2004 of DH5α competent cell (purchased from Tiangen Biotech (Beijing) Co., Ltd.), and then subjected to ice bath for 30 min, heat shock for 1.5 min at 42° C., and ice bath for 3 min. 8004 LB culture medium was added and cultured for 45 min at 37° C. Aliquots of the transformation reaction was plated on LB agar containing 50 μg/mL ampicillin and incubated overnight at 37° C. The transformants were screened by PCR using pBINOA-1 and pBINOA-2 as primers. PCR conditions were 94° C. 1 min, 60-73° C. 1 min, 72° C. 1 min, and 10 min of extension at 72° C. after 30 cycles. The PCR product was subjected to electrophoresis with agarose gel for verification. The positive transformant was named as pUCN. The positive transformant was shaken in liquid culture medium. Plasmid was extracted through alkaline lysis. The plasmid was subjected to single enzyme digestion identification with HindIII and double enzyme digestion identification with HindIII and BamHI. The results displayed by agarose gel electrophoresis are shown in FIG. 3 . M: DNA Molecular Weight Marker λDNA/EcoT14I; L1: product of restriction enzyme digestion of pUCN plasmid with HindIII as 3565 bp fragment; L2: products of double digestions of pUCN plasmid with HindIII and BamHI, as the vector fragment of 2662 bp and the promoter of 903 bp; and L3: promoter of 903 bp obtained from PCR detection of pUCN plasmid. pUCN is sequences according to the following procedures: (1) Using pUCN as template, conduct PCR reaction with pUC19 common sequencing primer to obtain PCR product; (2) purify PCR product to remove enzyme, florescent dye, primer, and other ions; (3) use 3730 sequencer (ABI Ltd.) to sequence the purified PCR product after degeneration and ice bath; (4) automatically analyze and print out colored sequencing map and DNA sequence by the machine. The length of the exogenous fragment in pUCN is 903 bp. The sequence is shown in SEQ ID NO:3. The molecular weight is 556.7 kDa. The enzyme digestion results and sequencing results suggest that, Brassica napus oleosin gene promoter was successfully cloned into pUC19.
Artificial synthesis of apolipoprotein A-I- Milano gene: Based on apolipoprotein A-I gene sequence (SEQ ID NO:4, NM000039) (amino acid sequence shown in SEQ ID NO:5) and the codon usage of Helianthus annuus (http://www.kazusa.or.jp/codon/cgi-bin/showcodon.cgi?species=4232), as well as the GC content in Helianthus annuus (genome, apolipoprotein A-I- Milano gene is redesigned and synthesized. Residue C at position 517 was mutated into T, and at the 5′ end of the gene a thrombin cleavage site was added, with the nucleotide sequence shown in SEQ ID NO:6 (CTGGTCCCAA GGGGTAGC) and the amino acid sequence shown in SEQ ID NO:7 (L V P R G S). The molecular weight of the synthesized apolipoprotein A-I- Milano gene was 462.4 kDa, and the sequence is shown in SEQ ID NO:8. The encoded protein is composed of 249 amino acid residues and the molecular weight is 28.585 kDa.
Amplification of Ole/apoA-I M fusion protein gene: Two pairs of specific primers (pBINOA-3/pBINOA-4 and pBINOA-5/pBINOA-6, wherein the sequences are SEQ ID NO:9, SEQ ID NO:10, SEQ ID NO:11, and SEQ ID NO:12 respectively) were designed according to the sequence of Arachis hypogaea oleosin gene (Genbank No. AF325917) and the sequence of apolipoprotein A-I- Milano gene (SEQ ID NO:8). pBINOA-3 and pBINOA-6 were provided with BamHI and SacI restriction sites (the underlined section) respectively. Moreover, Kozak sequence (the bolded part in the sequence, to improve the transcription and expression efficiencies) is positioned near the initiator codon of oleosin gene in pBINOA-3 primer. pBINOA-4 and pBINOA-5 were reverse complementary sequences.
SEQ ID NO.: 9 pBINOA-3:
CGC GGA TCC AGC AAA GCC GCC ACC ATG GCT ACT
GCT ACT GAT CG
SEQ ID NO.: 10 pBIN0A-4:
GCT ACC CCT TGG GAC CAG TGA TGA TGA CCT CTT
AAC
SEQ ID NO.: 11 pBINOA-5:
GTT AAG AGG TCA TCA TCA CTG GTC CCA AGG GGT
AGC
SEQ ID NO.: 12 pBINOA-6:
C GAG CTC TTA TTG TGT GTT AAG TTT CTT TG
Using pBINOA-3/pBINOA-4 as the primer, Arachis hypogaea (variety Jihua 4) genome DNA as template, the Arachis hypogaea oleosin gene lacking the terminate codon was amplified. PCR conditions are 94° C. 1 min, 50-55° C. 1 min, 68° C. 1 min, and 10 min of extending at 68° C. after 30 cycles. Using pBINOA-5/pBINOA-6 as the primer, the optimized apolipoprotein A-I- Milano as template, the apolipoprotein A-I- Milano gene was amplified. PCR conditions are 94° C. 1 min, 63-73° C. 1 min, 68° C. 1 min, and 10 min of extending at 68° C. after 30 cycles. The two PCR amplification products were recovered by agarose gel electrophoresis, and mixed at the molar ratio of 1:1 to serve as template. pBINOA-3/pBINOA-6 were used as primer for overlapping PCR. PCR conditions are 94° C. 1 min, 50-55° C. 1 min, 68° C. 2 min, and 10 min of extending at 68° C. after 30 cycles. Ole/apoA-I M fusion gene was obtained through agarose gel electrophoresis of the amplification product. The construction of Ole/apoA-I M fusion gene is shown in FIG. 4 . M: DNA molecular weight marker DL2000; L1: the 528 bp fragment of Arachis hypogaea oleosin gene lacking the termination codon, amplified with pBINOA-3/pBINOA-4 as the primer and Arachis hypogaea (variety Jihua 4) genome DNA as the template: L2: the 750 bp apolipoprotein A-I- Milano gene amplified with pBINOA-5/pBINOA-6 as the primer and the optimized apolipoprotein A-I- Milano gene as the template (the nucleotide sequence containing thrombin cleavage site); L3: Ole/apoA-I M fusion gene obtained by overlapping PCR with pBINOA-3/pBINOA-6 as the primer. The Ole/apoA-I M fusion gene was sequenced, and the results indicated that the sequence of Ole/apoA-I M fusion gene was as shown in SEQ ID NO:13. The length is 1278 bp, and the molecular weight is 787.9 kDa. The deduced amino acid sequence is shown in SEQ ID NO:14, comprising 425 amino acid residues. The molecular weight is 46.994 kDa. The construction results and sequencing results of oleosin-apoA-I M fusion gene showed that, we had already obtained ole/apoA-I M fusion gene.
Construction of intermediate vector pUCNOA: The ole/apoA-I M fusion gene was BamHI and SacI double digested and ligated with pUCN which was double digested in the same way. The ligation product was mixed with 200 μL DH5α competent cell (purchased from Tiangen Biotech (Beijing) Co., Ltd.), and subjected to ice bath for 30 min, heat shock for 1.5 min at 42° C., and ice batch for 3 min. 8004 LB culture medium was added and grown at 37° C. for 45 min. LB agar plate containing 100 μg/mL ampicillin was innoculated and incubated at 37° C. overnight. The transformants were selected by PCR using pBINOA-3 and pBINOA-6 as primers. PCR conditions were 94° C. 1 min, 60-73° C. 1 min, 72° C. 1.5 min, and extension of 10 min at 72° C. after 30 cycles. The PCR product was run on agarose gel. The positive transformant was named as pUCNOA and was shaken in liquid medium. Plasmid was extracted by alkaline lysis. The plasmid was identified by HindIII single digestion identification, HindIII and BamHI double digestion identification, and BamHI and SacI double digestion identification. The identification results of agarose gel electrophoresis are shown in FIG. 5 . M: DNA molecular weight marker λDNA/EcoT14I; L1: fragment of 4849 bp obtained by HindIII single digestion of pUCNOA plasmid; L2: vector fragment of 2647 bp and exogenous fragment of 2202 bp (containing Brassica napus oleosin gene promoter and ole/apoA-I M fusion gene) obtained by HindIII and SacI double digestion of pUCNOA plasmid; L3: vector fragment of 3571 bp and exogenous fragment of 1278 bp (ole/apoA-I M fusion gene) obtained by BamHI and SacI double digestion of pUCNOA plasmid. The pUCNOA plasmid was sequenced, and the sequencing results are shown in SEQ ID NO:15. The total length is 2202 bp and the molecular weight is 1357.5 kDa, including Brassica napus oleosin gene promoter and ole/apoA-I M fusion gene. The enzyme digestion results (as shown in FIG. 5 ) and sequencing results (as shown in Sequence List) (SEQ ID NO:15) indicated that, the expression cassette of Brassica napus oleosin gene promoter-driven Arachis hypogaea oleosin gene-apolipoprotein A-I- Milano fusion gene was obtained and the said expression cassette was successfully cloned into the vector pUC19.
Construction of seed-specific plant expression vector pBINOA: DNA of pUCNOA plasmid was extracted by alkaline lysis, and cleaved with HindIII and SacI. The exogenous fragment of 2202 bp was recovered by agarose gel electrophoresis and ligated to pBI121 cleaved with HindIII and SacI. The ligation product was mixed with 200 μL DH5α competent cell (purchased from Tiangen Biotech (Beijing) Co., Ltd.), and subjected to ice bath for 30 min, heat shock at 42° C. for 1.5 min, and ice bath for 3 min. 800 μL LB culture medium was added and cultivated for 45 min. LB plate containing 100 μg/mL kanamycin was plated and cultivated at 37° C. overnight. Transformants are screened by PCR using pBINOA-1 and pBINOA-6 as primers. PCR conditions were 94° C. 1 min, 60-73° C. 1 min, 72° C. 2 min, and extension or 10 min at 72° C. after 30 cycles. The PCR product were screened through agarouse gel electrophoresis. The positive transformant was designated as pBINOA. The positive transformant was cultured in liquid while shaking. Plasmid was extracted with alkaline lysis, and subjected to HindIII single digestion identification and HindIII and SacI double digestion. The identification results of agarose gel electrophoresis are shown in FIG. 6 . M: DNA molecular weight marker λDNA/EcoT14I; L1: fragment of 14205 bp, the product of HindIII digestion of pBINOA plasmid; L2: vector fragment of 12003 bp and exogenous fragment of 2202 bp (including Brassica napus oleosin gene promoter and ole/apoA-I M fusion gene), the products of HindIII and SacI double digestion of pBINOA plasmid. The pBINOA plasmid was sequenced, and the sequencing result is as shown in SEQ ID NO:15. The full-length nucleotide sequence of the vector is shown as SEQ ID NO:16. The entire expression cassette is 2202 bp long. The molecular weight is 1357.5 kDa, including Brassica napus oleosin gene promoter and ole/apoA-I M fusion gene. Brassica napus oleosin gene promoter is a strong seed-specific promoter, and drives the specific expression of apolipoprotein A-I- Milano in oil body as fusion with Arachis hypogaea oleosin in the transgenic plant. Arachis hypogaea oleosin carrying with apolipoprotein A-I- Milano is anchored on oil body surface. Utilizing the hydrophobic/lipophilic characteristics of oil body, the transgenic plant seeds were ground and extracted, centrifuged, and the upper oil phase recovered, thereby separating the protein from other components in the cell. More than 90% of the seed protein was removed. Thrombin recognition site was positioned between Arachis hypogaea oleosin and apolipoprotein A-I- Milano to release apolipoprotein A-I- Milano from oil body.
Example 3: Production of Apolipoprotein A-I- Milano (AIM) with the Vector
3.1 Introduce the Seed-Specific Expression Vector Constructed Above into the Explants of the Receptor Plant;
3.1.1 Preparation of the Competent Agrobacterium Cells
(1) Transfer Agrobacterium tumefacien LBA4404 single bacterium into 3 mL YEB medium (containing streptomycin Sm 125 μg/mL), and grow the cells at 28° C. overnight;
(2) Transfer 5004 overnight culture into 50 mL YEB (Sm 125 μg/mL) medium, and grow the cells at 28° C. until OD 600 is 0.5;
(3) 5,000 rpm, centrifuge for 5 min;
(4) Resuspend Agrobacterium cells in 10 mL 0.15M NaCl solution, 5,000 rpm, and centrifuge for 5 min;
(5) Resuspend Agrobacterium cells in 1 mL precooled 20 mM CaCl 2 for ice bath and use within 24 h, or dispense aliquots (200 μl) of the suspensions into tube and quick freeze for 1 min in liquid nitrogen, and preserve at −70° C. for later use.
3.1.2. Transformation of Agrobacterium Competent Cells with Seed-Specific Plant Expression Vector
1 μg thus constructed plasmid DNA was added to 2004 competent cells, and stored in liquid nitrogen for 1 min, in water bath at 37° C. for 5 min. Then 1 mL YEB medium was added, cultivated in liquid medium at 28° C. while slowly shaking for 4 h; and centrifuged at 1,000 rpm for 30 sec. The supernatant was discarded and 0.1 mL YEB medium was added for resuspension. Aliquots of the transformation reaction were plated on YEB agar plate containing 100 μg/mL Kan and 124 μg/mL Sm, and incubated at 28° C. for approximately 48 h.
Identification of Positive Clone
Single colony was picked into YEB medium (containing 100 μg/mL Kan and 125 μg/mL Sm), and cultivated in liquid medium at 28° C. overnight. Small amount of plasmid DNA was extracted with alkaline lysis. Using the plasmid DNA as template and pBINOA-1 and pBINOA-6 as primers, PCR amplification identification was carried out under the following conditions: 94° C. 1 min, 60-73° C. 1 min, 72° C. 2 min, and extension of 10 min at 72° C. after 30 cycles. Positive transformants were obtained after agar gel electrophoresis of PCR product.
Preparation of Agrobacterium Suspension Used for Oil Sunflower Transformation
5 mL YEB medium containing 100 μg/mL Kan and 125 μg/mL Sm was inoculated with a single colony of transformed Agrobacterium . The culture was grown overnight with shaking. 100-200 mL YEB liquid medium containing 100 μg/mL Kan and 125 μg/mL Sm was inoculated with 1 mL culture. The culture was grown at 28° C. with vigorous shaking until OD 600 is 0.4˜0.8, and centrifuged at 3500 rpm for 10 min to recover cells. The pellet was resuspended with MS (free of plant growth regulators or antibiotics) to make OD 600 at approximately 0.6 for transformation.
3.1.3 Genetic Transformation of Oil Sunflower Explants Mediated by Agrobacterium
The explants, in the forms of shoot apexes excised from sterile seedlings, cotyledon, cotyledonary node or seedlings with one cotyledon detached, of the seedling of oil sunflower seeds sprouting for 3˜4 d were immersed in said Agrobacterium suspension for 6˜8 min and transferred to MS solid medium for culture for 3 d (at 25° C., in dark). The seedlings with one cotyledon detached is preferred.
3.2 Cultivation of the Above Receptor Plant Materials into Complete Plant to Obtain Seeds for the Detection of Target Gene and Protein
3.2.1 Cultivate the Receptor Plant Materials into Complete Plant and Obtain Seeds
The transformed explants were transferred to MS agar medium containing 300 mg/L cephalosporin for approximately 7 d, then transferred to MS resistance screening medium (containing 300 mg/L cephalosporin and 70 mg/L kanamycin) for selective culture. The medium was exchanged every 15˜20 d. Resistance buds were obtained after three rounds of screening. 2˜3 cm resistance buds were transferred to rooting medium MS2 (MS+IBA0.1 mg/L+Kan 70 mg/L+cef 300 mg/L) and transplanted after rootage of resistance seedling into greenhouse for vermiculite and Nutritional soil mixture culture until maturity, seeds harvested.
3.2.2 Target Gene and Protein Detection
PCR detection was performed on apolipoprotein A-I- Milano gene during the Seedling Stage. Western blotting detection was performed on Arachis hypogaea oleosin and apolipoprotein A-I- Milano fusion protein after harvesting kernels.
PCR Detection and PCR-Southern Blotting Detection of Transgenic Oil Sunflower Seedling
SDS method was adopted to extract the genome DNA of the young leaves of resistant oil sunflower seedling as the template. PCR amplification was carried out with two pairs of primers nptIIF/nptIIR and pBINOA-5/pBINOA-6. The sequences of the premiers are nptIIF: ATG AAC TGC AGG ACG AGG (SEQ ID NO:17) and GCG ATA CCG TAA AGC ACG (SEQ ID NO:18) respectively. The PCR condition of nptIIF/nptIIR and pBINOA-5/pBINOA-6 includes 94° C. for 1 min, 60° C. for 1 mm, 72° C. for 1 min, and final extension for 10 min at 72° C. after 30 cycles. As anticipated, fragments of 567 bp (partial nptII gene) and apoA-I M gene fragment of 750 bp were amplified respectively. The results are shown in FIG. 7 and FIG. 8 . In FIG. 7 , M: DNA molecular weight marker DL2000; L1-L4: the fragment of 567 bp amplified with nptIIF/nptIIR as the primer and the genome DNA extracted from the kanamycin-resistant oil sunflower as the template, i.e., positive plants; L5: use non-resistant oil sunflower as control. In FIG. 8 , M: DNA molecular weight marker DL2000; L1-L4: the fragment of 750 bp amplified with pBINOA-5/pBINOA-6 as the primer and the genome DNA extracted from the kanamycin-resistant oil sunflower as the template, i.e., positive plant; L5: use non-resistant oil sunflower as control.
PCR-Southern Blotting Detection
1) Genomic DNA of the young leave of the transgenic oil sunflowers, in which both nptII and apoA-I M are positive, was extracted with SDS method. PCR amplification was performed on the genome DNA with pBINOA-1/pBINOA-6 as the primer. The PCR reaction condition includes 30 cycles of 94° C. for 1 min, 60° C. for 1 min, and 72° C. for 2.5 min; and final extension at 72° C. for 10 min.
2) The DNA was transferred from agarose gel to a nylon membrane, denatured and neutralized after electrophoresis, and subjected to semi-dry blotting. The membrane was dried and baked for 1.2 hr at 80° C. in a vacuum oven.
3) DNA probe marking
The pBINOA plasmid DNA digested with BamH□ and Sac□ was recovered. 3 μg DNA was used for labeling.
4) Hybridization
The membrane was pre-hybridized at 63° C. for 30 min and hybridized at 63° C. overnight, washed twice with 2×SSC, 0.1% SDS, and then washed twice with 0.5×SSC, 0.1% SDS preheated to 65° C. at 63° C.
5) Detection
The hybridized and washed membrane was briefly rinsed once with washing buffer, incubated in 100 ml Blocking solution for 30 min, incubated for 30 min in 20 ml Antibody solution, Washed 2×15 min in 100 ml Washing buffer, and equilibrated for 2-5 min in 20 ml Detection buffer. The membrane was placed in a hybridization bag (with DNA side facing up) and 1 ml CSPD added. The membrane was incubated for 10 min at 37° C. to enhance the luminescent reaction, and exposed to X-ray film at room temperature. The results are shown in FIG. 9 . M: DNA molecular weight marker λ DNA/EcoT14I; L1-L4: the Southern blotting results of the product amplified with the positive plant genome (detected as positive by PCR) as the template and pBINOA-1/pBINOA-6 as the primer. The hybridization signal was displayed at the place of 2.2 kb as expected, suggesting the integration of ole/-apoA-I M fusion gene into oil sunflower genome; L5: control of non-transgenic oil sunflower.
Western Blotting Detection of Arachis hypogaea Oleosin and Apolipoprotein A-I- Milano Fusion Protein in Transgenic Oil Sunflower Seeds
Transgenic oil sunflower seeds were ground in five volumes of grinding buffer (50 mM Tris-HCl pH 7.5, 0.4 M sucrose, 0.5M NaCl), centrifugated 10×g for 30 min, and separated into three parts. The oil phase was collected and resuspend in one volume of grinding buffer and mixed even. Five volumes of precooled 50 mM Tris-HCl pH 7.5 buffer was added, centrifugated 10×g for 30 min, and the oil phase collected. The above processes were repeated for two times to further remove the remaining water-soluble ingredients and insoluble ingredients, obtaining pure oil body (the ingredients of oil body include: neutral lipids, phosphatides, and oleosin). To the oil body was added 2V of diethyl ether and centrifugated. The neutral lipids were in the upper diethyl ether layer and phosphatides were left in the lower water phase. The intermediate protein layer was collected and suspended in 0.1M sucrose buffer. Chloroform methanol (2:1) mixture was added and extracted twice. The intermediate protein layer was collected, extracted with diethyl ether once and dissolved in sterile water. SDS polyacrylamide gel electrophoresis was performed, and then Western blotting analysis was performed using polyclonal goat anti-rabbit apolipoprotein A-I after transmembrane. The results are shown in FIG. 10 . M: protein molecular weight standard; L1 and L2: oil protein extracted from transgenic oil sunflower seeds, expression of apolipoprotein A-I- Milano is shown. A fusion protein of molecular mass of approximately 48 kDa was recognized, consistent with the anticipated result ( Arachis hypogaea oleosin 18.4 kDa, thrombin cleavage site 0.6 kDa, and apolipoprotein A-I- Milano 28.9 kDa). The fusion protein accounts for 1.1% of the total seed protein, exceeding the minimum commercialization requirement (1%) of recombinant medical protein in plant. Therefore, it is feasible and applicable to make use of plant oil body expression system to achieve the industrial production of apolipoprotein A-I- Milano .
3.3 Obtain Apolipoprotein A-I- Milano from the Seeds by Separation and Purification.
Step 1: Separate Oil Body from Other Components in Seeds
The kernel was ground in five volumes of grinding buffer (50 mM Tris-HCl pH 7.5, 0.4M sucrose, 0.5 M NaCl), centrifuged at 10×g for 30 min, and divided into three parts. The bottom part is insoluble precipitation (hull, fiber materials, insoluble sugar, protein and other insoluble dirt); the middle layer is aqueous phase, containing soluble cellular constituents (storage protein); the upper layer is the oil body and the associated oil body protein.
Step 2: Wash the Oil Body
The oil phase obtained from Step 1 was resuspended in the same volume of grinding butter and mixed even. Five volumes of precooled 50 m MTris-HCl pH 7.5 buffer are added and centrifuged at 10×g for 30 min. The oil phase was collected. The above processes were repeated twice to further remove the residual water-soluble ingredients and insoluble ingredients. The washed oil body was resuspended in precooled 50 mM Tris-HCl pH 7.5 of equivalent volume. The resulting oil body was substantially pure oil body, and he only protein left was oil body protein.
Step 3: Release Apolipoprotein A-I- Milano Protein by Restrictive Digestion
The oil body was washed with thrombin digestion buffer (20 m M Tris-HCl pH8.4, 150 m M NaCl, and 2.5 m M CaCl 2 ) for two times. Appropriate amount of thrombin was added, stored at 37° C. overnight, and centrifuged. Apolipoprotein protein exists in the aqueous phase.
Step 4: Purify Apolipoprotein A-I- Milano Protein with High Performance Liquid Chromatography (HPLC)
Reversed-phase chromatography C4 column (5μ, 0.24*25 cm) was used, at the ultraviolet wavelength of 214 nm. The column was equilibrated with 2 mL/min buffer A (10% acetonitrile, 0.1% trifluoroacetic acid), loaded with the aqueous phase obtained in the last step, and applied linear gradient elution of 0-60% buffer B (95% acetonitrile, 0.1% trifluoroacetic acid). Pure apolipoprotein A-I- Milano protein was obtained with the purity above 99.5%.
Example 4: Comparison Between Oil Sunflower and Carthamus Tinctorius as Bioreactor for the Production of Apolipoprotein A-I- Milano (AIM)
The same amount (280 mg) of trans-apolipoprotein A-I- Milano gene oil sunflower seed and carthamus tinctorius seed were used to obtain apolipoprotein A-I- Milano protein by separation and purification according to Example 3. The loading quantity was one-tenth of the total quantity obtained. Western blotting detection was performed, and the results are shown in FIG. 11 . M: protein molecular weight standard; L1: apolipoprotein A-I- Milano purified from transgenic carthamus 28.9 kDa as expected, with the amount of 50 ng; L2: the apolipoprotein A-I- Milano purified from transgenic oil sunflower, 28.9 kDa as expected, with the amount of 80 ng. It can be calculated that 1 kg of transgenic oil sunflower seed can produce 2.85 g of apolipoprotein A-I- Milano , while under the same condition, 1 kg transgenic carthamus tinctorius seed can produce 1.78 g of apolipoprotein A-I- Milano . Moreover, the yield per mu of oil sunflower is approximately 250 kg while that of carthamus tinctorius is approximately 200 kg. Therefore, oil sunflower is superior to carthamus tinctorius in terms of the yield of apolipoprotein A-I- Milano protein per seed weight or per plant area. | A seed-specific expression vector and its construction methods and applications are disclosed. A fusion protein expression cassette consisting of Arachis hypogaea oleosin gene-apolipopoprotein A-I Milano (A-IM) gene driven by Brassica napus oleosin gene promoter is inserted between the HindIII and SacI sites of a plant binary expression vector pBI121, obtaining the plant expression vector pBINOA of the invention. In addition, a method for producing apolipoprotein A-I Milano is provided, in which the expression vector is used to transform oil sunflower which is used as a plant bioreactor. The method can not only improve the yield of apolipoprotein A-I Milano , but also greatly reduce production costs, and is suitable for industrial production. | 2 |
The present invention relates to highly carboxylated cellulose fibers and a process for making such fibers. The highly carboxylated cellulose fibers of the inventions are water-insoluble and have enhanced absorbency toward water and body fluids, making them desirable for use in personal hygiene articles, high strength paper making, cellulose ester coatings with low volatile organic components (VOC), as well as in many other applications. The process of the invention is based on the reaction of organic dicarboxylic acid anhydrides, such as phthalic anhydride, maleic anhydride, succinic anhydride, glutaric anhydride, trimellitic anhydride, 1,2-cyclohexanedicarboxylic anhydride, and oxalyl chloride and cellulosic fibers.
BACKGROUND OF THE INVENTION
Carboxylated cellulose fibers have been used and proposed for use in a number of applications where the presence of carboxyl groups on the fibers is believed to enhance some properties of the cellulose fibers. However, the limited extent to which cellulose fibers could heretofore be carboxylated in a cost-effective and environmentally benign fashion has limited the use of such fibers.
Polymer composites or blends employing cellulose exhibit limited compatibility with certain polymeric materials, including nylon-6 and polypropylene. This incompatibility diminishes the mechanical properties of the polymer composite or blend products. The compatibility of cellulose to such polymeric materials is improved by adding carboxylic acid groups to the cellulose, where it is believed that the carboxyl groups enhance the compatibility between polymers and cellulose.
A need also exists for water-insoluble fibers having improved absorbency towards water or body fluids such as urine, blood, mucus, menses, lymph and other body exudates. Fibers having improved absorbency would find ready application in areas such as personal hygiene, medicine, house keeping, clothing and electronics, as well as in other products. One of the most important applications of water-insoluble fibers having improved absorbency is in disposable absorbent articles, such as diapers or incontinence pads. It would be particularly desirable if articles incorporating such fibers could be processed using conventional commercial equipment. To enable such processing, improved absorbency fibers must meet certain minimal values with regard to fiber strength and fiber length.
In the art of papermaking, there are materials which are used to improve the wet strength of paper. These materials are known in the art as “wet strength agents.” Cationic wet strength agents are perhaps the most widely used variety. The effectiveness of cationic wet strength agents is often limited by the low retention of the wet strength agent on conventional cellulose fibers. This low retention is frequently due to the cationic agents not finding suitable anionic sites for attachment to the fiber, which causes them to remain in solution or to be washed off the fiber after application. Although cationic promoters can be used to increase wetting agent retention, they do not increase the number of anionic sites on a fiber surface, and in some cases may actually decrease the number of such sites, thus inhibiting the wet strength agent from performing its function. It is desirable to increase the number of anionic sites on a fiber to improve the efficiency of wet strength agents. The anionic sites on conventional cellulose pulps can be measured in terms of the carboxyl group content of cellulose, which is typically in the range of about 20 to about 120 milliequivalents per kilogram (meq/kg) of cellulose. U.S. Pat. No. 5,935,383 discloses a method for improving the efficiency of aqueous cationic wet strength additives by pretreating cellulose surfaces with reactive anionic compounds, thus providing the cellulose surface with additional anionic sites suitable for retaining cationic wet strength additives on the cellulose.
Cellulose esters are often used in pharmaceuticals and industrial coatings. However, they frequently exhibit relatively low solid contents in suitable solvents, necessitating use of large amounts of solvent. The use of high solvent levels is undesirable since it is associated with prolonged drying times and atmospheric contamination through solvent evaporation. Although solvent borne cellulose esters provide desirable coatings properties, the current trend is to formulations which require reduced amounts of the volatile organic components (VOC), or which employ water soluble coating formulations, thereby entirely eliminating VOC. This trend has limited the use of solvent borne cellulose esters in coatings applications. WO99/40120 describes an attempt to make carboxylated cellulose esters having improved solvent solubility to enable high solids coating compositions. The method described in WO 99/40120 utilizes oxidized cellulose which is activated with water. The water in the activated cellulose is then displaced with acetic acid and the product esterified and then hydrolyzed. Cellulose esters using carboxylated cellulose fibers as starting material prepared according to the present invention overcome the poor solubility of conventional cellulose esters in aqueous media and thus reduce the need to use VOC in the production of coatings, for example, cellulose esters.
Cellulose fibers having high carboxyl content would be useful in all of the above applications. Carboxylated cellulose can be made through: (a) oxidation of cellulose, (b) etherification of cellulose with monochloroacetic acid, (c) esterification of cellulose with some dicarboxylic acid anhydrides or chlorides, such as phthalic anhydride, maleic anhydride, succinic anhydride and oxalyl chloride.
Some oxidants such as hypohalite, chlorine dioxide, nitrogen dioxide (dinitrogen tetraoxide), permanganate, dichromate-sulfuric acid and hypochlorous acid can be used to make carboxylated cellulose fiber; however, the obtained oxidized celluloses (or oxycelluloses) either have low carboxyl content (lower than 250 meq/kg) or very low intrinsic viscosity as measured in cupriethylenediamine (Cuene I.V.) In addition, some oxidized celluloses may contain aldehyde and/or ketone functionalities besides carboxyl group depending on the nature of the oxidant and the reaction conditions used in their preparation. This can impair their performance as coatings. Sodium (or potassium) periodate is a very effective oxidant, however, it cannot be used cost effectively because there is no viable method to recover periodate. Furthermore, carboxylated cellulose fibers made by the periodate method with carboxyl contents higher than 1000 meq/kg, have Cuene I.V. less than 2 dL/g, which limits their applications.
Etherification of cellulose by monochloroacetic acid yields carboxylated cellulose (carboxymethyl cellulose) with relatively high carboxyl content and high I.V.; however, the carboxylated cellulose products produced in this fashion are usually particles, instead of fibers, if the degree of substitution (DS) of carboxyl group is higher than 0.3. Particles are susceptible to water absorption except when present in the acid form and/or crosslinked. U.S. Pat. No. 4,410,694 discloses a method for preparing carboxylated fibers in water using monochloroacetic acid; however, the degree of substitution (DS) of the carboxylated fibers is very low.
U.S. Pat. No. 4,734,239 describes the production of water-insoluble fibers of cellulose monoesters of maleic acid, succinic acid and phthalic acid, having an high absorbability for water and physiological liquids. The carboxylated cellulose was prepared via esterification of cellulose by dicarboxylic acid in the presence of dimethylacetamide/lithium chloride (DMAc/LiCL) as solvent and potassium acetate as catalyst. The solvent medium, DMAc/LiCL is costly to use and DMAc is toxic. Further, the carboxylated cellulose produced according to the patent is substantially dissolved and must be spun to produce a fiber.
Accordingly, there exists a need for an economical and environmentally benign method of making highly carboxylated fibers from polysaccharide fibers, including wood cellulose, which retain their fiber form during carboxylation and which have sufficient fiber strength to be processed into commercial articles, and in particular absorbent articles, utilizing conventional processing equipment.
There is also a need for biodegradable disposable articles for personal hygiene, medical and domestic use. The carboxylated cellulose fibers of the invention are suitable for use in such articles. Highly carboxylated cellulose fibers can replace, partially or totally, base fiber non-woven materials in wipes and disposable articles, and fiber/super absorbent polymer mixes in absorbent products, to make biodegradable disposable absorbent articles.
SUMMARY OF THE INVENTION
The present invention provides water-insoluble, highly carboxylated cellulose fibers which are suitable for use in cellulose acetate coatings, absorbent core materials, high wet strength papers and polymer composites. The highly carboxylated cellulose fibers of the invention retain their fiber form throughout the carboxylation process and have sufficient fiber strength and length to be processed using conventional fiber processing technology. They can be made with a wide range of intrinsic viscosities and a high degree of substitution (“DS”) of carboxyl groups.
The highly carboxylated water-insoluble cellulose fibers of present invention are made by reacting cellulose with dicarboxylic acid anhydrides or chlorides using weak organic acid, and a base or basic salt. Preferably the weak organic acid acts as both a dispersing agent and induces fiber swelling while the base or basic salt acts as a catalyst. The fibers produced possess a unique combination of high carboxyl content and high intrinsic viscosity. The range of carboxyl content which can be achieved using the invention is from about 150 to greater than 4000 milliequivalents per kilogram (meg/kg). The range of viscosities achievable with the highly carboxylated cellulose fibers according to the invention is from about 0.5 dl/g to about 12 dl/g. This combination of carboxyl content and viscosity enable the carboxylated cellulose fibers of the invention to be utilized in a wide variety of applications, including absorbent products, health care products, specialty papers, adhesives, detergents, biodegradable fibers, ion exchange fibers and as precursors for aqueous coatings.
The highly carboxylated cellulose fibers of the invention can be made with any fibrous polysaccharide material, including cellulosic pulp derived from softwood pulp, such as various pines (Southern pine, White pine, Caribbean pine), Western hemlock, various spruces (e.g., Sitka Spruce), Douglas fir, from hardwood pulp sources, such as gum, maple, oak, eucalyptus, poplar, beech, or aspen, and from cotton linters, bagasse, cereal straw, reeds, kenaf, bamboo, and regenerated fibers such as rayon and lyocell, and mixtures of all of the foregoing. The cellulose fibers useful in the invention can be subjected to mechanical and/or chemical pretreatment, such as defiberization, bleaching, mercerization or chemical modification, prior to carboxylation.
In accordance with the invention a suitable cellulose fiber having an average Cuene I.V. in the range of from about 2 to about 15, and preferably in the range of from about 3 to about 13, is:
(a) dispersed in an weak organic acid to form a suspension having a consistency of about 0.5% to about 20% by weight, and preferably about 1% to about 15% by weight, at a temperature from about 15° C. to about 60° C., and preferably at about 20° C. to about 50° C.;
(b) the obtained suspension of cellulose and weak organic acid is reacted with a dicarboxylic acid anhydride or an anhydrous dicarboxylic acid chloride in a mole ratio from about 0.1:1.0 to 10:1.0 (dicarboxylic acid anhydride or chloride : cellulose), and preferably in a mole ratio of about 0.5:1.0 to about 5:1.0, at about 50° C. to about 118° C., and preferably from about 60° C. to about 100° C., in the presence of a basic catalyst, over a period from about 0.3 hours to about 15.0 hours, and preferably from about 0.5 hours to about 12.0 hours, and most preferably from about 2.0 hours to about 8.0 hours, to obtain carboxylated cellulose fibers; and
(c) the produced carboxylated cellulose fibers are separated from the reaction suspension by filtering, or centrifuging, or other separation method.
Where necessary or helpful, such as for fibers intended for absorbent material application, the carboxylated cellulose fibers of the invention can be partially or completely converted into the corresponding fiber-shaped salts by direct reaction with alkali metal hydroxide, carbonate, acetate, alkali metal alcoholates, ammonia or primary or secondary amine.
It is essential for obtaining carboxylated fibers with satisfactory mechanical characteristics that the fibers have sufficiently high degree of polymerization. It is therefore essential that the starting polysaccharide fibers display an average Cuene I.V. from 3.0 to 13.0, preferably from 4.0 to 13.0, which should be substantially maintained upon the reaction with dicarboxylic acid anhydrides or chlorides. The starting materials can be wood cellulose pulps including hard wood pulp and soft wood pulp, non-wood pulp such as cotton linter, bagasse or cereal straw or regenerate fiber such as Rayon and lyocell. The starting material can be also other polysaccharides such as starch, chitin, chitosan or pullulan.
The esterifying reagent can be a dicarboxylic acid anhydride such as phthalic anhydride, maleic anhydride, poly (maleic anhydride), succinic anhydride, glutaric anhydride or a dicarboxylic acid chloride, such as oxalyl chloride. The esterifying reagent can also be 1,2,4-benzenetricarboxylic anhydride, 1,2-cyclohexanedicarbocylic anhydride or mixtures of all of the foregoing. The esterifying reagents useful in the invention have the below general structures:
wherein R 1 , R 2 , R 3 , R 4 =H, alkyl, aryl, halogen, carboxyl, carboxyalkyoxyl or amide; and
wherein R=alkyl or aryl; X=halogen, —CN or CONH2; and m≧0, n≧1, o≧0, p≧0 and q≧0.
Generally, the esterifying reagents are employed in amounts from 10 to 1000% by weight relative to the starting cellulose fiber, depending on the carboxyl content of product needed. To avoid the hydrolysis of esterifying reagents and the degradation of cellulose, a weak acid dispersant, such as acetic acid or other organic acid, must be used. The reaction temperature and reaction periods must be adjusted relative to each other. Reaction temperatures of from about 50° C. to 130° C., and preferably about 60° C. to about 118° C., with reaction times of about 0.3 hours to about 15 hours, and preferably 0.5 hours to about 12 hours, are believed to yield carboxylated cellulose esters of the invention having desirable properties. Reaction temperatures from 70° C. to 118° C. and reaction times from 2 to 5 hours have proven to be particularly advantageous for the reaction of the invention.
Various acids are well known catalysts for the esterification reaction. Unexpectedly these acids are not suitable for the reaction of cellulose and dicarboxylic acid anhydride, as they not only result in fibers having low intrinsic viscosities and/or products not having a fiber shape, but also because of the low carboxyl content of the products made with them. However, basic esterification catalysts are well suitable for cellulose esterification reactions of the invention, especially suitable are those catalysts that minimize the degradation of the cellulose. By way of example, the following tertiary amines are useful in the present invention 4-N,N-dimethylaminopyridine, collidin, pyridine and triethylamine. Preferred as esterification catalysts are basic salts of monocarboxylic acids, such as sodium acetate, potassium acetate, sodium propionate, potassium propionate, sodium butyrate and potassium butyrate. Generally, these basic salts are employed in amounts from about 0 (i.e., not present) to about 150% by weight, and preferably from about 5% to about 50% by weight, and most preferably from about 10% to about 20% by weight, relative to the cellulose fibers treated.
The obtained carboxylated cellulose fibers can be characterized by solid state C 13 NMR, Cuene I.V. measurement, and carboxyl content measurement using a conductometric titration method.
A diaper incorporating the carboxylated fiber according to the invention comprises: (a) a liquid impervious backing sheet; (b) a relatively hydrophobic, liquid pervious topsheet; (c) a flexible absorbent core positioned between said backing sheet and the topsheet. The flexible absorbent core comprises of hydrophilic fiber material and optionally particles of a substantially water-insoluble hydrogel material, known as a super absorbent polymer (SAP). The highly carboxylated polysaccharide ester fibers of the invention can replace, partially or totally, the super absorbent polymer conventionally used in many absorbent articles.
The carboxylated cellulose fibers of the invention can also be used in feminine hygiene articles and other articles wherein absorbent fibers find application. The structure and method of fabrication for such articles are well known to those skilled in the art of the invention.
The advantage of the present invention is that it does not require toxic solvents and does not require spinning technology to produce a fibrous material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
In a three-necked reaction kettle of volume 2 liter, 18.5 g cellulose (Rayonier, Ethenier-UHV, available from Rayonier Performance Fibers Division of Jesup, Ga.; having Cuene I.V.=12.5 and approximately 92% oven dryness (OD)) was suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, 51 g of succinic anhydride and 25.5 g of sodium acetate trihydrate were added. The temperature then was gradually raised to 80° C. over a period of 1 hour and the reaction was carried out at this temperature for 8 hours. The reaction mixture was filtered and the obtained carboxylated cellulose fibers were washed with distilled water 5 times and prepared into a handsheet. The handsheet was air dried at a temperature below 50° C. before taking Cuene I.V. and carboxyl content measurements. The cellulose succinate fibers obtained in this manner displayed the following characteristics:
Sample
Cuene I.V.
Carboxyl content (meq/kg)
Ethenier-F-UHV (control)
12.5
70
1
8.87
773
EXAMPLE 2
Cellulose succinic acid ester was produced according to the same process described in Example 1, except the starting cellulose pulp was mercerized Ethenier-UHV, available from Rayonier Performance Fibers Division (Jesup, Ga.). The mercerized fiber was prepared by treating the Ethenier-UHV pulp with 16% sodium hydroxide solution at 10% consistency, for 15 minutes at room temperature and washing the product with distilled water 5 times prior to drying. The carboxylated pulp had a Cuene I.V.=5.34 and carboxyl content of 1280 meq/kg.
EXAMPLES 3-5
In a three-necked reaction kettle of volume 2 liter, 64.0 g of cellulose (Rayonier, Sulfatate-H-J, available from Rayonier Performance Fibers Division of Jesup, Ga.; having a Cuene I.V. of 8.13 units and approximately 92% OD) was suspended in 1200 ml of acetic acid. The suspension was stirred for 10 minutes at room temperature and then 320 g of succinic anhydride (Example 3) and 12.8 g of sodium acetate were added to it. The temperature of the suspension then was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for 5 hours. The reaction mixture was filtered and the obtained carboxylated cellulose fibers were washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements.
The procedure for Examples 4 and 5 were the same as Example 3 except that the esterifying reagent used were maleic anhydride (Example 4) and phthalic anhydride (Example 5.) The cellulose phthalate and maleate fibers obtained in this manner displayed the following characteristics:
Sample
Esterifying reagent
Cuene I.V.
Carboxyl content (meq/kg)
3
succinic anhydride
4.37
2210
4
maleic anhydride
2.82
1620
5
phthalic anhydride
4.84
763
EXAMPLES 6-7
In a three-necked reaction kettle of volume 2 liter, 20.0 g of cellulose (Rayonier, Sulfatate-H-J, with Cuene I.V.=8.13 units and approximately 92% OD) was suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, a mixture of 10 g of maleic anhydride and 10 g of phthalic anhydride, with 2.0 g of sodium hydroxide were added. The temperature of the suspension then was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for 4 hours. The reaction mixture was then filtered. The obtained carboxylated cellulose fibers were washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before measurement of their Cuene I.V. and carboxyl content. The procedure of Example 6 was followed for Example 7, except that the esterifying reagent in Example 7 was 20 g of glutaric anhydride. The carboxylated cellulose fibers obtained in this manner displayed the following characteristics:
Sample
Esterifying reagent
Cuene I.V.
Carboxyl content (meq/kg)
6
succinic anhydride/
2.88
593
maleic anhydride
7
glutaric anhydride
4.99
167
EXAMPLES 8-9
In a three-necked reaction kettle of volume 2 liter, 17.0 g of cellulose (Rayonier, Rayfloc-J; with Cuene I.V.=8.39 units) was suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, 51 g of phthalic anhydride (Example 5) and 25.5 g of sodium acetate trihydrate were added. The temperature was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for 8 hours. The reaction mixture was then filtered. The obtained carboxylated cellulose fibers were washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements. The procedure of Example 8 was repeated for Example 9, except that the esterifying reagent used was maleic anhydride. The cellulose phthalate and maleate fibers obtained in this manner displayed the following characteristics:
Carboxyl content
Sample
Esterifying reagent
Cuene I.V.
(meq/kg)
Rayfloc-J
8.39
103
(control)
8
phthalic anhydride
7.05
620
9
maleic anhydride
6.26
657
EXAMPLE 10
In a three-necked reaction kettle of volume 2 liter, 10.0 g of cellulose (Rayonier, Rayfloc-J; Cuene I.V.=8.39 units) was suspended in 265 ml of acetic acid. After 10 minutes stirring at room temperature, 100 ml of acetic acid containing pre-dissolved 5 g of poly (maleic anhydride) and 1.0 g of sodium acetate was added to the suspension. The temperature of the suspension was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for 8 hours. The reaction mixture was filtered and the obtained carboxylated cellulose fibers were washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements. The carboxyl content of the obtained product was 1250 meq/kg. A Cuene IV value could not be obtained because the product would not dissolve in Cuene solvent.
EXAMPLES 11-15
The cellulose phthalate were prepared for Examples 11-15 using the method of Example 8, except for the catalyst type and amount which were as set forth below. The obtained products displayed the following characteristics:
Carboxyl
Cuene
content
Sample
Catalyst/pulp ratio
I.V.
(meq/kg)
Rayfloc-J
8.39
103
(control)
11
1.5/1
(sodium acetate trihydrate)
7.05
620
12
0.5/1
(sodium acetate trihydrate)
6.32
737
13
0.1/1
(sodium acetate trihydrate)
6.54
767
14
0/1
(none)
5.02
273
15
0.05/1
(sulfuric acid)
1.90
163
EXAMPLES 16-18
In a three-necked reaction kettle of volume 2 liter, 17.0 g of cellulose (Rayonier, Rayfloc-J; Cuene I.V.=8.39 units) was suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, 8.5 g of phthalic anhydride and 1.7 g of sodium acetate trihydrate were added to the suspension. The temperature of the suspension was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for either 2 hours (Example 16), 4 hours (Example 17), or 8 hours (Example 18). The reaction mixture was filtered and the obtained carboxylated cellulose fibers from each reaction washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements. The cellulose phthalate fibers obtained in this manner displayed the following characteristics:
Sample
Reaction time (h)
Cuene I.V.
Carboxyl content (meq/kg)
Rayfloc-J
8.39
103
(control)
16
2
7.39
270
17
4
7.18
285
18
8
7.05
320
EXAMPLES 19-21
In a three-necked reaction kettle of volume 2 liter, 17.0 g of cellulose (Rayonier, Rayfloc-J; Cuene I.V.=8.39 units) was suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, 8.5 g of phthalic anhydride and 1.7 g of sodium acetate trihydrate were added to the suspension. The temperature of the suspension was gradually increased to the selected reaction temperature over a period of 1 hour. The reactions were carried out at the following reaction temperatures: 55° C. (Example 19), 80° C. (Example 20) and 118° C. (Example 21), all for 2 hours. The reaction mixture was filtered and the obtained carboxylated cellulose fibers washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements. The cellulose phthalate fibers obtained in this manner displayed the following characteristics:
Reaction
Sample
temperature (° C.)
Cuene I.V.
Carboxyl content (meq/kg)
Rayfloc-J
8.39
103
(control)
19
55
8.01
147
20
80
7.39
270
21
118
7.18
277
EXAMPLES 22-24
In a three-necked reaction kettle of volume 2 liter, 17.0 g of cellulose (Rayonier, Rayfloc-J; with Cuene I.V.=8.39 units) was suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, phthalic anhydride was added to the suspension in quantities of either 34 g (Example 22), 17 g (Example 23) or 8.5 g (Example 24) along with 1.7 g of sodium acetate trihydrate. The temperature was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for 2 hours. The reaction mixture was filtered and the obtained carboxylated cellulose fibers were washed with distilled water 5 times and prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements. The cellulose phthalate fibers obtained in this manner displayed the following characteristics:
phthalic anhydride/
Carboxyl
Sample
pulp ratio
Cuene I.V.
content (meq/kg)
Rayfloc-J
8.39
103
(control)
22
2/1
7.04
527
23
1/1
7.38
367
24
0.5/1
7.39
270
EXAMPLES 25-29
In a three-necked reaction kettle of volume 2 liter, 17.0 g of 5 different polysaccharides, namely, Hardwood pulp Sulfatate-H-J-EE (Example 25), Softwood pulp Rayonier Placetate-F (Example 26), both from Rayonier Performance Fibers Division (Jesup, Ga.), Rayon fiber (Example 27), corn starch (Example 28) and cotton linter (Example 29) were suspended in 365 ml of acetic acid. After 10 minutes stirring at room temperature, 8.5 g of phthalic anhydride and 1.7 g of sodium hydroxide were added to each suspension. The temperature of each suspension was gradually raised to 80° C. over a period of 1 hour and the reaction carried out at this temperature for 4 hours. The reaction mixtures were filtered and the obtained carboxylated cellulose fibers from Examples 25-29 washed with distilled water 5 times and then prepared into handsheets. The handsheets were air dried below 50° C. before taking Cuene I.V. and carboxyl content measurements. The cellulose phtalate fibers obtained in this manner displayed the following characteristics:
Sample
Polysaccharide
Cuene I.V.
Carboxyl content (meq/kg)
25
Sulfatate-HJ-EE
4.45
320
26
Placetate-F
5.96
367
27
Rayon fibers
2.29
303
28
Corn starch
1.48
550
29
Cotton linter
2.88
270
The invention has been illustrated, and described, as embodied in water-insoluble fibers of cellulose esters of dicarboxylic acids. However, the process and products of the invention are not intended to be limited to the specific examples shown, since various modifications and changes may be made thereto without departing from the spirit of the present invention. | Disclosed is a process for producing water-insoluble cellulose fibers having high carboxyl content by reacting cellulose fiber in suspension with dicarboxylic acid anhydride or chloride in the presence of a basic catalyst. The fibers produced possess a unique combination of high carboxyl content in the range of 100 to 4000 meq/kg, and high average viscosity, in the range of 0.5 to 12 dl/g. The carboxylated cellulose fibers according the invention can be made with a combination of carboxyl content and average viscosity which are suitable for use in numerous applications, including absorbent products, health care products, specialty papers, adhesives, detergents, biodegradable fibers, precursors for aqueous coatings and ion exchange fibers. | 3 |
RELATED APPLICATIONS
This patent application claims priority to U.S. provisional patent application Ser. No. 61/036,325 filed on Mar. 13, 2008, incorporated herein by reference.
BACKGROUND
Various subterranean formations contain hydrocarbons in fluid form which can be produced to a surface location for collection. Generally, a wellbore is drilled, and a production completion is moved downhole to facilitate production of desired fluids from the surrounding formation. Many of the formation fluids, however, contain particulates, e.g., sand, that can wear or otherwise detrimentally impact both downhole and surface components.
Gravel packing techniques, including frac packing procedures, are often used to control sand. In typical gravel packing operations, a slurry of gravel carried in a transport fluid is pumped into a well annulus between a sand screen and the surrounding casing or open wellbore. The deposited gravel is dehydrated (i.e., the transport fluid is removed), and the remaining gravel facilitates blocking of sand or other particulates that would otherwise flow with formation fluids into the production equipment.
In some gravel packing operations, difficulty arises in obtaining uniform distribution of gravel throughout the desired gravel pack region. For example, a poor distribution of gravel can result from premature loss of transport fluid, which causes the creation of bridges that can prevent or reduce further distribution of gravel past the bridge. Also, certain manmade isolation devices, such as packers, can present barriers to distribution of the gravel slurry. Shunt tubes have been used to bypass bridges and/or manmade isolation devices to ensure complete gravel packing (see, e.g., U.S. Pat. No. 7,407,007).
Traditionally, the method to attach hardware, such as the aforementioned shunt tubes, to oilfield sand screen tubulars (and other downhole equipment) involved welding. Unfortunately, welding often introduces stress into the tubulars that can cause defects (for example corrosion, corrosion cracking, and surface cracks) that can result in undesirable consequences, including, but not limited to failure of the tubular. Various post-welding procedures are available to minimize undesirable consequences (e.g., post-weld heat treatment to homogenize the metals or examination using dye penetrant to identify surface defects). However, these treatments can be expensive and time consuming and cause administrative hassles and only mitigate the risk of defects caused by welding rather than eliminate the risks.
Thus, for at least these reasons, it may be desirable to eliminate or reduce the welding necessary to attach hardware to tubulars or downhole equipment.
SUMMARY
Disclosed herein are methods to attach hardware to tubulars (such as sand screen basepipe) and other downhole equipment, including:
An assembly for use in a wellbore, comprising a base pipe; a filter medium surrounding at least a portion of the external surface of the base pipe; and an internally profiled sleeve surrounding at least a portion of the filter media.
Also included is a method for attaching a hardware accessory to a sand screen assembly, comprising providing a base pipe having an inner surface and an outer surface; surrounding the outer surface of the base pipe with a filter medium; engaging the sleeve with the filter medium; and connecting the hardware accessory to the sleeve.
Also included is a downhole apparatus comprising a basepipe, wherein at least a portion of the external surface of the basepipe comprises a profile; and a sleeve mounted external to the basepipe, wherein the internal profile of the sleeve corresponds to the external profile of the basepipe.
BRIEF SUMMARY OF THE DRAWINGS
FIG. 1 is a schematic drawing of a sandscreen deployed in a wellbore.
FIG. 1A is a more detailed schematic drawing of a sandscreen adjacent to a basepipe.
FIG. 2 is a schematic drawing of a sandscreen and sleeve in accordance with embodiments as disclosed herein.
FIG. 2A is a cross sectional view of an embodiment of a sleeve such as is shown in FIG. 2 .
FIG. 2B is an illustration depicting attachment of shunt tubes to the sleeve in accordance with an embodiment of the invention.
FIG. 3 is a schematic drawing of a sandscreen and sleeve in accordance with embodiments as disclosed herein.
FIG. 4 is a schematic drawing of non-exclusive examples of wire wrap profiles which may be used in embodiments as disclosed herein.
FIG. 5 is a schematic drawing of non-exclusive examples of wire wrap profiles which may be used in embodiments as disclosed herein.
FIG. 6 is a schematic drawing of a sandscreen and sleeve in accordance with embodiments as disclosed herein.
FIG. 7 is a schematic drawing of a basepipe and sleeve in accordance with embodiments as disclosed herein.
FIG. 8 is a schematic drawing of a sandscreen and sleeve in accordance with embodiments as disclosed herein.
FIG. 9A is a schematic drawing of a basepipe having longitudinal ribs.
FIGS. 9B and 9D are schematic drawings of a sleeve in accordance with embodiments as disclosed herein.
FIG. 9C is a schematic drawing of a sleeve installed on a device having longitudinal ribs as disclosed herein.
FIGS. 10A , 10 B, and 10 C are schematic drawings of a sandscreen and sleeve in accordance with embodiments as disclosed herein.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via another element.” As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention.
With reference to FIG. 1 , a sand screen assembly 10 is deployed in a wellbore 20 via a conveyance string 30 (e.g., coiled tubing). The sand screen assembly generally is comprised of one or more screen sections 10 A, 10 B, each of which comprise a base pipe 12 and a filter media 14 as is shown in FIG. 1A . The base pipe 12 may be a perforated base pipe or include inflow control devices (nozzles inserts or nozzle rings with chambers). The filter media 14 may include wire-wrapped screen, mesh screen, or any other type of filter media which is known in the art.
In some instances, it is desirable to attach external hardware to a sand screen assembly. One non exclusive example of hardware that may be desirable to attach external to a sand screen assembly is a shunt tube which provides an alternative flow path for fluids being transported downhole, e.g., gravel pack slurry. The conventional method for attaching hardware to a sand screen assembly involves welding to the tubular base pipe. Welding, however, introduces stresses into the base pipe forming the sand screen assembly that can cause stress corrosion cracking, surface cracks, and other defects that can result in failure of the base pipe. Typical weld procedures involve a post-weld heat treatment to homogenize the pipe material to remove induced stresses. Another post-welding process for tubulars typically performed is a non-destructive weld examination using dye penetrant which identifies surface defects that can result in cracking of the tubulars. These post-welding processes often involve an in depth system of quality control documents, traceability, and personnel training.
Base pipe tubulars used for screen applications are normally not designed to be welded. Depending on the metallurgy and mechanical properties of the tubular, the above-mentioned heat treatment process may, in some instances, regain the tubular's integrity. With increased yield of the tubular and more sophisticated metallurgy, regaining integrity after welding may, however, not be possible. Accordingly, in many applications, welding of the tubulars may permanently reduce its integrity. Eliminating welding to the base pipe tubular reduces the measures necessary to assure the base pipe integrity has not been compromised and the amount of quality assurance personnel time and documentation.
In one embodiment, as shown in FIG. 2 , a sand screen assembly 110 is provided having a base pipe 112 surrounded by wire-wrapped screen 114 . In this embodiment, the wire-wrap screen 114 has a dome-shape profile 114 A positioned on the outside of the wire-wrap screen 114 (direct-wrap or slip-on wrap). A sleeve 120 having ports 122 is machined (or otherwise formed with a particular profile) on its inner diameter such that the inner profile 120 A of the sleeve mates the dome-shaped outer profile 114 A of the screen 114 , and can be threadably connected thereon, essentially creating a nut-and-bolt joint where the sleeve is the nut and the wire-wrap screen is the bolt. Alternatively, the wrap wire could be flat on the outside and the slot opening of the wrap wire could be sufficiently wide such that a sleeve could have an inner diameter profile that engages the slot opening of the wrapped wire. These nut-and-bolt configurations allow for the transfer of axial load through the direct wrap screen into the base pipe. Indeed, other embodiments may include any shaped wrap wire whether round or shaped with multiple sides where the sides can be flat, rounded or scuffed (such as sand/bead blasted) such that the inner profile of the sleeve can be mated thereto in threaded engagement. This sleeve 120 thereby provides a surface external the base pipe 112 and isolated from the base pipe via the wire wrap filter 114 on which accessories or external hardware can be connected even by welding without reducing the integrity of the base pipe tubular, such that, for example, shunt tubes 152 (see FIG. 2B ) may be attached via hardware 150 to the sleeve 120 . Still further, in alternative embodiments, the wrap wire screen 114 can be designed with a protruding profile such that it provides a contact area for the “threaded sleeve” thus providing a greater loading capacity. After the wire is wrapped as a screen filter the resulting protruding feature will provide a significant thread contact area. The protruding profile of the wrap wire can have any shape or height (see FIG. 4 for non-exclusive examples of protruding profiles which it may be desirable to have on the wire wrap).
In other embodiments, still with respect to FIG. 2 , additional features can be added to the sleeve 120 to increase its axial and torsional loading capacity. For example, the sleeve 120 can be designed to provide an interference fit by machining its inner diameter “female thread” profile to match or have an interference with the wire wrap jacket “male thread” profile provided by the wrap wire. As is shown in FIG. 2A , the sleeve could include a longitudinal split 124 , which, when the sleeve is positioned on the wire wrap jacket 114 and the sleeve is clamped in place, could be welded along the split or bolted together or using a similar method to attach the two sides. The shrinking of the weld during cooling creates a squeeze of the sleeve onto the wire wrap jacket outer diameter. Or, alternatively, the sleeve 120 could be heated to expand the sleeve thus allowing it to be positioned on the wire wrap screen and then subsequent cooling of the sleeve would allow the sleeve to shrink-fit onto the wire wrap screen 114 .
The sleeve 120 can also be designed to have holes 122 in it within which plug welds can be placed thus welding the sleeve to the outer diameter surface of the wire wrap jacket 114 . The number of holes and plug welds can be adjusted to meet the torsional and axial loading capacity requirements as would be determined by one of ordinary skill in the art.
In other embodiments, the sleeve 120 could be coated on the inner diameter with an adhesive (e.g., JBWeld available from JB-Weld Company of Sulphur Springs, Tex. (www.jbweld.net or Loctite available from Henkel Int'l (www.loctite.com) or other adhesive as would be known to one of ordinary skill in the art), which, when put in place, bonds with the wire wrap jacket outer diameter providing substantially complete contact area for resisting torsion and axial loading.
The sleeve can be designed to implement all features above simultaneously or select ones. Moreover, the various sleeve embodiments can be applied either anywhere along the wire wrap screen (as shown in FIG. 2 and discussed above) or at the termination of the wire wrapped screen (as shown in FIG. 3 ). The embodiment shown in FIG. 3 includes the same features as described above for FIG. 2 , except that the sleeve 120 may also be connected (e.g., by weld or other) to the end ring (load ring or termination ring) 118 , where the end ring provides a weld surface isolated from the base pipe.
In yet another embodiment the wrap wire of an already-wrapped wire wrap screen 200 can be machined to have a protruding profile 210 that provides a contact area for the “threaded sleeve.” This embodiment is similar to that described above except that the profile is machined after wrapping as opposed to the wrap wire having the desired profile before wrapping. FIG. 5 depicts a protruding profile 210 created by machining/grinding the wrap wire of an already-wrapped screen. Some of the material on the edge of the wrapping wire is removed to make the slot opening bigger and thus making it possible for the “threads” on the ID of the sleeve to engage into the bigger slots created between the wrapping.
With reference to FIG. 6 , in a further embodiment, a sleeve 320 can be mechanically joined to a base pipe 330 by pinning. A sleeve 320 and base pipe 330 can be drilled with matching holes in which pins 340 are inserted to provide a joint that can withstand axial and torsion loads. To prevent the pins from backing out they may be of a weldable material or alternatively, they may be covered by a weldable retaining pin 310 which is then welded on by welds 300 . The number of holes/pins is determined by one of ordinary skill in the art without undue experimentation with consideration of the strength of the pin, sleeve, and base pipe materials and the size of the holes and pins.
With reference to FIG. 7 , a sleeve 410 can be mechanically joined to a base pipe 400 by cutting, forming, or grinding a recess 420 in the base pipe outer diameter and sleeve inner diameter and installing a heat-expanded sleeve 410 over the recess 420 and allowing the sleeve to cool and shrink into the recess. This joint requires the inner diameter of the sleeve 410 to be equal to or less than the recess 420 outer diameter machined into the base pipe 400 . The recess profile in the base pipe 400 can have multiple recesses providing greater axial loading resistance. Alternatively, the sleeve can be split axially (not shown) and the split welded once positioned creating a shrink fit upon cooling of the weld similar to 124 in FIG. 2A .
With reference to FIG. 8 , due to the tapered top of the wrap wire 500 , the screen outer diameter can be machined down 510 to expose more space/width 520 between wrap wires. A sleeve can be machined with an inner diameter thread profile that matches opening width of the machined wrap wire.
With reference to FIGS. 9A , 9 B, 9 C, and 9 D, as is well known in the art, it is often desirable to run axial ribs 700 along the basepipe 710 below the filter layer (e.g., the wire wrap) (not shown for clarity). When installed on the base pipe, 710 , the sleeve 820 can have threads that extend through the filter medium and into the axial wire profile where the sleeve's threads are “cut out” 810 to allow the axial wires 700 to pass through the sleeve threads. This allows the sleeve 820 to engage the axial wires 700 thus allowing the transfer of torque through the axial wires. A schematic view of the inside of the sleeve 820 , unfolded, is shown in FIG. 9D in which the internal “threads” 830 on the sleeve not only have spaces 800 for the wire wrap, but also have spaces 810 to fit within the axial ribs 700 to provide the transfer of torque through the axial wires.
With reference to FIGS. 10A , 10 B, and 10 C, a direct wrap wire wrap jacket has a gap between two wrapped sections 600 and 610 where one of the sections have axial wires running below the wire wrap jacket exposed 620 and the other section has the axial wires cut flush with the wrap wire (not shown, hidden below wire wrap 610 ). A split ring 630 having a profile 670 on its inner diameter for mating with the axial wires is installed in the region of no axial wires. With both halves on base pipe the two halves are slid to engage with the axial wires 620 . A second split ring 640 with a stepped inner diameter profile is placed between the previously installed split ring 630 and the wrapped section without axial wires exposed 610 . The second ring traps the two rings in place. The two rings are welded together at weld 650 . Both rings have an extension that resides over the wrap wire of the jacket which provides sand control for the jacket termination. The axial wires provide torque resistance and the jacket sections provide axial load resistance.
In all embodiments of the present invention, the terms “sleeve” and “ring” may be used interchangeably. Moreover, it is the intention of the present invention that each embodiment described herein provides a surface external the base pipe on which accessories/hardware may be connected to the sand screen assembly, as by welding, bolting, or any other acceptable method as would be determined by one of ordinary skill in the art without undue experimentation.
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the invention. | Disclosed herein is an assembly for use in a wellbore which includes a base pipe; a filter medium surrounding at least a portion of the external surface of the base pipe; and an internally profiled sleeve surrounding at least a portion of the filter media. Also included is a method for attaching a hardware accessory to a sand screen assembly which includes providing a base pipe having an inner surface and an outer surface; surrounding the outer surface of the base pipe with a filter medium; engaging the sleeve with the filter medium; and connecting the hardware accessory to the sleeve. Also included is a downhole apparatus which includes a basepipe, where at least a portion of the external surface of the basepipe is profiled; and a sleeve mounted external to the basepipe, where the internal profile of the sleeve corresponds to the external profile of the basepipe. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to vehicle control systems, and more particularly to integrating sub-system control.
BACKGROUND OF THE INVENTION
[0002] Modern vehicles incorporate a number of active vehicle control sub-systems that enhance comfort and safety. Two such vehicle control sub-systems include an active front steering (AFS) system and a vehicle stability enhancement (VSE) system.
[0003] The AFS system electronically varies the steering ratio based on the intended steering angle, vehicle speed, road conditions and feedback control. Vehicle steering is more direct under normal road conditions at low and medium speeds, reducing operator steering effort. The AFS system also increases vehicle agility in city traffic or for parking maneuvers. Vehicle steering becomes less direct at higher vehicle speeds improving directional stability. Steering stiffens during high speed cornering or sudden maneuvers by monitoring the vehicle yaw rate.
[0004] The VSE system assists the vehicle operator in controlling vehicle handling on surfaces such as wet or uneven pavement, ice, snow or gravel. The VSE system also helps the vehicle operator maintain control during rapid or emergency maneuvers. The VSE system recognizes wheel skid based on sensor inputs from wheel speed sensors, steering angle sensors, vehicle speed and a yaw rate sensor. After analyzing the various inputs, the VSE system reduces engine torque and applies braking to maintain vehicle travel along the intended path.
[0005] The development of such vehicle control sub-systems reaches a natural limit that presents a compromise in fulfilling contradicting requirements of vehicle comfort, stability, performance and cost. Superimposing the control of each sub-system is not always the most effective means in achieving total vehicle performance.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention provides an integrated vehicle control system including a first control system having a maximum authority to selectively operate a first vehicle sub-system and a second control system to selectively operate a second vehicle sub-system. A controller is adapted to monitor a first parameter associated with the first vehicle sub-system and a second parameter associated with the second vehicle sub-system. The controller is operable to control the first and second parameters by selectively invoking operation of the second control system when the first control system exceeds the maximum authority and the second parameter exceeds an upper threshold.
[0007] In one feature, the first parameter is a steering angle and the first control system includes a steering system that generates a steering angle command based on a steering angle input. The integrated vehicle control system further includes a steering angle sensor that measures a vehicle steering angle. The first control system exceeds the maximum authority when the steering angle command exceeds a steering angle threshold.
[0008] In another feature, the second control system includes a vehicle stability enhancement system. The integrated vehicle control system further includes a second sensor that generates a signal upon which the second parameter is based. The second sensor includes one of a yaw rate sensor that measures a vehicle yaw rate and a lateral accelerometer that measures a vehicle lateral acceleration.
[0009] In another feature, the second vehicle parameter includes one of a yaw rate error and a yaw rate error acceleration. The yaw rate error is a difference between a yaw rate measured by the second sensor and a yaw rate command generated by the controller. The controller invokes operation of the second control system when one of the yaw rate error exceeds a yaw rate error upper threshold and the yaw rate error acceleration exceeds a yaw rate error acceleration upper threshold.
[0010] In another feature, the controller segregates operation of the first and second control systems when one of the yaw rate error is less than a yaw rate error lower threshold and the yaw rate error acceleration is less than a yaw rate error acceleration lower threshold for a threshold period.
[0011] In still another feature, the second parameter further includes a velocity and a lateral velocity rate. The controller invokes operation of the first and second control systems when the velocity exceeds a velocity threshold and the lateral velocity rate exceeds a lateral velocity rate threshold.
[0012] In yet another feature, the controller segregates operation of the first and second control systems when the second vehicle parameter is less than a lower threshold for a threshold period.
[0013] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0015] FIG. 1 is a schematic illustration of a vehicle including an active front steering (AFS) system and a vehicle stability enhancement (VSE) system; and
[0016] FIG. 2 is a flowchart illustrating an integrated control according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0018] Referring now to FIG. 1 , a vehicle 10 is schematically illustrated. The vehicle 10 includes an engine 12 that produces driving torque that is transferred to front and/or rear road wheels 14 , 16 , respectively. The driving torque is transferred through a transmission 18 to the road wheels 14 , 16 . A steering wheel 20 enables a vehicle operator to steer the front road wheels 14 to a desired steering angle (α). More specifically, the steering wheel 20 is an input to a steering system 21 that steers the front road wheels 14 . The vehicle 10 also includes a brake system 22 having a master cylinder (not shown) that feeds pressurized fluid to brakes 24 located at each of the road wheels 14 , 16 .
[0019] The vehicle 10 includes a controller 26 that monitors and controls vehicle operation based on the integrated control of the present invention. Wheel speed sensors 28 , 30 generate wheel speed signals for the road wheels 14 , 16 , respectively, which are communicated to the controller 26 . A steering wheel angle sensor 32 generates a steering wheel angle signal that is received by the controller 26 . A steering wheel angle (δ) is determined based on the steering wheel angle signal. A yaw rate sensor 34 generates a yaw rate signal and a lateral accelerometer 36 generates a lateral acceleration signal, both of which are communicated to the controller 26 . The controller 26 controls brake actuators 38 associated with each brake 24 to modulate brake force to the road wheels 14 , 16 . The controller 26 actively controls the brakes 24 based on the integrated control described herein.
[0020] The vehicle operator manipulates a driver input 40 that signals the controller 26 . The driver input 40 can include a throttle, cruise control or a brake pedal. In the case of a throttle or cruise control, the driver input 40 generates an engine torque command and the controller 26 operates the engine based on the engine torque command. In the case of a brake pedal, the driver input 40 generates a brake command and the controller 26 operates the braking system to control braking of the road wheels based on the brake command.
[0021] The vehicle includes an active front steering (AFS) system and vehicle stability enhancement (VSE) system. The AFS system and VSE system incorporate the various sensors and actuators described herein and control vehicle operation via the controller 26 . More particularly, the AFS and VSE systems include software-based algorithms processed by the controller 26 as well as mechanical components. Control signals generated by the controller 26 are based on the software-based algorithms. The control signals control operation of the mechanical components associated with the AFS and VSE systems.
[0022] The AFS system electronically influences the steering angle (α) of the road wheels 14 based on operator steering input (i.e., steering wheel angle (δ)) and vehicle speed. The AFS system also influences the steering angle (α) based on feedback from sensors such as the yaw rate sensor 34 . The controller 26 generates a corrected steering angle (α CORR ) that is greater than, equal to or less than a target steering angle (α TARGET ) based on the steering wheel angle (δ). In other words, the AFS system can turn the road wheels 14 at angle that is different than the indicated angle to which the vehicle operator turns the steering wheel 20 . The AFS system has limited authority in the amount of steering angle it can correct. For example, the AFS system will limit α CORR to a threshold (α THRESH ) if necessary. Such a condition occurs if when a vehicle operator inputs too much steering for a given vehicle speed.
[0023] The VSE system aids the vehicle operator in controlling the vehicle 10 when driving on dangerous surfaces including wet pavement, ice, snow and gravel or when the vehicle operator makes sudden maneuvers. The VSE system includes various sensors that help determine wheel skid. More particularly, the VSE system monitors the relationship between δ and α CORR , the vehicle speed, yaw rate and other factors. The VSE system reduces engine torque and selectively actuates one or more of the brakes 24 to maintain vehicle movement along an intended path. More particularly, the controller 26 generates a yaw rate command (YR COM ) based on steering angle and vehicle speed. A yaw rate error (YR ERR ) is determined as the difference between YR COM and the measured yaw rate (YR MEAS ). YR MEAS is determined based on the yaw rate signal generated by the yaw rate sensor. The VSE system operates to minimize the yaw rate error (YR ERR ).
[0024] The controller 26 calculates an estimated yaw rate error (YR ERREST ) according to the following equation:
YR ERREST ( k )=(1− T·G 1 ) YR ERREST ( k− 1)+ T·G 1 ·YR ERR +T·YR ERRACCEL ( k− 1)
where: k=current time step;
k−1=previous time step; T=sampling interval (e.g., 10 msec); G 1 =constant; and YR ERRACCEL =yaw rate error acceleration.
[0029] G 1 is calculated according to the following equation:
G 1 =4ζπf n
where: ζ=damping coefficient (e.g., 0.707); and
f n =frequency coefficient (e.g., 2 Hz).
[0031] The controller 26 also determines YR ERRACCEL , which is the rate at which YR ERR is changing. YR ERRACCEL is calculated based on the following relationship:
YR ERRACCEL ( k )= YR ERRACCEL ( k− 1)+ T·G 2 ( YR ERR ( k )− YR ERREST ( k ))
where: G 2 =constant.
[0032] G 2 is calculated according to the following equation:
G 2 =(2 πf n ) 2
The VSE system selectively actuates on or more brakes 24 and/or reduces engine output torque to minimize YR ERRACCEL .
[0033] A lateral velocity rate (V LAT ) is calculated based on the following equation:
V LAT = ( VR MEAS 57.3 ) ( V 3.6 ) - 9.81 A LAT
where: V=vehicle velocity; and
A LAT =lateral acceleration.
V is determined by the controller 26 based on the wheel speed signals generated by the wheel speed sensors 28 , 30 . A LAT is determined based on the lateral acceleration signal generated by the lateral accelerometer 36 .
[0035] More detailed descriptions of the AFS and VSE systems are provided in U.S. Pat. No. 5,720,533, issued Feb. 24, 1998 and entitled Brake Control System, U.S. Pat. No. 5,746,486, issued May 5, 1998 and entitled Brake Control System and U.S. Pat. No. 5,941,919, issued Aug. 24, 1999 and entitled Chassis Control System, the disclosures of which are incorporated herein by reference. U.S. Pat. Nos. 5,720,533, 5,746,486 and 5,941,919 disclose exemplary methods for determining YR COM .
[0036] The controller 26 also executes AFS and VSE system diagnostics to determine whether the AFS system and VSE system are functioning properly. More particularly, the diagnostics periodically check function and rationality of the various sensors and functioning of the various actuators used to implement the AFS and VSE control. If all of the sensors and actuators are functioning properly, the diagnostic indicates that the particular system is operative or healthy. If any of the sensors or actuators are not functioning properly, the diagnostic indicates that the particular system is non-operative or unhealthy. In the event that one or both the AFS system and the VSE system are deemed unhealthy, an alert is issued. The alert can be visual, audible or both.
[0037] Referring now to FIG. 2 , the integrated control (hereinafter “control”) of the present invention will be described in detail. In step 100 , control determines whether a key is on. More particularly, control determines whether the vehicle 10 is operating. If the key is on, control continues in step 102 . If the key is not on, control ends. Control resets a timer in step 102 . The timer times the amount of time the VSE control is operating, as discussed in further detail below.
[0038] In step 104 , control determines whether the AFS system is healthy (i.e., operative) based on a signal generated by the AFS diagnostic. If the AFS system is healthy, control continues in step 106 . If the AFS system is not healthy, control determines whether the VSE system is healthy in step 108 based on a signal generated by the VSE diagnostic. If the VSE system is not healthy, control loops back to step 100 . If the VSE system is healthy, control continues in step 110 to operate the vehicle using VSE control only. In this manner, if neither the AFS or VSE systems are healthy, control continuously loops and re-checks the AFS and VSE systems until either the key is off or at least one of the AFS and VSE systems become healthy. If only the VSE system is healthy, as shown at step 110 , control continues to loop back to step 100 to determine if the AFS system becomes healthy.
[0039] In step 106 , control operates the vehicle 10 using AFS control only. Control checks a first condition in step 112 . More particularly, control compares α CORR to α THRESH , to determine whether the AFS control is attempting to exceed its authority. If α CORR is not less than α THRESH ,the first condition is not satisfied and control continues in step 114 . If α CORR is less than α THRESH , the first condition is satisfied and control checks a second condition in step 116 . The second condition indicates whether YR ERR and YR ERRACCEL are below respective upper thresholds. If so, the AFS system alone is sufficient to control the vehicle 10 . Specifically, control determines whether YR ERR is less than YR ERRTHR1 or whether YR ERRACCEL is less than YR ERRACCELTHR1 . If either YR ERR is less than YR ERRTHR1 or YR ERRACCEL is less than YR ERRACCELTHR1 , then the second condition is satisfied and control loops back to step 100 . If either YR ERR is not less than YR ERRTHR1 or YR ERRACCEL is not less than YR ERRACCELTHR1 , then the second condition is not satisfied and control continues in step 118 .
[0040] Control checks a third condition in step 118 , which indicates whether V and V LAT are below respective thresholds. If so, the VSE system is not employed to assist the AFS system in maintaining vehicle control. More particularly, control determines whether V is less than V THRESH and whether V LAT is less than V LATTHRESH . If V is less than V THRESH and V LAT is less than V LATTHRESH , the third condition is satisfied and control loops back to step 100 . If V is not less than V THRESH or V LAT is not less than V LATTHRESH , the third condition is not satisfied and control continues in step 114 .
[0041] To summarize the integrated control to this point, in step 106 , control controls the vehicle 10 using AFS control only. In steps 112 , 116 and 118 , control checks first, second and third conditions, respectively. If the first condition is not satisfied (i.e., α CORR is equal to or exceeds α THRESH ), control determines that AFS control alone is insufficient to stabilize vehicle handling and seeks to integrate VSE control, as described in further detail below. If the first condition is satisfied, control checks the second and third conditions. If neither the second nor third conditions are satisfied, control seeks to integrate VSE control, as described in further detail below. In this manner, AFS control is used to the maximum of its capability before VSE control is implemented to further assist in stabilizing vehicle handling.
[0042] In step 114 , control determines whether the VSE system is healthy. If the VSE system is not healthy, control loops back to step 100 . If the VSE system is healthy, control controls the vehicle 10 using both AFS and VSE control in step 120 . More particularly, the AFS system adjusts α CORR and the VSE system selectively actuates one or more brakes 24 and/or reduces engine output torque to reduce YR ERR and YR ERRACCEL . In this manner, vehicle yaw rate is controlled and the vehicle 10 travels along the intended path.
[0043] In step 122 , control checks a fourth condition, which indicates whether YR ERR or YR ERRACCEL are less than respective lower thresholds. More particularly, control determines whether YR ERR is less than YR ERRTHR2 or whether YR ERRACCEL is less than YR ERRACCELTHR2 . If neither YR ERR is less than YR ERRTHR2 nor YR ERRACCEL is less than YR ERRACCELTHR2 , the fourth condition is not satisfied and control loops back to step 114 . If either YR ERR is less than YR ERRTHR2 or YR ERRACCEL is less than YR ERRACCELTHR2 , the fourth condition is satisfied and control continues in step 124 . In this manner, control controls the vehicle 10 using both AFS and VSE control until either YR ERR or YR ERRACCEL are less than their lower thresholds.
[0044] In step 124 , control checks a fifth condition, which indicates whether the VSE control is still active. Generally, if the fourth condition is satisfied, the VSE control becomes inactive as it is not required to bring either YR ERR or YR ERRACCEL below their respective thresholds (i.e., YR ERRTHR2 and YR ERRACCELTHR2 , respectively). However, there may be some instances where the VSE control remains active even though the fourth condition is satisfied. For example, the VSE control may be registered as active, immediately after the fourth condition is satisfied. If the VSE control is active, the fifth condition is satisfied and control continues in step 130 . Control resets the timer in step 130 and loops back to step 114 . If the VSE control is not active, the fifth condition is not satisfied and control continues in step 126 .
[0045] In step 126 , control increments the timer. In step 128 , control checks a sixth condition, which indicates whether the timer has exceeded a timer threshold (t THRESH ). If the timer exceeds t THRESH , the sixth condition is satisfied and control loops back to step 100 . If the timer does not exceed t THRESH , the sixth condition is not satisfied and control loops back to step 114 .
[0046] Steps 114 and 120 through 130 enable integrated AFS and VSE control to bring YR ERR or YR ERRACCEL below their respective thresholds. Once the integrated control succeeds in bringing YR ERR or YR ERRACCEL below their respective thresholds, control ensures that VSE remains inactive afterward for t THRESH . In this manner, the yaw rate characteristics are within acceptable limits below (i.e., the lower thresholds) for at least the time t THRESH and the VSE control is not intermittently activated. If VSE control again becomes active before the timer exceeds t THRESH , the timer is reset in step 130 . If VSE control remains inactive for t THRESH , control begins again at step 100 .
[0047] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An integrated vehicle control system includes a first control system having a maximum authority to selectively operate a first vehicle sub-system and a second control system to selectively operate a second vehicle sub-system. A controller is adapted to monitor a first parameter associated with the first vehicle sub-system and a second parameter associated with the second vehicle sub-system. The controller is operable to control the first and second parameters by selectively invoking operation of the second control system when the first control system exceeds the maximum authority and the second parameter exceeds an upper threshold. | 1 |
The present invention relates to method and an apparatus for the manufacture of mineral wool plates by dividing a continuous mineral wool mat into pieces having the same mutual length and width, said method and apparatus being useful in reducing the spreading of fibers and other particles from the edges of mineral wool plates by using suction slot apparatus or a corresponding means for exhausting air from the area adjacent the mineral wool surfaces so that loose fibers and other particles are brought with the air and into the exhaust slot or slots.
BACKGROUND OF THE INVENTION
When handling mineral wool products large or small amounts of dust are formed, which dust includes, among other things, fibers. It is a general aim in the work environement to minimize the amount of dust, including fibrous dust, to which the working persons are exposed, and the present invention is intended to solve this problem.
The invention is based on studies of the mechanisms which cause origin of dust and also the mechanisms which can be used to prevent spreading of dust. These studies have shown that the air-borne dust which is produced when handling mineral wool mainly comprises thin, short mineral fibers. The studies also have shown that the air-borne fibers and other particles which are produced emanate from the surfaces of the mineral wool products.
In the manufacture of mineral wool a melted mineral material is fabricated into fibers and formed by one or several steps into a continuous mineral wool mat having flat top and bottom surfaces. The main part of the mineral wool fibers is bound by means of a binder. The binder is added during the fabrication process, and the binder is hardened as the mineral wool mat is moved through a hardening furnace in which the mat also is given its final thickness. Upon leaving the hardening furnace the mat of mineral wool has a more or less solid shape and a fixed thickness. Said mineral wool mat is then divided into several pieces. This is done in several operations. Practically without exception the edges are cut clean by means of edge saws and the mat is then cut into pieces of predetermined length by means of a cutting machine. The cutting machine may be of guillotine type or may be formed with one or more rotating saw blades which are movable across the mineral wool path. In most cases the mineral wool mat is also divided in the longitudinal direction by means of a partition machine so that the mat is divided into two or more narrow mats moving aside of each other. In some cases the mat may also be split into two or more thicknesses by one or more band saws making horizontal cuts in the mineral wool mat thereby splitting or stripping same into several thinner mats each lying directly on top of the other.
Generally there are no serious problems in vaccum cleaning the upper surface and the bottom surface of the mineral wool mat for rmeoving dust and loose fibers. Also the edge surfaces which are formed when the edges are cut are easy to reach with a vacuum cleaning apparatus. On the contrary it is difficult to vacuum clean the partition cuts, and in particular the cross cuts, for the purpose of removing particles. It has been suggested that the different mats, which are formed when the mineral wool mat is "partition divided", should be moved apart so that a vacuum cleaning apparatus can be introduced in the space thereby formed between the mats. Said method, however, has not really come into practical use. Irrespective how this problem is solved it can be stated that vacuum exhausting of dust and loose fibers from the cross cut extending perpendicularly to the moving direction of the mat causes much greater problems. Modern manufacturing lines for mineral wool operate at speeds of 25 m/min or more. After cross cutting the cut apart pieces are often accelerated and thus the moving speed becomes still higher. It is very difficult to arrange an effective vacuum cleaning of surfaces which are perpendicular to the moving direction and moving at such high speeds.
SUMMARY OF THE INVENTION
The present invention is intended to solve the above mentioned problem, and this is accomplished by cutting the mineral wool mat into individual plates which are arranged into a pile of plates, whereupon suction slots or suction nozzles or similar apparatus are moved over all four sides of the pile. It is thereby possible to cause the suction slots to move in relation to a pile which is standing still, or to cause a pile to move past fixed mounted suction slots or similar apparatus.
In order to improve the flexibility so that it is possible to treat piles of different size plates in the same apparatus the suction slots are preferably arranged in pairs so that two oposite sides of the pile are treated in a first step and thereafter the two remaining sides are treated in a second step, whereby the treatments in each step with are done with separate sets of suction slots. In order to bind the fibers and other particles which are left in the mineral wool after the vacuum cleaning, but which still form a potential source of dust, the mineral wool surfaces which have been vacuum cleaned are preferably treated with a dust binding substance.
The best total effect is obtained if both flat surfaces of the mineral wool plates to be piled are vacuum cleaned before being piled, and that said surfaces are eventually also treated with a dust binding substance.
In high efficiency plants it may be good to have the mineral wool plates form a continuous pile which is then continuously moved past a stationary vacuum cleaning apparatus which vacuum cleans the edge surfaces of the plates. In this embodiment the plates are preferably turned up on edge so that the pile is placed horizontally and the mineral wool plates consequently are standing vertically in the pile.
In less efficient production plants it may, on the other hand, be preferred to form piles of plates with each pile comprising the predetermined number of plates that a final mineral wool plate package is to contain for shipping. In particular in available plants, in which there is no free floor space for additional installations it is preferred to have the pile of plates move vertically up and then, possibly after some side displacement, vertically down again. Thereby the vacuum cleaning of the edges and any eventual treatment with a dust binding substance is made during the vertical movement and, in an actual case, also during the side displacement.
In this case an especially suitable method is to execute the vacuum cleaning while the pile is moving vertically upwards. Then the pile is moved sideways and then back vertically down to a place relatively close to the place from where the movement vertically upwards started. In this case a possible treatment of the mineral wool with a dust binding substance is preferably made while the pile is moving downwards. In some cases the local conditions may be such that the first vertical movement is more easily made in the direction downwards, whereupon the second vertical movement is made in the direction upwards.
BRIEF DESCRIPTION OF THE DRAWINGS
Now the invention will be described more closely with reference to five principle figures, in which
FIG. 1 diagrammatically shows a side view of an apparatus according to the invention;
FIG. 2 shows a detail of an alternative embodiment of the invention having an upwards-sideways-downwards moving vacuum cleaning function;
FIGS. 3 and 4 show a couple of further alternative arrangements of an apparatus according to the invention; and
FIGS. 5 and 6 show more in detail two different arrangements for vacuum cleaning of loose fibers and particles from the edges of mineral wool plates.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a mineral wool mat 1 which is moved on a roll conveyor 2. The mineral wool mat 1 is cut into short pieces, named plates 3, by means of a cutting apparatus 4, which in FIG. 1 is symbolized by a guillotine blade 5 which is movable between two guide plates 6a and 6b and which is driven by an intermittently rotatable eccentric apparatus 7.
By means of a conventional apparatus which is not shown in the drawing the plates 3 are turned to edge standing position by being turned 90°, whereby said plates form a horizontal, continuous pile 8 of plates standing on their edge. The pile 8 is moved with a speed which matches the production line speed by means of a roll conveyor 9. Vacuum cleaning slots 10 are mounted at the two vertical sides of the pile for exhausting or sucking off dust and loose fibers from the vetical sides of the pile, and some distance downstream from said slots 10 additional vacuum cleaning slots 11, 12 are mounted for vacuum cleaning the top and bottom surfaces of the pile 8. After the four sides of the pile 8 have been vacuum cleaned a dust binding substance is sprayed onto the two vertical sides of the pile by means of a pair of nozzles 13, and then the top surface and the bottom surface are sprayed with a dust binding substance by means of nozzles 14 and 15 respectively. The dust binding substance may for instance be a mineral oil diluted with some solvent. The dust binding substance is then dried by exposing the surfaces to infrared rays as symbolized in FIG. 1 by the heating and radiation apparatus 16 and 17 at the upper side and the bottom side of the pile respectively. In practice, of course, the radiation apparatus are arranged so as to also expose the vertical sides of the pile to the radiation.
After the dust binding substance has become dried the continuous pile 8 is broken up into individual pile units 18 which are later to form a package and which are prosecuted on the roll conveyor 19.
In FIG. 2 mineral wool plates 3 supplied on the roll conveyor 2 have been piled into a pile 8' by means of a conventional piling apparatus which is not shown in the drawing. When the pile 8' is ready it is moved by the roll conveyor 9' to a new position symbolized by the pile standing in the position 20. From this position the pile is moved vertically up past the suction nozzles 10 which vacuum clean the surfaces of the pile extending in the plane of the drawing, and suction nozzles 11 and 12 which vacuum clean the two further sides of the pile. After the vacuum cleaning process the pile 8' is moved further upwards past the nozzles 13, 14 and 15 which apply a dust binding substance on the edge surfaces of the pile 8'. From the position marked with the arrow 21 the piles are moved horizontally to a position marked with the arrow 22, and from there the piles are moved downwards past the radiation apparatus 16 and 17 which provide a drying or evaporation of the dust binding substance which has been sprayed onto the pile surfaces. After having passed the radiation apparatus the piles are moved further down to a position marked with the arrow 23 and are then moved out of the apparatus by the roll conveyor 19'.
FIG. 3 illustrates another method of executing the invention.
FIG. 3 basically shows a pile 8" of mineral wool plates which is moved in the direction of the arrow 24 in between two suction slots 25 and 26 which vacuum clean the edge surfaces of the pile 8" which are parallel to the moving direction. The pile 8" is then moved on to the position marked by the arrow 27. From this position the pile is moved at a right angle in the direction of the arrow 28, past suction slots 29 and 30 which vacuum clean the two other surfaces of the pile 8". After the pile has been vacuum cleaned it is moved past the two nozzles 31 and 32 which spray a dust binding substance onto the edge surfaces which have just been vacuum cleaned. The pile is then moved on to the position marked with the arrow 33. From this position the pile is moved at a right angle in direction marked by the arrow 34, past two nozzles 35 and 36 respectively, which cover the two further edge surfaces with a dust binding substance. The pile is further moved past a first radiation apparatus 37, 38, in which the dust binding substance is dried or evaporated, for instance by means of infrared radiation, and then to the position marked by the arrow 39. From this position the pile is moved at a right angle, marked by the arrow 40, past a second set of radiation apparatus 41 and 42, which dry or evaporate the dust binding substance on the two further sides of the pile. The pile is then moved in the same direction to the position marked with the arrow 43 and then once again at a right angle as marked with the arrow 44 and into the plant.
FIG. 4 shows a corresponding apparatus, in which the change of moving directions provided for in the arrangement according to FIG. 3 is accomplished by rotations of the pile. In FIG. 4 reference numeral 8"' symbolizes the row of incoming piles. The pile is moved following the arrow 45 past the vacuum cleaning slots 25' and 26', which vacuum clean the longitudinal, vertical surfaces. In position 46 the pile is rotated 90° and is moved on in the direction of the arrow 47 past the vacuum cleaning slots 29' and 30', which vacuum clean the two further edge surfaces of the pile. Then the pile is moved on in the direction of the arrow 48 past the two nozzles 31' and 32' respectively which over the said vacuum cleaned surfaces with a dust binding substance which is then dried by a first step of radiation apparatus 37' and 38'. In the position marked with the arrow 49 the pile is once again rotated 90° and is then allowed to pass the nozzles 35' and 36' which cover the two further edge surfaces of the pile with a dust binding substance which is then dried by a second set of radiation apparatus 41' and 42'.
FIG. 5 shows a cross section through an exhaust slot means 50a for mechanically treating and exhausting loose fibers and particles from the edge surfaces of a pile 8 of mineral wool plates. The exhaust slot means 50a comprises a cylindric brush 51 rotating in the opposite direction to the moving direction of the mineral wool piles and which brushes up loose fibers from the surface. Air is at the same time sucked into the exhaust slot over the narrow air slot which is formed at least on the rear side of the exhaust slot as marked with the arrow 52. The loosened fibers and particles are then exhausted through an exhaust pipe, not shown, of the exhaust slot means 50a. Fibers and particles can easily stick to the brush and for removing same it is possible to have the brush rotate against a plate 53 mounted at or adjacent the upper side of the brush and which plate releases fibers and particles which have become stuck to the brush.
FIG. 6 shows an alternative exhaust slot means 50b for releasing or lifting off and exhausting loose fibers and particles from the edge surfaces of a pile 8 of mineral wool plates. In this case the exhaust slot means 50b comprises a blowing box 54 which directs a flow of air 55 obliquely downwards to the edge surface of the pile 8 and which thereby releases and whirls up loose fibers and particles. Also in this case the exhaust slot means 50b is connected to an exhaust pipe, not shown which exhausts such loose fibers and particles together with the air which is introduced through the air slot at the rear side of the exhaust slot means as indicated with the arrow 56.
It is also possible to combine the apparatus according to FIG. 5 and FIG. 6 in the same unit, whereby said unit will operate both by blowing action and by brush action. | A method and apparatus for manufacturing individual plates from a mineral wool mat while minimizing the spread of loose fibers. The method comprises the steps of cutting the mat into individual plates, forming the plates into a pile, establishing a region of vacuum for exhausting air from areas adjacent the sides of the pile and causing movement between the pile and the vacuum to vacuum the sides of the pile. The apparatus for performing the method includes a cutting device for cutting the mat into individual plates, a stacking device for combining the cut plates into a pile of plates, a vacuum device positioned to establish a vacuum for withdrawing air and loose fibers from the sides of the pile, and a conveyor for causing relative movement between the pile and the vacuum device. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Italian Patent Application Serial No. TO2010A000260, which was filed Apr. 6, 2010, and is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] This disclosure relates to techniques for supplying light sources such as, for instance, low voltage halogen lamps.
[0003] This disclosure was devised with specific attention paid to its possible application to those power supply devices which are adapted to perform an intensity regulating function (so-called “dimming”) of the light source.
BACKGROUND
[0004] For the power supply of light sources such as halogen lamps, for example halogen lamps with low supply voltage, electronic transformers are used which can perform an intensity regulating function on the light source, i.e. a so-called “dimming” function.
[0005] The implementation of this function makes use of the fact that the light intensity of such sources is dependent on the (average) intensity of the current flowing through the light source.
[0006] The intensity regulating device—named “dimmer” for brevity—operates so to say by “cutting” the sine wave form, which normally has already undergone a rectification, via an operation of phase cut.
[0007] This function can be performed both on the rising edge and on the falling edge of the sine (half) wave. The devices named “phase-cut dimmers” can therefore be classified into two groups:
[0008] devices acting on the rising edge or on the front of the sine (half) wave, i.e. at the beginning of the period at 100 Hz (reference is obviously being made to a sine wave form at 50 Hz, which has already undergone a half-wave rectification),
[0009] devices acting on the falling edge, or on the tail of the sine (half) wave at 100 Hz.
[0010] The devices of the first kind, known as “leading edge dimmers” are the more widespread at present, because they are more economical to produce.
[0011] The electronic transformers currently employed in the presently considered applications normally include a self-oscillating half-bridge topology, adapted to work suitably with phase-cut dimmers of the previously considered type.
[0012] In the case of electronic transformers having a rather high power (for example an input power of 300 W), the use of a self-oscillating topology is more difficult. This is due to the need of a suitable control of input and output currents and of output voltages, particularly during start-up and in protection stages against abnormal operating conditions (overload, overheating, over-temperature).
[0013] In order to properly control the power stage, it is then possible to provide a processor, such as a digital microcontroller, combined with an external driver. Both the processor (microcontroller) and the driver require a constant voltage supply, usually of the order of a few Volts (Vcc). For reasons due to energy saving requirements (specifically in order to reduce consumption in a stand-by mode), this voltage is obtained with a Switch Mode Power Supply stage (SMPS).
[0014] FIG. 1 is a block diagram showing a solution corresponding to what has been previously described.
[0015] Specifically, in the block diagram of FIG. 1 , reference 10 denotes a power stage including, for example, two electronic switches (for example power mosfets) adapted to be alternatively switched on and off, i.e. to be made conductive and non-conductive, associated with respective capacitors 14 in a self-oscillating half-bridge arrangement, adapted to drive the primary winding 16 a of a transformer 16 . The secondary winding 16 b of transformer 16 feeds load L, which is a lamp or lamps (which of course, though shown in the drawing, are not in themselves a part of the supply circuit).
[0016] In the example considered in FIG. 1 , feeding power stage 10 from mains M is achieved with an input filter 18 and a diode bridge rectifier 20 , wherefrom a feed line 21 from mains branches which has a “bus” voltage Vbus, adapted to feed power stage 10 .
[0017] Reference 22 denotes the drive stage or driver, which turns the switches 12 in power stage 10 on and off alternatively, on the basis of controls received from a processor such as microcontroller 24 .
[0018] Reference 26 identifies a supply stage (Switch Mode Power Supply stage or SMPS) connected to the feed line 21 from mains. On the output of stage 26 a direct voltage Vcc is present which is adapted to be used as a supply voltage for driver 22 and for the microcontroller processor 24 .
[0019] Finally, reference 28 denotes a phase-cut dimmer (which is assumed to be interposed between the input of mains voltage M and the input filter 18 ) which, by operating according to well-known criteria, performs a “cutting” function on the wave form of the mains supply; under the action of an external dimming control (produced according to well-known criteria and means), dimmer 28 is therefore selectively switchable between:
[0020] a conductive state (wherein the mains supply flows to the device) and
[0021] a non-conductive state (wherein the mains supply to the device is interrupted),
[0022] so as to either permit or interrupt the supply to the device from mains.
[0023] The circuit topology shown in FIG. 1 is to be considered as known in itself, which makes it unnecessary to provide for its detailed description herein.
[0024] It will be realized, moreover, that in order to solve the technical problem explained in the following, the circuit arrangement of FIG. 1 must be considered exemplary, in general terms, of the topologies of the power supply device for light sources wherein the device includes:
[0025] a feed line from mains (e.g. line 21 ) through a phase-cut dimmer which performs a “cutting” function on the wave form of the supply from mains, the dimmer being selectively switchable between a conductive state (wherein the supply from mains flows to the device) and a non-conductive state (wherein the supply from mains to the devices is interrupted), so as to either permit or interrupt the supply from mains to the device,
[0026] a power stage to feed at least one light source from said feed line from mains,
[0027] a drive stage for the power stage, and
[0028] a supply stage for the drive stage, said supply stage being connected to said feed line from mains.
SUMMARY
[0029] In various embodiments, a power supply device for light sources may include a feed line from mains via a phase-cut dimmer, selectively switchable between a conductive state and a non-conductive state, to permit or interrupt feeding of the device from mains. The device may include a power stage to feed at least one light source from said feed line from mains; a drive stage for said power stage; and a supply stage for said drive stage, said supply stage connected to said feed line from mains. The device may further include a sensor to detect when said dimmer is non-conductive and when said dimmer is conductive. The drive stage may be coupled to the sensor to disable driving of said power stage when the sensor indicates that the dimmer is non-conductive, and enable driving of the power stage when the sensor indicates that the dimmer is conductive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the invention are described with reference to the following drawings, in which:
[0031] FIG. 1 has already been described in the foregoing;
[0032] FIG. 2 shows a block diagram representative of various embodiments; and
[0033] FIGS. 3 and 4 show further details of various embodiments.
DETAILED DESCRIPTION
[0034] In the following description, numerous specific details are given to provide a thorough understanding of embodiments. The embodiments can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the embodiments.
[0035] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0036] The headings provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0037] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration”. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs.
[0038] In various embodiments, the inventor has observed that in arrangements such as the one shown in FIG. 1 (and in similar or equivalent topologies), when during the dimming action the dimmer cuts the input voltage (and as a consequence the supply on line 21 ) beyond a certain level, the stage which supplies the driver and the processor is fed insufficiently and, in turn, can no longer feed the supply voltage to the driver and to the processor; as a result, in the lamp supply flickering or flashing effects appear which are clearly perceivable.
[0039] The most unfavourable conditions occur in the case of “leading edge” dimmers, which perform the cutting function on the rising edge of the supply wave form, so that the supply voltage drop to the driver and to the processing unit takes place at the very moment when the power stage is to be activated.
[0040] The inventor has therefore realised that electronic transformers controlled by a commercially available device, such as a microcontroller, cannot operate satisfactorily with “phase-cut” dimmers; when the dimming level increases, i.e. when the lighting intensity is reduced below a certain level, the control processing unit and the power stage driver are supplied insufficiently, and the light source undergoes flickering or flashing effects.
[0041] Various embodiments may overcome the previously described drawback.
[0042] In various embodiments, this may be achieved through a device having the features specifically set forth in the claims that follow. Various embodiments concern a related method. The claims are an integral part of the technical teaching of the invention provided herein.
[0043] Various embodiments base their operation on the principle of reducing the overall energy consumption when the dimmer is “open”, i.e. non-conductive. In these conditions, wherein no supply takes place to the power stage of the electronic transformer, various embodiments propose not to supply (particularly not to supply voltage to) the electronic transformer. In this way it is possible to prevent a drop of the output voltage on the stage which generates the supply voltage, preventing therefore a malfunction of the integrated circuits supplied thereby.
[0044] Various possible embodiments will be described in the following, reference being made to FIGS. 2 to 4 . In these two Figures, parts, elements or components identical or equivalent to parts, elements or components already described with reference to FIG. 1 are denoted by the same reference numbers; for the sake of brevity, therefore, the description thereof will not be repeated in the following.
[0045] In the general diagram of FIG. 2 , the circuit topology which has previously been described referring to FIG. 1 is complemented by the provision of a sensing element or detector 30 , adapted to detect when dimmer 28 is non-conductive, i.e. when it is cutting the supply wave form.
[0046] In this connection, it will be appreciated that dimmer 28 is not necessarily a part of the supply device according to the disclosure.
[0047] In various embodiments, element 30 may include any device which senses the wave form from dimmer 28 , and which is adapted to detect when this wave form crosses zero because the dimmer is “cutting” the sine wave form from mains M.
[0048] In various embodiments, such a device may essentially comprise a so called Zero Crossing Detector (ZCD).
[0049] In various embodiments, detector 30 is arranged at the output of input filter 18 . Such an arrangement is however not mandatory, as the ZCD might be arranged in another position as well, for example directly at the output of dimmer 28 .
[0050] When detector 30 detects the zero level of the supply towards the device, it outputs a signal to processor 24 (in the following simply named “microcontroller” 24 for brevity).
[0051] When the signal from detector 30 indicates a zero level, which corresponds to dimmer 28 interrupting the supply to the device, microcontroller 24 operates:
[0052] by disabling the outputs to power stage 10 , interrupting the supply to the stage from the feed line 21 form mains (i.e. by “switching off” the related half-bridge circuit),
[0053] by activating a dummy load 32 to voltage Vbus from rectifier 20 , and
[0054] by automatically setting to a low-consuption stand-by mode.
[0055] The first and the third command/operation are aimed at minimizing the energy consumption of the circuit, in a state wherein the circuit itself does not receive supply power from mains, because dimmer 28 is “cutting” the wave form from mains M and at the moment is an open circuit.
[0056] The second command/operation is aimed at making dimmer 28 operate correctly when it closes, i.e. when dimmer 28 becomes conductive again, by restoring the voltage supply from mains M to the electronic transformer. A detector stage 34 senses the level of voltage Vbus on feed line 21 from mains M, and is therefore able to send to microcontroller 24 a signal indicating that such voltage has exceeded a predetermined threshold level, which reveals that dimmer 28 has so to say “switched on” the converter again.
[0057] The dummy load 32 is designed so as to take into account the needs of a minimum absorption of the power induced by dimmer 28 , in order to avoid flickering and flashing. As a matter of fact, when dimmer 28 closes, i.e. becomes conductive and therefore applies again the voltage from mains to the circuit, the current flows through load 32 , therefore allowing dimmer 28 to operate properly. At the same time, the detector stage 34 sends a corresponding signal to microcontroller 24 , indicating that dimmer 28 has restored the supply to the device.
[0058] Microcontroller 24 , as a consequence, operates:
[0059] by restoring the normal operating conditions, from the low absorption stand-by mode;
[0060] by enabling again the outputs to driver 22 , i.e. enabling again the supply to power stage 10 from feed line 21 from mains, and
[0061] by deactivating dummy load 32 , so as to maximize the efficiency of the electronic transformer, while preventing the load 32 to stay activated in states wherein its presence is no longer needed to ensure the operation of dimmer 28 .
[0062] In various embodiments, the output voltage Vcc of stage 26 (although the latter stage is connected to the feed line 21 from mains) is not subjected to a drop even in the case wherein the dimming level is high, i.e. when the lamp is brought to a low brightness state, as low as an almost total switch-off, allowing therefore to use dimmers particularly of the phase-cut type, even for electronic transformers provided with a processor such as microcontroller 24 .
[0063] In various embodiments, for example in the case of high power transformers, it is possible to use an electronic transformer in place of standard electromagnetic transformers operating at 50 Hz.
[0064] In the embodiments depicted in FIGS. 3 and 4 , the zero level detector 30 may include two RC networks which operate as two voltage dividers, the higher branches whereof (resistors R 1 c and R 3 c ) are connected to both output lines of filter 18 , and the lower branches whereof (respectively parallel to resistor R 2 c and capacitor C 1 c and parallel to resistor R 4 c and capacitor C 2 c ) operate between the centre point of divider/filter rc and ground, transferring the charge voltages of capacitors C 1 c and C 2 c to the base terminals of two bipolar transistors Q 1 c and Q 2 c, e.g. npn transistors. The emitters of both transistors Q 1 c and Q 2 c are grounded, and the related collectors, mutually connected, give microcontroller 24 a “zero crossing” signal. Both bipolar transistors Q 1 C, Q 2 C are driven by the line and the neutral phase of the supply voltage.
[0065] In practice, for example thanks to the presence of capacitors C 1 c and C 2 c ), said signal not only indicates an instantaneous zero crossing, but also reveals that the output of dimmer 28 stays at zero for a certain period of time (longer or shorter as a function of the dimming level), because dimmer 28 is “cutting” the wave form from mains therefore interrupting the supply to the device.
[0066] Reference R 5 denotes a biasing resistor, interposed between voltage Vcc and the collector of transistor Q 1 c.
[0067] In the embodiment of FIG. 3 , dummy load 32 may include simply a resistor Rb connected between line Vbus and an electronic switch including, for example, a mosfet Mb, the gate of which is driven by microcontroller 24 . When switch Mb is closed, resistor Rb is interposed between voltage Vbus and ground, and represents therefore a load for the related voltage. When switch Mb is open, resistor Rb is disconnected from ground and is floating, therefore not representing a load.
[0068] In the shown embodiment, load 32 is designed in such a way that microcontroller 24 drives switch Mb, e.g. a mosfet N, so that the switch is energized at every zero crossing, and is de-energized as soon as dimmer 28 is conductive and enables the power stage.
[0069] The converting stage 26 can therefore be designed with a “buck” topology, by using voltage Vbus as an input voltage to the buck converter.
[0070] In the embodiment of FIG. 3 , the detector stage 34 is designed with a structure which substantially resembles a voltage divider, interposed between line 21 (voltage Vbus) and ground, the divider including a first resistor R 1 d and a second resistor R 2 d, the lower branch of the divider including moreover a zener diode Dz connected in parallel to resistor R 2 d, the cathode being coupled to the centre point of the divider and to a corresponding input of the microcontroller.
[0071] The zener diode Dz in stage 34 performs a “clamping” function on high voltage values.
[0072] The output of the corresponding voltage divider follows the state of line 21 (voltage Vbus) so that, when voltage Vbus on line 21 reaches a “high” level, higher than an enable threshold, microcontroller 24 leaves the stand-by mode, activating the power stage and disabling load 32 .
[0073] In the embodiment of FIG. 4 , detector 30 is designed according to the criteria which have already been described referring to FIG. 3 .
[0074] For stage 34 , the embodiment of FIG. 4 has the voltage divider arrangement, with the zener diode Dz previously described with reference to FIG. 3 , complemented by the presence of an electronic switch Md (once again comprising for example a mosfet), which selectively connects the output of the voltage divider, provided with zener diode Dz, to a grounded resistor R 3 d, which is serially connected with the switch of interest, the connection line to microcontroller 24 being linked to the centre point between electronic switch Md and resistor R 3 d.
[0075] In this embodiment, the gate of switch Md is connected to voltage Vcc through the voltage divider, with the possibility of having the said gate voltage “clamped” by the zener diode. The source voltage of switch Md is connected to microcontroller 24 , so as to supply the signal for activation.
[0076] The said source voltage, denoted by Vs, equals Vbus until the value of resistor R 3 d is much higher than resistance Rds_on (i.e. the on-state resistance) of mosfet Md, so that the following relation is fulfilled:
[0000]
V
G
−V
BUS
≧V
TH
→V
BUS
≧V
G
−V
TH
[0077] where V G is the gate voltage e V TH is the threshold voltage of mosfet Md. Once the condition is no longer fulfilled, Vs, i.e. the source voltage of the mosfet, equals V G -V TH . In this way, in comparison with the embodiment of FIG. 3 , the signal supplied to microcontroller 24 has sharper and more precise edges.
[0078] In the embodiment of FIG. 4 , dummy load 32 is practically embedded within stage 26 , which in this example is realised as a converter, having a topology currently known as SEPIC (Single-Ended Primary Inductance Converter).
[0079] The SEPIC converter therefore includes a diode 260 , the anode of which is coupled to voltage Vbus and the cathode of which is connected to a grounded capacitor 262 . References 264 and 266 denote two (mutual) inductors which are typical in SEPIC topology.
[0080] Specifically, the first inductor 264 can be considered as included in a first Π-shaped structure, the side branches of which, connected to ground, are respectively made up by previously described capacitor 262 and by an electronic switch such as a mosfet 268 , while inductor 264 is the horizontal branch of the letter Π.
[0081] The second inductor 266 can on the contrary be considered as a part of a further Π-shaped structure, cascaded with the previous Π-shaped structure, with the interposition of a capacitor 270 . The second Π-shaped structure includes, as side or vertical branches connected to ground, the second inductor 266 and a further capacitor 272 , at the ends whereof the output voltage Vcc is applied, and the horizontal branch whereof is comprised of a diode 274 , the anode of which is connected to inductor 266 and the cathode of which is connected to capacitor 272 , and therefore to voltage Vcc.
[0082] A SEPIC converter allows moreover the output voltage to be higher than, lower than or equal to the input voltage; as a matter of fact, the output of the SEPIC converter is controlled by the duty cycle of the control switch (mosfet 268 in the illustrated embodiment). The SEPIC converter resembles therefore a traditional buck-boost converter, with added advantages due to having a non-inverted output (the output voltage has the same sign as the input voltage), to the isolation between input and output (provided by capacitor 270 in series) and to the possibility of a complete shutdown; when switch 268 is off, the output is zero.
[0083] Resorting to this SEPIC topology with voltage regulation allows to perform at the same time the function of a dummy load for the dimmer.
[0084] In normal operating conditions (without dimming) the output voltage of the SEPIC topology is set to the value Vcc, and the duty cycle of the electronic switch (mosfet) 268 varies according to the value of the input voltage.
[0085] When the dimmer is activated, microcontroller 24 turns off the driver 22 and switches to the stand-by mode. The mosfet of the SEPIC topology is then maintained on (it is assumed that voltage Vcc does not decrease) by the control loop, so that between voltage Vbus and ground an equivalent network is obtained comprising input inductor 264 of SEPIC topology, connected in series to the SEPIC mosfet. In this way a dummy load is created, essentially by the SMPS converter, without the need of providing a separate and discrete stage adapted to operate as a dummy load.
[0086] When voltage Vbus returns to high, because the dimmer has been restored to conductive, the SEPIC stage starts to operate normally again, performing its function of regulating voltage Vcc.
[0087] While the invention has been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced. | In various embodiments, a power supply device for light sources may include a feed line from mains via a phase-cut dimmer, selectively switchable between a conductive state and a non-conductive state, to permit or interrupt feeding of the device from mains. The device may include a power stage to feed at least one light source from said feed line from mains; a drive stage for said power stage; and a supply stage for said drive stage, said supply stage connected to said feed line from mains. The device may further include a sensor to detect when said dimmer is non-conductive and when said dimmer is conductive. The drive stage may be coupled to the sensor to disable driving of said power stage when the sensor indicates that the dimmer is non-conductive, and enable driving of the power stage when the sensor indicates that the dimmer is conductive. | 7 |
BACKGROUND
This invention relates to carpentry measuring devices, and in particular to a tool combining a number of important carpentry measuring tools, including the bevel gauge, level, straight edge, framing square, plumb, and bench marker.
In constructing a typical building, as, for example, a home, carpenters and other building professionals employ a variety of measuring devices essential to insure the correct placement of the foundation, side walls, floors, roof, and window and door placements. Typically to this end, it is important to ascertain if structures are level in a horizontal plane, and plumb in a vertical line in relation to a horizontal plane. Also a variety of angles, including non-square angles, must be accurately measured. Multiple calculations are required from data supplied by these tools so that structures are placed correctly within a given foundation, windows and doors are inset with precision, the rise and pitch of a roof and all the required roofing carpentry calculated correctly, the accurate placement of stairs, so on. Tools usually employed include a variety of levels such as a two-foot, four foot, and six foot level; a line level; a water level; a plumb bob; a framing square; a level benchmarker; and a bevel gauge.
Obviously, while these tools admirably serve the building trades, they do not address the time saving conveniences obtained with the combination carpentry measuring tool of the invention. In addition to combining these important devices into a single tool, the invention also provides for extremely accurate and convenient digital read out of angles with the convenience of a built-in calculator at the ready for the many calculations continuously being required.
Further, the invention addresses the problem of providing a level bench marker for laser precision layout for the installation of cabinets, paneling and floors, and for the precision layout for foundations to houses and the framing of the walls afterwards.
Therefore, it is a primary object of the invention to provide a combination level, bevel gauge, straight edge, framing square, and plumb measuring tool.
An additional object of the invention is to provide a standard level that is extendable in length by unfolding said level.
A further object of the invention is to provide a framing square that enables the user to make certain that any opening in a structure is square and plumb at the same time.
Still another object of the carpentry measuring tool of the invention is to provide a bevel gauge for measuring angles including complex compound angles.
Another object of the carpentry measuring tool of invention is to provide a built-in calculator for conveniently and rapidly determining pitch, rise and run measurements, spans and other required construction calculations.
A further object of the invention is to provide a digital read out of angles being measured, and the orientation of the device measuring said angles from a position considered to be true level.
Still another object of the invention is to provide a laser light precision level bench marker for the installation of cabinets, paneling, leveling out of walls, ceilings and floors, and for the precision layout for foundations to houses, and the framing of walls afterwards.
SUMMARY
These and other objects are obtained in the instant invention of a multi-purpose carpentry measuring device.
It has been found that the functions of the typical level, straight edge, framing square, and plumb bob can be combined into one measuring device with resultant time saving conveniences for the user. Typically, a level is a straight length of wood or metal having a glass or plastic vial containing a bubble suspended in either alcohol or ether to indicate when the device is in a true horizontal position or true vertical position relative to a known surface. In the instant invention, two similar levels are connected at one end of each level by a pivot. The first level referred to as the "foot" has a fixed bubble tube located at approximately the center along the length of the foot to be used for horizontal measurements. The second level referred to as the "leg" contains at least one and preferably two bubble tubes either in a fixed, or preferably in a rotatable position as will be more fully explained, located a spaced distance apart along the length of the leg, to be used for vertical measurements. The foot and the leg are configured to fit together in a closed position, with both the foot and the leg having a flat base portion and upstanding side walls so that when they fit together in said closed position, they take the shape of a long, rectangularly shaped box. When manually lifted apart, the pivot maintains the foot and leg members in a planar relationship, the junction of the leg and the foot at the pivot being configured so as to limit their extension one from another to a maximum of 180 degrees. A device, such as a wing nut, acting as the pivot, can serve to lock the foot and leg at any given angle between the closed 0 degrees and fully open 180 degrees. A rule(s) that is approximately the same length as either the foot or the leg member can be externally affixed to the base portion of either or both members by means of, for example, a tongue in groove joint. The device is envisioned as being supplied, as when in the closed position, in a one foot size, a two foot size, and a four foot size. Therefore, in its open position at 180 degrees, the device becomes either a two foot, four foot or eight foot level or straight edge.
The device of the invention can further serve as a precision bevel gauge or bevel square (an adjustable tool for measuring and laying out angles) by adding angle indicating grooves on the leg member at the pivot junction of the leg member and the foot member. Significant convenience and precision is added to this angle determining operation, i.e., the angle between the two arms of the members in a given plane, by incorporating a calculating machine or calculator affixed to the leg member. The calculator is preferably battery operated, and is connected by an electric wire to a magnetic disc secured to the foot member at the pivot junction of the two members. An optical sensor located in the leg member at the pivot junction reads a bar code calibrated in angle degrees, which then provides for a digital read out on a display on the face of the calculator indicating the precise angle between the foot and the leg member. In addition, a magnetically positioned detectable bubble tube affixed to the calculator provides a digital read out on the calculator as to the orientation of the leg member relative to a position considered to be true level. Obviously, the calculator can serve as a general purpose calculating tool for the myriad of other calculations continuously being required in construction activities.
The device of the invention can also serve as a precision level bench marker. Installing a laser pin light at the ends of the foot and leg, opposite the pivot junction, now permits a precise marking to be made on walls, ceilings, and floors for precision determination of the relative position of one structure and another. The laser pin lights are preferably battery operated, retractable when not in use, and can be pivoted at a 45 degree angle up or down, or left and right. A retractable pin (collinear at its point with the laser pin lights when the laser pin lights are operating in the same planar relationship as the position of the leg member and foot member in fully open position) mounted at the center of the carpentry device when the two arms of the device are in fully open, 180 degree position, can be employed to affix the device to a structure and be balanced in a level position while an operator proceeds to mark the precise spots on adjacent walls illuminated by the laser.
The advantages of the multi-purpose carpentry measuring device of the invention can best be understood by a brief discussion of current carpentry measuring techniques. At present, the methods and tools used in basic framing for constructing residential rural housing and interior framing for multiple dwelling and high-rise urban structures consists of up to five levels; a two foot, four foot, six foot level, a line level, and a water level. In combination with these levels, a plumb bob, and a framing square (or carpenter's square) is used to verify relationships of true vertical and true horizontal positions of the various parts of constructing members to themselves where important. For example, when installing a door frame, all parts of the door jambs must be square, or at a perfect 90 degree angle from one another in order that a new door fit properly into the frame, and the frame itself must be plumb front to back, and side to side. In order to achieve that goal now, a plum bob is set at the top of a header, or top horizontal member of the door buck frame for the door. The plumb bob is set by nailing a small nail into the header piece and tying the string around the nail at usually two inches away from the to-be-referenced side of the door buck or vertical member. The distance from the string and the side of the door buck is measured at the top, middle, and bottom of the construction member, and each measurement must be exactly the same in order for the member to be read as plumb or true vertical. The string is also a visual reference to insure that the buck is straight all the way from top to bottom. This process is then repeated on the other side. Once the two vertical members of the frame are determined as plumb, then the header, or top piece to the door frame, must be determined as horizontally level. Normally, this is where a two foot level is used, and theoretically, if the two vertical members of the frame and the header, or top piece of the frame are plumb and level, then they should be square to one another. In other words, the two corners at the top of the door frame should be at a perfect 90 degrees. For this confirmation, a framing square, also known as a carpenter's square, is used. If there are not spaces between the two edges of the square and the two surfaces of the door frame, then it is square. To help better confirm the vertical measurement a four or six foot level is used.
Unfortunately, the precision of measuring with levels and a plumb bob are only as accurate as the average eye can see. Sometimes, the levels are a little off, and other times, vision is impaired due to poor lighting or poor eye sight, and can cause the true vertical read on a level, or read on the measuring tape, to be off by a fraction of an inch which will magnify over the greater distance of the span it is measuring, resulting in the opening being off from top to bottom or side to side. This results in costly re-framing and hanging of doors and windows.
The device of the invention combines the use of the square, the two and six foot levels eliminating the need for using a plumb bob, saving time and making the task physically easier.
By turning the device of the invention into a square, with levels on both arms of the square, the frame is assured of being plumb and square at the same time, and that measurement is read simultaneously. In addition, after checking that plumb and square are true, the invention can be unfolded to make a four foot level and straight edge to verify that the vertical members of the door frame are plumb and straight.
Another very important task in framing, especially for interior renovation and finish carpentry, is establishing bench marks for installing cabinets, paneling, hung ceilings, moldings, closets, etc. A bench mark is a level line drawn around a room usually sixty inches off the floor at given points to establish a level line of reference from floor to ceiling to establish any differences in height in floor and/or ceiling levels so that hanging cabinets and moldings, or hanging ceilings, will be level from one end to another.
Often times, due to sagging structures, the floors and ceiling will have a slope in them that needs to be compensated. For this task, presently, a water level is used, and while this can at times be accurate over long distances from one end or side of a room, the result is often an inaccurate read because of bubbles in the line, bad reading of the water line at either end of the line, or other factors not easily controlled at the time of use. It is also a cumbersome instrument to use on crowded job sites, and requires two people.
With the device of the present invention, when it is unfolded to its extended two, four, or eight foot level position, with the two laser pin lights, one at each end, the device can be secured to a wall and balanced in the level position and left by itself. The laser pin light will spot light each surface to the left and right of the wall the device is affixed to. A mark with a pencil can then establish the points for the next two walls and the wall with the level on it. The device can then be placed on the next wall to the original placement, and the same procedure repeated.
Another important application for the multi-purpose carpentry measuring device of the invention is its use as a bevel gauge. Any angle can be copied with each side measured from 20 inches up to 84 inches on either side of the corner. This allows a more accurate tracing of slopes or non-square angles onto material for cutting and placing, such as sheet rock, plywood sheathing, shelving, and so on.
While angles can be traced using the device of the invention, basic calculations for rise and run, or pitch can also be ascertained. With the addition of the built-in calculator, the total height of a ceiling or stair rise can be calculated. For instance, if the device is placed at the bottom of a stair case with one arm lying parallel to the slope of the stairs, and the other arm positioned level and reads 45 degrees, then dividing 3.75 into 45 degrees will result in 12. This is the number of inches that the stairs rise per every 12 inches that the stairs run forward. Multiply that number by the total number of feet that the stairs run forward, and you get the total rise. The built-in calculator can be programmed to handle specific calculations for framing, as well as dealing with fractions, and the conversion of scales.
Thus, the multi-purpose carpentry measuring device of the invention provides new conveniences and increased accuracy for a wide variety of building construction procedures. Horizontal and vertical determinations are made, angles laid out and measured, bench markings made with laser precision, and calculations conveniently performed, all with hitherto unavailable speed and accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one version of the device of the invention being used as a framing square in a door installation.
FIG. 2 is a side elevation, perspective view of one version of the device of the invention shown in a fully open, 180 degrees position.
FIG. 3 is a sectional view of one version of the device of the invention taken along the line 3--3 of FIG. 2, illustrating the tongue in groove joint connection of the extendible rule on the base of the foot member of the device of the invention.
FIG. 4 is a side elevation, perspective view of one version of the device of the invention showing rotatable levels in the leg member of the invention, indicating the angle subscribed from the horizontal.
FIG. 5 is a side elevation, perspective view of one version of the device of the invention, shown in open, 180 degrees position, with laser pin lights in place at the non-pivoting ends of the foot and leg members of the invention.
FIG. 6 is a plan view of one version of the device of the invention taken along the line 6--6 of FIG. 5, illustrating a pin, for securing the device of the invention to a structure, at the approximate center of the foot and leg members shown in open, 180 degrees position.
FIG. 7A is a plan view taken along the line 7A--7A of FIG. 5, illustrating a laser pin light at the end of the leg member of one version of the device of the invention.
FIG. 7B is an elevation view taken along lines 7B--7B of FIG. 7A.
FIG. 8 is a perspective view of one version of the invention illustrating the device of the invention as connected to the exterior or a cabinet, with the laser pin light activated and illuminating a bench marker point on an adjacent wall.
FIG. 9 is a sectional view of one version of the device of the invention, taken along the line 9--9 of FIG. 5 showing a wing nut acting as the pivot, with a magnetic disc connected to the foot member at the pivot end of the member with an optical bar code reader in place at the pivot end of the leg member of the device of the invention.
FIG. 10 is a side elevation, perspective view of one version of the device of the invention, showing the foot member in a horizontal position with the leg member indicating a 15 degree angle digital read out on the calculator.
DETAILED DESCRIPTION
Referring now to the drawings, a version of the invention 10 is shown being used by an operator 40 as a framing square to insure that a door opening is plumb and square. The multi-purpose carpentry measuring device 10 is shown as manually opened around a connecting pivot 34 to a 90 degree angle. The device of the invention basically consists of two members, a foot member 12 and a leg member 16, connected together at one end of each member by a pivot 34. As shown in the drawings, (FIGS. 3 and 9) the pivot can be a wing nut 46, which provides for maintaining the two members in a planar relationship, and also enables the two members to be secured at any angle from a closed (FIG. 4) 0 degrees to a fully open (FIG. 2) 180 degrees. The two members are configured to be joined together at the pivot 34 at a maximum of 180 degrees in a planar relationship in the fully open (FIG. 2) position. Typical approximate dimensions for a two foot version of the device 10 would be a foot member being 24" in length, with a flat base portion 26 measuring 11/4" inches wide, the base 26 being contiguous with an upstanding side wall 24 measuring 1/2" wide by 13/4" in height above the base 26. The leg member 16 has similar dimensions, with a flat base portion 28 contiguous with an upstanding side wall 22.
The foot and leg members are configured so as to be able to fit together (FIG. 4) to form a substantially rectangularly shaped, elongated box-like structure. The rectangular structure can be manually opened and secured at any angle subscribed by the pivot and the two members between 0 degrees and 180 degrees in a planar relationship between the two members. The device 10 can be fabricated in plastic, but preferable materials of construction are metals, such as steel or aluminum, or wood. The foot member 12 has a bubble tube 14 fixedly inset at approximately the center of its length, so as to act as a level for determining a horizontal position, while the leg member 16 has at least one and preferably two bubble tubes 18 inset along its length so as to act as a level for determining a vertical (perpendicular) position. The bubble tube(s) in the leg member can be rotatably inset so that they can be positioned vertically or horizontally, depending on intended use. Or, the bubble tubes can be manually rotated to determine any angle (FIG. 4) between the foot and leg members as determined by angle gauge calibration markings 20 immediately adjacent the bubble tube(s) 18. The pivot 34 is also immediately adjacent angle gauge calibration markings 36 as a further convenience in noting the angle subscribed between the foot and leg members.
As illustrated in FIG. 1, an operator has positioned the device 10 between a door header 42 and a door buck frame 44 so that the door frame can rapidly and conveniently be determined to be perfectly square at precisely a 90 degree angle as determined by the bubble tube 14 in the foot member 12 and the bubble tube(s) 18 in the leg member, and the calibrations for both the pivot 34 and the calibrations 20 for the leg bubble tube(s). A calculating machine or calculator 38 can be affixed to the leg member, the calculator 38 being programmed to handle specific construction equations, and having frequently used conversion scales, for added convenience to the construction professional.
In FIG. 2, the device 10 is shown in the fully open position, with a wing nut 46 (FIG. 3) acting as the pivot and securing the foot and leg members in this fully open position. With the rotatable bubble tube(s) 18 in the leg member set for horizontal level determinations, the device 10 can be used as an extended level for horizontal readings. The device can also be used as an elongated straight edge, or set in a vertical position with the bubble tube(s) 18 in the leg member rotated for a perpendicular level reading to verify, for example, that the door frame 44 of FIG. 1 is plumb and straight. The usefulness of the device is further increased by adding a rule to one or both members of the device. As depicted in FIG. 2, a first rule 30 is shown affixed to the flat base 26 of the foot member, and a second rule 32 is shown affixed to the flat base 28 of the leg member. Both rules have a tongue portion 48 (FIG. 3) which slides within a groove portion 50 (FIG. 3) on both the foot and leg flat base portions, yielding a convenient tongue and groove joint for both rules. The rules 30, 32 are approximately the same length as the flat base portion of the members to which they are attached, and can be manually caused to slide out extendibly either to the left or right of the fully open device 10 depicted in FIG. 2. And, of course, the rules can be extended to selected spaced distances by an operator in any relative angle of the two members between 0 degrees and 180 degrees.
FIG. 4 shows the device in fully closed position, with both the foot and leg members fitted together to give a unitary appearance. This position illustrates the convenience of having the bubble tube(s) 18 in the leg member rotatable over a full 360 degrees, with convenient adjacent angle gauge calibration markings 20 so that the device can be used for a rapid determination of an angle with a given flat surface.
FIGS. 5-8 illustrate an important new convenience achievable with the device 10 of the invention when a laser pin light 52 is built into the device. A retractable and pivotable laser pin light holder 64 and laser pin light are affixed to either the end of the foot member opposite the pivot 34, or the end of the leg member opposite the pivot. Or, two laser pin lights may be employed simultaneously, each connected as described to opposite ends of the device. The laser pin light 52 can be operated from a line cord connected to a standard 115 VC, A.C. outlet, or more conveniently operated from a battery (not shown) affixed to the device 10. The laser pin light holder 64 can be retracted when not in use so as not to extend beyond the length of either member. When required, the holder simply pulled forward for illuminating a spot on a wall up to 100 feet away. The holder 64 may also be pivoted at 45 degree angles in the same plane while the holder 64 is in extended, operable position so as to enable an operator to spot light several walls from the one position, or up or down at 45 degree angles from this plane. The laser pin light is collinear with the point of the pin 62 which is retractably affixed at the center of the device 10, as measured while the device is in fully open position. FIG. 8 illustrates utilizing this pin 62 to mount the fully extended device below a shelf extension 68 of a cabinet 66 so as to be able to make a pencil mark 70 for the exact height of this shelf on adjacent walls with laser precision.
FIGS. 9 and 10 best illustrate another important new convenience that can be incorporated into the device 10 of the invention for rapid and accurate determination of angles when the device is employed as a bevel gauge. As shown in FIG. 9, a magnetic disc 72 is affixed to the foot member at the pivot 34 area of this member. An optical bar code reader 74 (FIG. 9--dotted lines) is connected electrically by a wire 76 to the calculator 38. When the calculator is activated, motion of the leg member relative to the foot member will cause the optical bar code reader 74 to detect angular information encrypted on the magnetic disc 72, which angular deviations will then be displayed in a digital display window 56 on the calculator 38. In addition, the calculator has a magnetic bubble level indicator 58 similarly electrically connected to the calculator which will give a digital readout of the orientation of the leg member relative to true level. The angular information is instantly observed by an operator who can then make use of the information using the keyboard 60 on the calculator to determine the rise and run, pitch, and so on.
The laser pin light 52, its holder 64 and the mechanism of operation of the pin light 52 and holder 64 are conventional. The magnetic disc 72 encrypted with an angular bar code, together with the optical bar code reader 74 are conventional devices. The calculator 38, together with its built-in specific programs and magnetic bubble level indicator are also conventional, and well known to the art.
Thus, the multi-purpose combination carpentry measuring device of the invention provides a unique tool for aiding the construction professional in a variety of important tasks. A single tool now provides fast and accurate level, framing, plumb, angle, and level bench mark information. Aided by the built-in, programmed calculator, all of this accurate information is available for immediately performing the host of calculations routinely required.
While the present invention has been disclosed in connection with preferred versions shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is to be limited only by the following claims. | A multi-purpose carpentry measuring device is described. The tool combines the functions of a framing square, level and plum bob in one function and with just one measurement. Further, the tool can also be used as a bevel gauge and a level bench marker. A foot and leg member, joined by a pivot, contain bubble tubes for all necessary horizontal and vertical level measurements. Extendible rules on both members further increase the usefulness of the device. The tool has a built-in magnetic disc and bar code reader for continuously displaying angular read out on an integral calculator. Laser pin lights at either end of the tool allow for laser precision in all level bench marker observations as may be facilitated by a positioning pin disposed in said device. | 6 |
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